RU2775308C1 - Systems and methods used in welding pipe segments in a pipeline - Google Patents

Abstract

FIELD: welding.

SUBSTANCE: invention relates to a system for cooling pipes after welding (variants). System for cooling pipes comprises a frame configured to be placed inside at least one of multiple welded pipes, multiple rollers, a driving motor for driving the multiple rollers to move the frame inside one pipe, a brake system for preventing the movement of the frame in a set position inside the pipe, one or several accumulator batteries for supplying energy to the driving motor and brake system, a cooler configured to blow down the cooling gas inside the pipe, and one or several processors for controlling the cooler.

EFFECT: possibility of effective cooling of the welded pipes before inspecting the welding quality or performing subsequent operations, and possibility of provide internal cooling so that in the course of the processing stages, when the external surface of the pipe is inaccessible, cooling can be provided to quickly ensure the necessary condition of the pipe for subsequent stages requiring low temperatures.

36 cl, 169 dwg

Description

BACKGROUND OF THE INVENTION

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a partial continuation of PCT/US2015/047603, filed Aug. 28, 2015, which claims priority over U.S. Provisional Application No. 62/043 757, filed August 29, 2014. This application is also a continuation in part of PCT/US2015/022665, filed March 26, 2015, and US Patent Application No. 14/228,708 filed March 28, 2014. PCT/US2015/022665 claims priority on US application no. 14/228 708. This application is also a continuation in part of PCT/US2014/039148, filed May 22, 2014, and US Patent Application No. 14/272,914, filed May 8, 2014, which claim priority on U.S. provisional application no. 61/826,628, filed May 23, 2013. Application PCT/US2014/039148 claims priority on US application no. 14/272 914. This application also claims priority over US Provisional Application No. 62/175,201, filed June 12, 2015, and U.S. provisional application no. No. 62/189 716, filed on July 7, 2015. The entire content of all of these applications is incorporated herein by reference.

Technical field

[0002] This patent application relates to various field systems and methods used to weld pipe segments of a pipeline.

[0003] Piping systems that contain extended sections or pipe segments (e.g., miles of pipe segments) containing steel pipes, stainless steel pipes, or pipes made from other types of metals are used to transport liquids such as water, oil, and natural gas. between two locations (for example, from a source of origin, which may be on land or water, to a suitable storage location). The design of piping systems typically involves joining together pipe segments of the required diameter and longitudinal dimension by means of a welded joint, for example capable of providing a watertight seal to the pipe segments to be joined.

[0004] When forming a welded joint between two pipe segments (for example, two segments having the same or similar cross-sectional dimensions), the end of one pipe section or segment is in close proximity to or in contact with the end of the second pipe section or segment. The pipe segments are held relative to each other and a welded joint is made to join the two ends of the pipe segments using a welding process. Welding and cleaning field The weld seam is checked. After checking, it is desirable to apply an external protective coating to the welded joint.

[0005] Traditional internal welding machines often contain internal alignment mechanisms that are located radially outward to connect with the inside of the pipe. The alignment of the two pipe segments is accomplished from the inside when the center member extrudes are connected to the inside of the pipe close enough to the mating surfaces of the pipe segment on both sides of the joint, as illustrated in US Pat. Nos. 3,461,264; 3 009 048; 3,551,636; 3 612 808 and UK 1261814 (each of which is incorporated herein by reference). In order to weld the joint, the expander structure must be designed to provide sufficient space to accommodate the rotary torch. It would be an advantage to provide an internal alignment that provides sufficient space for a rotary or hinged torch, or for external alignment of pipe segments, in order to eliminate the need for an internal expander, which can create significant internal interference.

[0006] That being said, conventional internal welding processes typically involve internal or external alignment and positioning of the internal welder so that the torch is aligned with the mating surface. With such a process, it is difficult to determine the positioning accuracy of the internal welding machine in general and the welding torch in particular. It is even more difficult to determine the positioning accuracy of the welding torch, since the welding torch moves transversely inside the pipe along its orbital path during welding. Thus, it is desirable to provide a system for monitoring the structure or positioning of the pipe edges on the pipe contact surface to control the welding torch by using the tracked position of the contact surface. In a specific case, it is desirable to first record the contact surface profile with a laser before sending a signal to an electronic controller controlling the position and orientation of the welding torch relative to the tracked contact surface profile.

[0007] In addition, in conventional pipeline welding systems using external alignment mechanisms, typically two segments are held on rollers and the position and orientation of the segments is controlled until a satisfactory alignment is obtained. Despite this, satisfactory alignment is typically based on, for example, appropriate commercial weld mismatch gauges that are fairly accurate, but are controlled and positioned manually at discrete locations rather than over the entire pipe contact surface. In other cases, the contact surface or the structure of the contact surface studied inside the pipe, as a rule, does not give an idea of the quality of the alignment. Thus, it is desirable to provide an alignment system in which contact surface profile information read by a laser is used as input during an external alignment process. In a particular case, it is desirable to provide information from the laser controlling the welding torch to a controller that will use this information in external alignment control mechanisms.

[0008] Moreover, conventional piping systems for welding pipe segments lack the ability to visually inspect the weld being applied by the welding torch. Thus, it is desirable to provide a camera that will follow the welding torch when applying a weld and a screen to show an image of the weld to an operator for visual inspection of the quality of the weld. Other advantages of the present invention will become apparent from the review of the present description. Patent benefits are not limited to those highlighted in this section. Additionally, the benefits discussed in this document should be considered independently of each other and without regard to each other, unless otherwise explicitly stated in this document. Additional advantages are also described in the claims attached to this application.

[0009] In welding operations, as a rule, pipes are preheated to the required temperature before starting welding, and a significant amount of heat is generated during the welding process itself.

[0010] Sometimes, after completion of welding and cleaning work, the weld is inspected. It is desirable to test the weld at a temperature closer to the operating temperature of the pipe than at a high weld temperature. Therefore, after the welding process, it is desirable to carry out cooling before starting the test. After checking, it is desirable to apply an external protective coating to the connection. To provide such a protective coating, heat is applied to the pipe to raise its temperature to the temperature necessary to apply a particular outer protective coating (eg, polypropylene).

[0011] After such heating, the pipe joint is ideally suited to be cooled to a predetermined temperature prior to additional processing steps being performed (e.g., prior to wrapping the connected pipe sections or transporting/placement of the pipe sections in water, or other suitable location on the surface of the earth).

[0012] During certain stages of pipe processing (eg, after welding and before inspection), the outer segments of the pipe to be joined are easily accessible, and cooling of the outer surface is an option. However, during some parts of the process (for example, after applying certain materials to the outer surface of the pipe), the outer surface to which the pipe cooling process is applied is not accessible.

[0013] Internal cooling may be convenient during certain stages of the processing process (for example, even when external cooling is available). Internal cooling within a pipe requires special considerations given the size of the pipes and the difficulty of accessing the interior of the pipe sections located on or adjacent to the welded joint. In this regard, it is highly desirable to provide internal cooling in such a way that during processing steps when the outer surface of the pipe is not accessible, cooling can be implemented to quickly bring the pipe to the desired condition for subsequent steps requiring low temperatures (eg wrapping).

[0014] Existing pipeline welding verification processes, such as ultrasonic testing and radiography, can be quite complex. For example, some processes may require a large team ( eg 4 or more employees) of highly qualified personnel to be transported to a remote location where a pipeline is being built; may require field computers to be transported by separate truck to a remote location and used in harsh environments; provide inspection equipment that is wired (“tethered”) to dedicated computer equipment and field trucks; processes can be inefficient, as each team member may be required only for certain stages of the process; requires carefully trained technical personnel at the work site to decipher the test results; and requires that the necessary analysis be performed and the results recorded on the pipe before moving the team to the next weld. Of course, this is all a general statement and not all of these problems exist on all systems.

[0015] Today's pipe joining technologies remain a field of technology based on the prevention of errors by the worker performing the weld. Some welding technologies require appropriate data management, work management and work progress monitoring. Due to such issues, weld quality, lead times and economics are also mixed.

[0016] This patent application provides improvements over prior art field systems and methods.

BRIEF DESCRIPTION OF THE INVENTION

[0017] The present invention relates to field systems and methods involved in pipe welding applications. Field systems are represented by a variety of implementations relating to pipe welding systems and methods that are used in combination with one another, or separately. Such welding systems and methods include, for example, internal welding systems and methods, pipe welding systems and methods, pipe inspection systems and methods, pipe supply and installation systems and methods, internal pipe cooling systems and methods, non-destructive testing systems and methods, and, for example, remote interface and database (uLog) systems and methods. The application further relates to pipes welded by some or all of these processes.

[0018] One aspect of the present patent application provides a field system for welding two pipes. The field system includes a first pipe engagement device; a second pipe engagement device; measuring sensor; engine; one or more processors; and a welding torch. The first pipe engagement device is configured to engage with the inner surface of the first pipe, allowing the first pipe engagement device to be fixed relative to the first pipe. The second pipe engagement device is configured to engage with the inner surface of the second pipe allowing the second pipe engagement device to be fixed relative to the second pipe. The measuring sensor is located between the first pipe engaging device and the second pipe engaging device, wherein the measuring sensor is configured to emit a research radiation beam. The engine is functionally connected to the measuring sensor for directing the research radiation beam along the contact surface between the tubes. One or more processors are operatively coupled to the measurement sensor to determine the profile of the contact surface between the two pipes. The welding torch is configured to create a weld between the pipes based on the profile of the contact surface between the pipes.

[0019] Another aspect of the present patent application provides a field system for welding two pipes. The field system includes a first pipe engagement device; a second pipe engagement device; measuring sensor; engine; one or more orientation motors; one or more processors; and a welding torch assembly. The first pipe engagement device is configured to engage with the inner surface of the first pipe, allowing the first pipe engagement device to be fixed relative to the first pipe. The second pipe engagement device is configured to engage with the inner surface of the second pipe allowing the second pipe engagement device to be fixed relative to the second pipe. The measuring sensor is located axially between the first pipe engaging device and the second pipe engaging device, wherein the measuring sensor is configured to check the area of the contact surface between the pipes and generate profile data based on such a check. One or more orientation motors are operatively connected to the measuring sensor for directing the research radiation beam along the contact surface between the tubes. One or more processors are operatively coupled to the measurement sensor and configured to receive profile data from the measurement sensor to determine one or more characteristics of the contact surface area between the pipes. The welding head assembly comprises a welding torch and at least one welding torch motor, wherein the welding torch and at least one welding torch motor are driven by one or more processors to create a weld between pipes based on one or more characteristics of the area of contact surface between pipes.

[0020] Another aspect of the present patent application provides a field system for welding two pipes. The field system includes a frame configured to be placed inside the pipes; a plurality of rollers configured to hold the frame in a rotatable manner; a drive motor that drives rollers to move the frame inside the tubes; a brake system holding the frame in a predetermined position inside the pipes from moving; a measurement sensor held by the frame, the measurement sensor being configured to detect characteristics of a contact surface area between pipes; a welding torch held by the frame; one or more batteries held by the frame, wherein the one or more batteries are configured to power the drive motor, the measurement sensor, and the welding torch; and one or more processors operatively associated with the drive motor, the measurement sensor, and the welding torch.

[0021] Another example of the present patent application provides a method for welding together a pair of insulated pipes. Each pipe contains an inner metal part of the pipe surrounded by an insulating material. The ends of the welded pipe have a protruding metal inner part. The method includes aligning the protruding metal ends to be welded, welding the protruding metal ends to each other, heating the welded protruding pipe ends, applying an insulator to the heated protruding ends of the welded pipes in such a way that the insulator adheres to the outer surface of the inner metal part of the pipe, thus isolating the previously protruding pipe parts, and applying cooling energy inside the pipes to the inner surface of the metal pipes.

[0022] Another aspect of the present patent application provides a system for welding together a pair of insulated pipes. Each pipe contains a metal interior surrounded by an insulating material. The ends of the welded pipe have a protruding metal inner part. The system includes a welding torch configured to weld the protruding metal ends of the pipe to each other; a heating device configured to heat the protruding ends of the welded pipes; an insulator supply device configured to apply an insulating material to the heated protruding ends of the welded pipes so that the insulator sticks to the outer surface of the inner metal pipe, thereby insulating the previously protruding ends of the pipes; and a cooler system that applies cooling energy to the inner surface of the metal pipes, which helps to cool the metal pipes after application of the insulating material.

[0023] Another example of the present patent application provides a method for welding together a pair of insulated pipes. Each pipe contains an inner metal part of the pipe surrounded by an insulating material. The ends of the welded pipe have a protruding metal inner part. The method includes aligning the protruding metal pipe ends to be welded, welding the protruding metal pipe ends to each other, heating the protruding ends of the welded pipes, applying an insulator to the heated protruding ends of the welded pipes in such a way that the insulator adheres to the outer surface of the inner metal part of the pipe, thus insulating previously protruding ends of the pipes, and the application of cooling energy inside the pipes to the inner surface of the metal pipes after applying the insulator; and performing a pipeline deployment procedure. The use of cooling energy reduces the waiting time between the application of the insulator and the execution of the pipeline deployment procedure.

[0024] Another aspect of the present patent application provides a welded pipe assembly. The welded pipe assembly comprises a first metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches; a second metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches; weld metal connecting the first pipe to the second pipe, wherein the weld metal comprises a plurality of weld layers, wherein the plurality of weld layers comprises a root pass and a hot pass located on top of the root bead, with the hot pass layer being closer internal longitudinal axis of the welded first and second pipes than the root roller.

[0025] Another aspect of the present patent application provides a welded pipe assembly. The node contains the first metal pipe having a length of at least 30 feet and an outer diameter of less than 24 inches; a second metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches; weld metal connecting the first pipe to the second metal pipe, wherein the weld metal comprises a first internal groove made in the first metal pipe and a second internal groove made in the second metal pipe, and a root welding pass of the weld metal, located in the region defined by the first internal groove and the second internal groove.

[0026] Another aspect of the present patent application provides a pipe cooling system. The pipe cooling system comprises a frame, a plurality of rollers, a drive motor, a braking system, and one or more processors. The frame is made with the possibility of placement inside the welded pipes. Many rollers are made with the possibility of holding the frame with the possibility of rotation. The drive motor controls the movement of the frame inside the tubes. The braking system keeps the frame in a predetermined position inside the pipes from moving. The cooler is a cooler held by the frame, where the cooler applies cooling energy to the inner surface of the metal pipes, which helps to cool the welded metal pipes. One or more processors are operatively associated with the drive motor, brake system, and coolant. One or more processors control the chiller to reduce the temperature of the welded pipes to a predetermined level.

[0027] Another aspect of the present patent application provides a welded pipe assembly. The welded pipe assembly comprises a first metal pipe; a second metal pipe; and a weld metal connecting the first metal pipe to the second metal pipe. The first metal pipe has a length of at least 30 feet and an outside diameter of less than 24 inches. The second metal pipe is at least 30 feet long and less than 24 inches outside diameter. The weld metal contains a plurality of weld layers. The plurality of weld layers comprises a root welding passage and a hot passage located on top of the root welding passage. The hot pass layer is located closer to the inner longitudinal axis of the welded first and second pipes than the root pass.

[0028] Another aspect of the present patent application provides a welded pipe assembly. The welded pipe assembly comprises a first metal pipe, a second metal pipe, and a welded joint connecting the first metal pipe to the second metal pipe. The first metal pipe has a length of at least 30 feet and an outside diameter of less than 24 inches. The second metal pipe is at least 30 feet long and less than 24 inches outside diameter. The welded joint contains the first internal groove, made in the first metal pipe, and the second internal groove, made in the second metal pipe, and the passage when welding the weld root of the weld metal, located in the area defined by the first internal groove and the second internal groove .

[0029] Another aspect of the present patent application provides a field system for welding two pipes. The field system includes a first pipe engagement device configured to engage with an inner surface of the first pipe, allowing the pipe engagement device to be secured with respect to the first pipe; a second pipe engaging device configured to engage with an inner surface of the second pipe, allowing the pipe engaging device to be secured with respect to the second pipe; one or more welding torches configured to be placed inside the pipes to create an internal weld on the surface of the region between the pipes; a motor operatively associated with one or more welding torches for rotating one or more welding heads along a contact surface between pipes to be welded; one or more processors controlling the motor and one or more welding torches, wherein the one or more processors control the motor and one or more welding torches to form a complete circumferential weld along the contact surface region by rotating one or more welding torches along the contact surface region in one direction until the girth weld is completed.

[0030] Yet another aspect of the present patent application provides an inspection system for pre-checking a contact surface area between two pipes that are butt-welded. The system contains a frame made with the possibility of placement inside the pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for moving the frame inside the pipes; a brake system that holds the frame in a predetermined position inside the pipes from moving; a sensor movable with the frame that detects a contact surface area between pipes; a measuring sensor configured to generate signals based on the profile of the area of the contact surface between the pipes; a motor that rotates the measuring sensor along the area of the contact surface; and one or more processors operatively associated with the drive motor, the sensor, the measurement sensor, and the motor, wherein the one or more processors control the drive motor to move the scaffold through at least one of the tubes until the sensor detects a contact surface area between pipes, one or more processors control a braking system to hold the frame in position inside the pipes from moving, which positions the sensor with respect to the contact surface area between the pipes so that the sensor can detect the profile of the contact surface area between the pipes; one or more processors control a sensor and a motor to scan the contact surface area between the pipes, and, in response to detecting one or more undesirable characteristics of the contact surface area, based on these data, one or more processors send instructions.

[0031] Another aspect of the present patent application provides a field system for preliminary inspection of the area of the contact surface between two butt-welded pipes. The system contains a frame made with the possibility of placement inside the pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for moving the frame inside the pipes; a brake system holding the frame in a predetermined position inside the pipes from moving; a measuring sensor configured to generate signals based on the profile of the area of the contact surface between the pipes; one or more orientation motors rotating the measurement sensor along the contact surface region; and one or more processors operatively associated with the drive motor, the sensor, the measurement sensor, and the engine, wherein the one or more processors control a braking system for holding the frame in position inside the tubes from moving, which positions the measurement sensor with respect to the contact surface area between pipes so that the measuring sensor can detect the profile of the area of the contact surface between the pipes; one or more processors control a sensor and a motor to scan a contact area between pipes to generate pre-weld contact surface data, and, in response to detecting one or more undesirable pre-weld contact surface characteristics, based on the data, one or more processors send instructions.

[0032] Yet another aspect of the present patent application provides a method for pre-inspection of a contact surface area between two butt-welded pipes. The method includes moving the frame inside at least one of the pipes to be welded; detection of the area of the contact surface between the pipes; holding the frame in the area of the contact surface between the pipes from moving; detection of the profile of the area of the contact surface between the pipes; and, in response to detection of one or more undesirable characteristics of the area of the contact surface between the pipes, generating, based on these data, instructions.

[0033] Another aspect of the present patent application provides a pipe cooling system. The pipe cooling system comprises a frame configured to be placed inside the welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor that drives rollers to move the frame inside the tubes; a brake system holding the frame in a predetermined position inside the pipes from moving; a cooler carried by the frame, wherein the cooler applies cooling energy to the inner surface of the metal pipes, which contributes to the cooling of the welded metal pipes; and one or more processors operatively associated with the drive motor, the brake system, and the cooler, wherein the one or more processors control the cooler to reduce the temperature of the welded pipes to a predetermined level.

[0034] One aspect of the present patent application provides a method for welding two pipes. The method includes internal fixation of the first pipe with the first clamp; fixing the second tube internally with a second clamp, wherein the first and second tubes are fixed in such a way that they are butted against each other with a contact surface area therebetween; scanning the area of the contact surface based on the position inside the pipes and between the clamps to obtain data about the profile of the area of the contact surface between the pipes; welding two pipes located end-to-end with respect to each other based on the profile data; and internal checking of the welded pipes based on the position inside the pipes and between clamps.

[0035] One aspect of the present patent application provides a welding data processing system facilitating pipe welding remotely from the field system for performing welding operations between a first pipe and a second pipe. As an example, the remote field system includes a measurement sensor configured to emit a research beam to scan the profile of the contact surface area between the first and second pipes, and a welding torch configured to create a weld between the first and second pipes based on the profile of the contact surface area. between the first and second pipes. The welding data processing system comprises: a receiver configured to receive, from a remote welding system, profile data determined by scanning a contact surface area between pipes with a measuring sensor; one or more processors configured to compare one or more characteristics of the profile data when scanning an area with one or more characteristics of predefined profile data over predefined areas of the contact surface, and configured to determine control system operation data for a remote field system based on such comparisons; and a transmitter configured to transmit control system operation data to a remote field system. The control system operation data is configured to cause the welding torch to perform one or more welding operations in the area of the contact surface between the pipes.

[0036] One aspect of the present patent application provides a method for welding pipes. Said method includes: aligning the ends of two pipes to be welded, wherein the pipes to be welded comprise an inner metal part of the pipe surrounded by an insulating material, the metal inner part of the pipe protrudes beyond the parts of the pipe adjacent to the ends of the pipes to be welded; internally welding the aligned pipes to each other to form a welded joint; generating welding data during welding of aligned ends, wherein the welding data corresponds to welding parameters associated with welding; inspection of the weld with a verification laser from inside the welded pipes to obtain data on the internal inspection of the weld; checking the weld with a source of research radiation to obtain data on the verification using radiation; transmitting welding data, internal verification data and radiation verification data to a remote computer system to obtain additional welding data; and retrieving additional welding data collected. Additional welding data is derived from the transmitted data and additional test data obtained by the remote system by testing other pipes.

[0037] One aspect of the present patent application provides a field system for facilitating field inspection and performing, based on it, physical operations. The specified field system contains: a field device configured to perform operations that physically affect the object; a verification device configured to scan the object; and one or more processors in communication with the verifier and configured to receive verifier data associated with the object being scanned by the verifier. One or more processors are in communication with the remote computer system, and are configured to transmit test data to the remote computer system. One or more processors are configured to receive data related to the execution of operations from a remote computer system capable of responding to the transmission of verification data and instructing the field device to perform operations that physically affect the object, based on the data related to the execution of operations. Data related to the execution of operations is derived from the verification data and other verification data associated with a single scan of another object.

[0038] One aspect of the present patent application provides a method for facilitating field inspection and performing, based on it, physical operations. Said method includes: scanning the inspection device of the field system of the object to provide inspection data associated with the scanning of the object, one or more processors; transmitting, by one or more field system processors, test data to a remote computer system; receiving, by one or more processors, data associated with the execution of operations that physically affect the object, from a remote computer system capable of responding to the transmission of verification data; and directing one or more processors, based on the data associated with the execution of the operations, to perform operations that physically affect the object. Data related to the execution of operations is derived from the verification data and other verification data associated with a single scan of another object.

[0039] One aspect of the present patent application provides a computer system facilitating field verification and physical operations based on such verification remotely from the field system on which such field verification and physical operations are performed. The remote field system includes a verification device configured to scan an object and a field device configured to perform operations that physically affect the object. Said computer system comprises: a receiver configured to receive data related to scanning of an object by the inspection device from a remote field system; one or more processors configured to process the verification data to generate data related to performing operations that physically affect the object; and a transmitter configured to transmit operation related data to the remote field system instructing the remote field system to perform operations that physically affect the object, the operations being performed based on the operation data associated with the operation.

[0040] One aspect of the present patent application provides a method for facilitating field testing and performing physical operations based on such testing remotely from the field system on which such field testing and physical operations are performed. The remote field system includes a verification device configured to scan an object and a field device configured to perform operations that physically affect the object. Said method includes: receiving, by the receiver, data related to scanning of an object by a checking device from a remote field system; processing, by one or more processors, the verification data to generate data related to the execution of operations that physically affect the object; and transmitting, by the transmitter, operation related data to the remote field system, causing the remote field system to perform operations that physically affect the object, the operations being performed based on the operation data associated with the operation.

[0041] One aspect of the present patent application provides a computer system for facilitating field inspection and performing, based on it, physical operations. The field system includes a verification 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 from the computer system verification data associated with scanning of an object by the verification device. The scanning of an object by a checking device follows the performance of one or more operations by one or more field devices that physically act on the object. One or more operations are performed using the first set of input parameters. The computer system also includes one or more processors configured to: determine, based on the inspection data, defects associated with the object; generate an operation execution protocol associated with at least one operation type from one or more operations in response to the detection of a defect, wherein the operation execution protocol contains a second set of input parameters having at least one input parameter different from the first set of input parameters ; select an operation execution protocol for performing a subsequent operation similar to at least one or more operations; and generate, based on the at least one incoming operation protocol parameter, data associated with the execution of the subsequent operation. The computer system further comprises a transmitter configured to transmit data associated with the operation to one or more field systems to perform a subsequent operation. The subsequent operation is performed based on the data associated with the execution of the operations.

[0042] One aspect of the present patent application provides a method for facilitating field inspection and performing, based on it, physical operations. The field system includes a verification 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 the receiver from the field system the verification data associated with the scanning of the object by the verification device. The scanning of an object by a checking device follows the performance of one or more operations by one or more field devices that physically act on the object. One or more operations are performed using the first set of input parameters. Said method also includes: detection of a defect by one or more processors based on inspection data related to the object; one or more processors generating an operation protocol associated with one type of operation from one or more operations responsive to the detection of a defect, wherein the operation execution protocol contains a second set of input parameters having at least one input parameter different from the first set of input parameters ; one or more processors selecting an operation protocol to perform a subsequent operation similar to at least one of the one or more operations; generating by one or more processors, based on at least one input parameter, the operation protocol, data related to the execution of a subsequent operation; and transmitting, by the transmitter, data relating to the execution of the operations of one or the field systems, instructing the one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the data associated with the execution of the operations.

[0043] One aspect of the present patent application provides a computer system for facilitating field inspection and performing, based on it, physical operations. The field system includes a verification 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 from the computer system verification data associated with scanning an object. Scanning an object follows the execution of one or more operations that actually affect the object. One or more operations are performed using the first set of input parameters. The computer system also includes one or more processors configured to: determine, based on the inspection data, whether the quality of one or more aspects of the object, obtained as a result of performing one or more operations, exceeds the quality standards specified in a predefined quality profile; generate an operation protocol associated with at least one type of operation from one or more operations, wherein the operation protocol is generated to include one or more parameters from the set of input parameters responsive to the quality of one or more aspects of the object exceeding the quality standards specified in a predefined quality profile; select an operation protocol for performing a subsequent operation similar to at least one of the one or more operations; and generate, based on at least one input parameter of the operation protocol, data related to the execution of the subsequent operation. The computer system further comprises a transmitter configured to transmit data associated with the operation to one or more field systems for performing a subsequent operation. The subsequent operation is performed based on the data associated with the execution of the operations.

[0044] One aspect of the present patent application provides a method for facilitating field inspection and performing, based on it, physical operations. The field system includes a verification 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 the receiver from the field system the verification data associated with scanning the object. Scanning an object follows the execution of one or more operations that actually affect the object. One or more operations are performed using the first set of input parameters. Said method also includes: determining by one or more processors, based on the verification data, whether the quality of one or more aspects of the object obtained as a result of performing one or more operations exceeds the quality standards specified in a predefined quality profile; one or more processors generating an operation protocol associated with at least one type of operation from one or more operations, wherein the operation protocol is generated to include one or more parameters from the set of input parameters responsive to the quality of one or more aspects of the object exceeding the quality standards specified in the predefined quality profile; one or more processors selecting an operation protocol to perform a subsequent operation similar to at least one of the one or more operations; and generating by one or more processors, based on at least one input parameter of the operation protocol, data related to the execution of a subsequent operation; and transmitting, by the one or more processors, data associated with the execution of the operations to the one or more field systems, causing the one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the data associated with the execution of the operations.

[0045] One aspect of the present patent application provides a computer system for facilitating field inspection and performing, based on it, physical operations. The computer system also includes one or more processors configured to: receive from one or more field systems data associated with the study of one or more operations performed on a plurality of objects. The set of objects contains (i) one or more objects determined to have a defect as a result of performing one or more investigated operations and (ii) one or more objects that do not have defects. The one or more processors are also configured to: compare, based on study-related data, a first set of operations studies performed on an item identified as having a defect with one or more other sets of operations studies performed on one or more other objects, without defects; determining, based on the comparison, differences between the first set of studies and one or more other sets of studies; and directing, based on these differences, to implement the operation trigger such that the field system performs the operations corresponding to the operation trigger when the state corresponding to the differences occurs during a subsequent operation that physically affects one or more additional objects.

[0046] One aspect of the present patent application provides a method for facilitating field inspection and performing, based on it, physical operations. The method includes receiving by one or more processors from one or more field systems data associated with studies of one or more operations performed on a plurality of objects. The set of objects contains (i) one or more objects determined to have a defect as a result of performing one or more investigated operations and (ii) one or more objects that do not have defects. Said method also includes: comparing by one or more processors, based on data associated with the study, the first set of operations studies performed on an object determined to have a defect with one or more other sets of operations studies performed on one or more other objects, without defects; determining by one or more processors, based on the comparison, differences between the first set of studies and one or more other sets of studies; and causing one or more processors, based on those differences, to implement an operation trigger such that the field system performs the operations corresponding to the operation trigger when the state corresponding to the differences occurs during a subsequent operation that physically affects one or more additional objects.

[0047] One aspect of the present patent application provides a system for aligning and welding together two pipe segments. The system comprises a welding mechanism for welding a mating surface between two segments, wherein the welding mechanism comprises an articulated welding torch, a laser sensor for reading the profile of the mating surface, and an electronic controller for receiving information signals from the laser sensor to control the position and/or orientation of the welding torch; an alignment mechanism for controlling alignment of the longitudinal axis of at least one segment with respect to the other; and, at the same time, the welding mechanism further comprises a carriage for fixing the position of the welding mechanism in the pipe and a part of the welding mechanism capable of rotating relative to its surrounding part inside the pipe; and wherein the welding torch and the laser sensor are rotatably held by the welding mechanism part such that the welding torch follows the laser sensor along the mating surface during welding.

[0048] One aspect of the present patent application provides a method for aligning and welding together two pipe segments. Said method comprises the steps of: placing a first pipe segment on an alignment device; placing an internal welder having a laser and a welding torch in the first pipe segment; overall alignment of the second pipe segment with respect to the first pipe segment and the welder; gripping the outside of the first and second pipe segments to adjust the axial position of the inner welder so that mating surfaces of the first and second pipe segments generally match; adjusting the alignment of the first and second pipe segments with the alignment device based on signals from the internal welder; starting a root weld cycle in which the laser scans the mating surface, the welding torch follows the laser, and the laser output signals are used to control the position of the hinged welding torch, where the position and orientation of the welding torch relative to the mating surface is controlled to produce a quality weld; determining the profile of the mating surface due to the laser; releasing the leveling device and removing the inner welder from the open end of the pipe segment; and repositioning the next pipe segment on the external alignment mechanism in preparation for welding the next mating surface.

[0049] One aspect of the present patent application provides an internal heat exchanger (IHEX) for pipeline welding. The internal heat exchanger includes a drive system configured to move the IHEX to a certain position within at least one pipe section adjacent to the location of a welded joint with another pipe section; a cooling section comprising a cooling device configured to selectively cool one or more portions of the inner surface of at least one pipe section; and a controller in communication with the refrigeration device and configured to actuate the refrigeration section when the IHEX is at a certain location within at least one section of the pipe.

[0050] One aspect of the present patent application provides a welding system. The welding system contains a plurality of welding stations, each welding station contains a computer of the welding station and a welding system that is connected with the possibility of exchanging data with the computer of the welding station, each welding station contains one or more sensors, wherein one or more sensors are configured to measure welding data , including data on the speed of the supply wire; a plurality of wireless devices communicatively connected to one or more welding station computers for receiving welding data, including measured power wire speed data; and a cloud server connected to communicate with wireless devices, wherein the cloud server is configured to process welding data, including power wire speed data, and configured to determine the amount of consumed welding material used by a plurality of welding stations in a given period of time wherein the cloud server is configured to transmit the amount of used consumable welding material to one or more wireless devices.

[0051] One aspect of the present patent application provides a welding system. The welding system comprises a welding station, wherein the welding station comprises a welding station computer and a welding system connected to communicate with the welding station computer, the welding system comprises a welding consumable feeder, a welding device and a welding consumable feeder motor assembly that moves the welding consumable to the welding machine a welding device operatively connected to the welding station computer and configured to measure the weight of the supplied welding material and transmit the weight of the supplied welding material to the welding station computer in the form of weight data; and sensors operatively associated with the welding material supply motor assembly and the welding station computer to transmit the speed of the welding material supply motor assembly to the welding station computer in the form of welding data; wherein the welding station computer is operatively coupled to the welding material supply device motor assembly and configured to control the speed of the motor assembly based on the speed data.

[0052] One aspect of the present patent application provides a welding control method. The method includes measuring, using a weight measuring device, a first mass of a supplied welding material at a first time; measuring, using the weight measuring device, a second mass of the supplied welding material at a second time point following the first time point; calculating, using a computer, a difference in the measured mass between the first mass and the second mass, wherein the difference in the measured mass corresponds to the measured used welding consumable; measuring, using a computer, an estimated mass of the used welding material based on the speed of the motor assembly supplying the welding material to the welding device; computer comparing the calculated mass of the used welding consumable with the measured mass of the used welding consumable; and adjusting the speed of the motor assembly by the computer to correct slippage of the motor assembly.

[0053] One aspect of the present patent application provides a welding system. The welding system comprises a plurality of welding stations, each welding station includes a welding station computer and a welding system connected to communicate with the welding station computer, wherein each welding system comprises one or more sensors, and one or more sensors are configured to measure data on welding, including feed wire speed; a plurality of wireless devices communicatively connected to one or more welding station computers for receiving welding data, including measured power wire speed data; and each welding station computer is configured to process welding data, including power wire speed data, for the welding system with which they are in communication communication, wherein the welding station computer is configured to determine the amount of consumable welding material used by the welding system within a given period of time and generate, based on it, consumption data.

[0054] One aspect of the present patent application provides a system for testing a pipeline. The system comprises a verification device configured to generate non-destructive test data relating to at least a portion of the weld; said test device transmits said non-destructive test data to a second device that is configured to receive said non-destructive test data; and said verification device is configured to operate remotely from means for analyzing said non-destructive test data.

[0055] One aspect of the present patent application provides a system for non-destructive inspection of a pipeline. The system comprises visualization equipment for generating non-destructive test data relating to a portion of a welded pipe; a remote processing device configured to receive and process test data relating to said portion of said welded pipe.

[0056] One aspect of the present patent application provides a method for non-destructive inspection of a pipeline. Said method comprises the steps of: providing imaging equipment; generating non-destructive test data; providing the means to provide said non-destructive test data for analysis; and said non-destructive test data is provided for analysis at a location remote from the tested pipe part and equipment adjacent to the tested pipe part.

[0057] One aspect of the present patent application provides a system for building a pipeline. The system contains a real-time welding data recording system; and said welding data is provided for analysis by computerized means and/or subject matter experts.

[0058] One aspect of the present patent application provides a computer program product that provides a welding process. The computer program product comprises computer readable program code means providing welding data to a computer memory; computer readable program code means that provide data to said memory from a dataset containing pipeline data; computer readable program code means that process said welding data and said pipeline data to provide an output record.

[0059] One aspect of the present patent application provides a data management method performed on a computer. Said method comprises the steps of: transmitting first data from the first device to the second device, said first data being pipeline construction related data; processing said first data by network means using cloud computing.

[0060] One aspect of the present patent application provides a computer system. The system comprises a first device containing a processor that processes pipeline construction data, wherein said first device transfers said pipeline construction data to memory using cloud computing, said pipeline construction data is processed by the processor using cloud computing.

[0061] These and other aspects of the present patent application, as well as the methods of performing the operations and functions of the associated structural elements, as well as the combination of parts and the organization of production, will become more apparent after consideration of the following description and the appended claims with reference to the accompanying drawings, all of which are part of the present description, while the same designated reference positions correspond to details in different figures. In one embodiment of the present patent application, the structural components illustrated herein are drawn to scale. However, it should be expressly understood that these graphics are for illustrative and descriptive purposes and are not intended to describe the limitations of this patent application. It should also be understood that the features of one embodiment of the invention set forth herein may be used in other embodiments of the invention set forth herein. In this detailed description and claims, the singular forms ʺa,ʺ ʺan,ʺ and ʺtheʺ include the plural unless the context clearly requires otherwise. In addition, in this specification and claims, the term "or" means "and/or" unless the context clearly requires otherwise. It should also be understood that some components and features described herein may be described in relation to only one (individual) of such components, and that additional components of the same type described herein may not be described in detail in order to reduce redundancy. . Just by way of example, where one welding torch is described, a similar configuration can be used for additional welding torches provided in another system (e.g. internal welding system) and can also be used in other welding systems (e.g. butt welders) described in this document. Likewise, various components such as clips, seals, brakes, weld metal consumption detection systems, or other components described herein may be used in various embodiments of the invention described herein. For example, the braking system, motors, clamp seals described in one embodiment of the invention may be used in other embodiments of the invention described herein, as will be appreciated by those skilled in the art.

BRIEF DESCRIPTION OF GRAPHICS

[0062] FIG. 1A and 1B illustrate process flow diagrams for welding pipe segments, wherein FIG. 1A illustrates a high level flow diagram of the method, and FIG. 1B illustrates a more detailed flow diagram of a method, in accordance with an embodiment of the present patent application;

[0063] FIG. 2 illustrates a cross section of a welded joint connecting a first pipe and a second pipe, in accordance with an embodiment of the present patent application;

[0064] FIG. 2A and 2B illustrate the details of a groove for one pipe segment and for a connection (before welding) between two pipe segments in accordance with an embodiment of the present patent application;

[0065] FIG. 2C-2F illustrate front view, perspective view, side view, and detail view of an angle gauge used as a groove gauge in accordance with an embodiment of the present patent application;

[0066] FIG. 2G-2I illustrate a cross section of a pipeline with a weld formed between its pipes, wherein FIG. 2G illustrates a welded joint in which the root pass is formed by the internal welding system and the layers of the fill pass and the facing weld pass are formed by the external welding system, wherein FIG. 2H illustrates a welded joint in which the root pass is formed by the internal welding system and the layers of the hot pass, fill pass, and facing weld pass are formed by the external weld system, and FIG. 2I illustrates a weld formed by an external welding system according to an embodiment of the present patent application;

[0067] FIG. 3-7 illustrate flow charts of pipe segment welding methods for different welding stations in accordance with an embodiment of the present patent application;

[0068] FIG. 7A and 7B illustrate the appearance of a clamp used to externally butt pipes to each other, in accordance with an embodiment of the present patent application;

[0069] FIG. 8 illustrates a perspective view of a system for welding two pipe segments in accordance with an embodiment of the present patent application;

[0070] FIG. 9 illustrates an enlarged view of the contact surface between two pipe segments being welded using the system of FIG. 8 according to an embodiment of the present patent application;

[0071] FIG. 9A illustrates a partial cross-section of a pipeline in which the welding torch is ideally aligned with the internal groove (along the longitudinal axis of the pipes), in accordance with an embodiment of the present patent application;

[0072] FIG. 10-1 illustrates the system in FIG. 8 in which an internal welding system is introduced into the first pipe segment, in accordance with an embodiment of the present patent application;

[0073] FIG. 10-2 and 10-3 illustrate the system in FIG. 8 in which the internal welding system is inserted into the first pipe segment and the second pipe segment is aligned with the first pipe segment in accordance with an embodiment of the present patent application;

[0074] FIG. 10A and 10B illustrate the appearance of an internal welding system built and installed to fit in pipes having an outside diameter of 26 to 28 inches, and pipes having an outside diameter of less than 24 inches, respectively, in accordance with an embodiment of the present patent application;

[0075] FIG. 10C and 10D illustrate a left side perspective view and a bottom perspective view of a first pipe and second pipe transportation and handling platform according to an embodiment of the present patent application;

[0076] FIG. 10E and 10F illustrate two pipe alignment errors, with FIG. 10E illustrates the pipe angular alignment error, and FIG. 10F illustrates a pipe alignment error;

[0077] FIG. 11 illustrates an internal welding system for two pipe segments in accordance with an embodiment of the present patent application;

[0078] FIG. 11A illustrates the appearance of a tether operatively connected to an internal welding system, in accordance with an embodiment of the present patent application;

[0079] FIG. 12 illustrates a detailed view of the frontmost section of the internal welding system according to an embodiment of the present patent application;

[0080] FIG. 13-22 illustrate the appearance of various components of the frontmost section of the internal welding system according to an embodiment of the present patent application;

[0081] FIG. 22A illustrates an exemplary wire winding spool according to an embodiment of the present patent application;

[0082] FIG. 22B illustrates an exemplary welding material supply assembly according to an embodiment of the present patent application;

[0083] FIG. 23 and 24 illustrate a front view and a cross section of the central section of an internal welding system in accordance with an embodiment of the present patent application;

[0084] FIG. 25-31 illustrate the appearance of various components of the center section of an internal welding system according to an embodiment of the present patent application;

[0085] FIG. 32A and 32B illustrate side and top views of a drive section of an internal welding system in accordance with an embodiment of the present patent application;

[0086] FIG. 33 illustrates an external view of the center section of an internal welding system installed inside the pipe segments, with both clamps and seals engaging the inner surface of the pipes, and some components of the center section are not illustrated for clarity, in accordance with an embodiment of the present patent application;

[0087] FIG. 34 illustrates a cross-section of the center section of the internal welding system located inside the pipe segments, and some components of the center section are not illustrated for clarity, in accordance with an embodiment of the present patent application;

[0088] FIG. 35 illustrates an external view of the center section of an internal welding system installed inside the pipe segments, with only the clamps engaging the inner surface of the pipes, and some components of the center section are not illustrated for clarity, in accordance with an embodiment of the present patent application;

[0089] FIG. 35A and 35B illustrate cross-sections of the center section of the internal welding system with the clamps in the extended and folded positions, respectively, and some components of the center section not illustrated for clarity, in accordance with an embodiment of the present patent application;

[0090] FIG. 35C illustrates a side (front) view of an internal welding system according to an embodiment of the present patent application;

[0091] FIG. 36 illustrates an external view of a clamp shoe of an internal welding system according to an embodiment of the present patent application;

[0092] FIG. 37 illustrates an external view of the spider clamp of an internal welding system according to an embodiment of the present patent application;

[0093] FIG. 38 illustrates an external view of a clip shoe pin of an internal welding system according to an embodiment of the present patent application;

[0094] FIG. 39 and 40 illustrate a clamp assembly of an internal welding system with a clamp shoe pin and a lever connected thereto, in accordance with an embodiment of the present patent application;

[0095] FIG. 41 and 42 illustrate a front perspective view and a back perspective view of a welding head assembly of an internal welding system according to an embodiment of the present patent application;

[0096] FIG. 43 illustrates another rear perspective view of the welding torch assembly of the internal welding system, while the welding torch of the welding head is raised to the desired welding position, in accordance with an embodiment of the present patent application;

[0097] FIG. 44-46 illustrate a left side perspective view, a perspective view, and a cross section of a welding head assembly, with some components of the welding head assembly not illustrated for clarity, in accordance with an embodiment of the present patent application;

[0098] FIG. 47, 48 and 49 illustrate a perspective view of the welding head assembly with the welding torch positioned, by means of an axial positioning system, at the central axial position in FIG. 47 and the welding torch is positioned, by means of an axial positioning system, in the right and left axial positions in FIG. 48 and 49, respectively, in accordance with an embodiment of the present patent application;

[0099] FIG. 50 and 51 illustrate a left side perspective and exploded view of a welding head assembly, with some components of the welding head assembly not illustrated for clarity, in accordance with an embodiment of the present patent application;

[00100] FIG. 52 illustrates a bottom perspective view of an upper positioning member of a welding head assembly according to an embodiment of the present patent application;

[00101] FIG. 53 illustrates a top elevational view of a welding head assembly, with some components of the welding head assembly omitted for clarity, in accordance with an embodiment of the present patent application;

[00102] FIG. 54 illustrates a cross-sectional view of a welding head assembly in which the welding torch is located in a normal, non-tilted position, in accordance with an embodiment of the present patent application;

[00103] FIG. 55 and 56 illustrate, respectively, a rear perspective view and a cross-sectional view of a welding head assembly in which the welding torch is set by the tilt angle control system to a +5° tilted position, in accordance with an embodiment of the present patent application;

[00104] FIG. 56A illustrates a cross-sectional view of a welding head assembly according to an embodiment of the present patent application.

[00105] FIG. 57 and 58 illustrate, respectively, a rear perspective view and a cross section of a welding head assembly in which the welding torch is set by the tilt angle control system to a tilt position of -5° according to an embodiment of the present patent application;

[00106] FIG. 59 illustrates an exploded view of the weld head assembly, with some components of the weld head assembly omitted for clarity, in accordance with an embodiment of the present patent application;

[00107] FIG. 60A-63 illustrate a schematic of an internal welding system with one welding torch, a control chamber, and two test probes, in accordance with an embodiment of the present patent application;

[00108] FIG. 64-69 illustrate a schematic representation of an internal welding system with two welding torches, a control chamber and two test sensors, in accordance with an embodiment of the present patent application;

[00109] FIG. 70 illustrates a schematic diagram of compressed air flow through an internal welding system, in accordance with an embodiment of the present patent application;

[00110] FIG. 71 is a schematic diagram showing power flow distribution including welding power supply, communication data transmission and control data transmission through the internal welding system according to an embodiment of the present patent application;

[00111] FIG. 72 illustrates a schematic diagram of shielding gas flow through an internal welding system, in accordance with an embodiment of the present patent application;

[00112] FIG. 72A, 72B and 72C illustrate, respectively, close-up views of the internal welding torch used in the prior art system and the internal welding system, the pipes having a wide range of gap alignment and radial displacement;

[00113] FIG. 72D illustrates exemplary welding parameters for welding, bottom-up and top-down welding procedures, in accordance with an embodiment of the present patent application;

[00114] FIG. 73 illustrates a perspective view of a system for welding two outer edged pipe segments held on alignment mechanisms, in accordance with an embodiment of the present patent application;

[00115] FIG. 74 illustrates an enlarged external view of the contact surface between two pipe segments being welded using the system of FIG. 73, in accordance with an embodiment of the present patent application;

[00116] FIG. 75 illustrates a system in which a welding system is inserted inside a pipe segment, in accordance with an embodiment of the present patent application, with one of the pipe segments omitted for clarity;

[00117] FIG. 76 illustrates an enlarged view of the section illustrated in FIG. 75 illustrating the welding portion of a welding system set in position to weld in a pipe segment, in accordance with an embodiment of the present patent application, with one of the pipe segments omitted for clarity.

[00118] FIG. 77 illustrates a cross section of the detail in FIG. 76 taken along the B-B axis showing the layout of various parts of the welding mechanism according to the embodiment of the present patent application;

[00119] FIG. 78 and 79 illustrate a side view of the welding system illustrated in FIG. 75 with the pipe segment omitted for clarity, in accordance with an embodiment of the present patent application;

[00120] FIG. 80 illustrates a perspective view of the system illustrated in FIG. 73 in a configuration showing a first procedure in which a pipe segment is placed on an external alignment mechanism according to an embodiment of the present patent application;

[00121] FIG. 81 illustrates a perspective view of the system illustrated in FIG. 73 in a configuration showing the following with respect to FIG. 80 a procedure in which a welding system is introduced into a pipe segment according to an embodiment of the present patent application;

[00122] FIG. 82 illustrate a side view of a portion of the welding mechanism of the system illustrated in FIG. 73, in accordance with an embodiment of the present patent application;

[00123] FIG. 83 illustrates an enlarged perspective view of a section of the welding mechanism portion of the system illustrated in FIG. 73, in accordance with an embodiment of the present patent application;

[00124] FIG. 84 illustrates another enlarged perspective view of a section of the welding mechanism portion of the system illustrated in FIG. 73, in accordance with an embodiment of the present patent application;

[00125] FIG. 85 illustrates an enlarged perspective view of the pivot mechanism of the system illustrated in FIG. 73, in accordance with an embodiment of the present patent application;

[00126] FIG. 86 illustrates a purge and test system in accordance with an embodiment of the present patent application;

[00127] FIG. 87 illustrates a detailed view of the frontmost section of the purge and test system according to an embodiment of the present patent application;

[00128] FIG. 88 illustrates a purge assembly of a purge and test system according to an embodiment of the present patent application;

[00129] FIG. 89 and 90 illustrate a front view and a cross section of the central section of the purge and test system in accordance with an embodiment of the present patent application;

[00130] FIG. 91 illustrates the gas seals of the purge and test system in accordance with an embodiment of the present patent application;

[00131] FIG. 92 illustrates the pivot hub of the purge and test system according to an embodiment of the present patent application;

[00132] FIG. 93 illustrates a detailed view of a drive section of a purge and test system according to an embodiment of the present patent application;

[00133] FIG. 94 is a schematic diagram showing purge gas flow through a purge and test system, in accordance with an embodiment of the present patent application;

[00134] FIG. 95 is a schematic diagram showing compressed air flow through a purge and check system according to an embodiment of the present patent application;

[00135] FIG. 96 is a schematic diagram showing purge gas flow through a purge and check system in accordance with another embodiment of the present patent application;

[00136] FIG. 97 illustrates a partial view of a purge and test system in accordance with an embodiment of the present patent application;

[00137] FIG. 98 illustrates a close-up view of an external welding torch of an external welding system used in a purge and test system according to an embodiment of the present patent application;

[00138] FIG. 99 and 100 illustrate close-up views of an external welding torch of an external welding system used in the prior art system and the purge and test system, respectively, with pipes having a wide range of gap alignment and radial displacement;

[00139] FIG. 101 illustrates a butt internal welding system according to an embodiment of the present patent application;

[00140] FIG. 102 illustrates a detailed view of a power supply section of a butt internal welding system according to an embodiment of the present patent application;

[00141] FIG. 103 is a schematic diagram showing power flow distribution including welding power supply, communication data transmission and control data transmission through the butt internal welding system according to an embodiment of the present patent application;

[00142] FIG. 103A illustrates a cross-sectional view of the center section of a butt internal welding system with the clamps in the extended and folded positions, respectively, and some components of the center section not illustrated for clarity, in accordance with an embodiment of the present patent application;

[00143] FIG. 103B illustrates a method for aligning two pipes, pre-checking a contact surface area between two butt-welded pipes, welding two pipes, checking after welding a weld formed between two pipes according to an embodiment of the present patent application;

[00144] FIG. 103C illustrates a side view of a butt internal welding system in accordance with another embodiment of the present patent application;

[00145] FIG. 103D illustrates a perspective view of a butt internal welding system according to another embodiment of the present patent application;

[00146] FIG. 103E illustrates a perspective view of a welding head assembly of a butt internal welding system according to another embodiment of the present patent application;

[00147] FIG. 103F illustrates a front view of the welding head assemblies of a butt internal welding system in accordance with another embodiment of the present patent application;

[00148] FIG. 103G-103J illustrate a procedure in which one or more weld head assemblies operate in a clockwise and counterclockwise direction to perform welding operations in a butt internal welding system in accordance with another embodiment of the present patent application;

[00149] FIG. 104 illustrates a perspective view of an exemplary internal cooling system used in pipeline welding according to an embodiment of the present patent application;

[00150] FIG. 105 illustrates a perspective view of the internal cooling system illustrated in FIG. 104, just prior to insertion from the end of a pipe section according to an embodiment of the present patent application;

[00151] FIG. 106 illustrates a perspective view of the internal cooling system illustrated in FIG. 104 located inside the first pipe section, fixed by welding to the second pipe section in accordance with an embodiment of the present patent application;

[00152] FIG. 107 illustrates another view illustrated in FIG. 106, in which the internal cooling system is located inside the first and second segments in a desired position with respect to the weld, promoting internal cooling of the weld in accordance with an embodiment of the present patent application;

[00153] FIG. 108 illustrates a perspective view of the internal cooling system illustrated in FIG. 104 connected to a docking clamp according to an embodiment of the present patent application;

[00154] FIG. 109 illustrates a perspective view of the internal cooling system illustrated in FIG. 104 connected to a docking clamp according to another embodiment of the present patent application;

[00155] FIG. 110A and 110B illustrate, respectively, a perspective view and a partial perspective view of an internal cooling system used in pipeline welding according to another embodiment of the present patent application;

[00156] FIG. 111A and 111B illustrate a partial perspective view of parts of an internal cooling system used in pipeline welding, in accordance with an embodiment of the present patent application, in which the internal heat exchanger part is inside two pipe segments connected to each other by a welded joint, and a water pump is provided at the end of a section of pipe;

[00157] FIG. 112A and 112B illustrate a partial perspective view of parts of an internal cooling system used in pipeline welding, in accordance with an embodiment of the present patent application, in which the internal heat exchanger part is inside two pipe segments connected to each other by a welded joint, and a water pump is provided at the end of a section of pipe;

[00158] FIG. 113 illustrates a cross section of pipes with their protruding metal ends aligned in accordance with an embodiment of the present patent application;

[00159] FIG. 114 illustrates a cross section of pipes with a welded joint formed between their projecting metal ends, in accordance with an embodiment of the present patent application;

[00160] FIG. 115A and 115B illustrate, respectively, a cross-sectional and perspective view of pipes with a welded joint formed between their protruding metal ends, and a heater located on the pipes for heating the protruding metal ends of the welded pipes, in accordance with an embodiment of the present patent application;

[00161] FIG. 116A and 116B illustrate, respectively, a cross-sectional and perspective view of pipes with a welded joint formed between their protruding metal ends, and an insulator supply device located on the pipes for applying an insulating material to the heated protruding metal ends of the welded pipes, in accordance with an embodiment. implementation of this patent application;

[00162] FIG. 117A and 117B illustrate, respectively, a cross-sectional view of pipes with a weld formed between their protruding metal ends, and a perspective view of an insulator supply device located on the pipes for applying insulating material to the heated protruding metal ends of the welded pipes, in accordance with an embodiment. this patent application;

[00163] FIG. 118 illustrates a cross section of pipes with a weld formed between their protruding metal ends and an insulator adhered to the outer surface of the inner metal pipe, thus isolating the previously protruding pipe ends in accordance with an embodiment of the present patent application;

[00164] FIG. 119 illustrates a perspective view of a cooler system configured to apply cooling energy to the inner surface of the pipes to help cool the pipes after application of an insulating material in accordance with an embodiment of the present patent application;

[00165] FIG. 120 illustrates a partial cross-sectional view of an in-pipe cooler system in accordance with an embodiment of the present patent application;

[00166] FIG. 121 and 122 illustrate a partial cross-sectional view of an in-pipe cooler system, with FIG. 121 illustrates a refrigerant system heat exchanger in contact with the inner surface of the welded pipes to remove heat from the welded pipes, and FIG. 122 illustrates the heat exchanger in the withdrawn position and not in contact with the inner surface of the welded pipes, in accordance with an embodiment of the present patent application;

[00167] FIG. 123 illustrates a perspective view of a coolant system, with fluid nozzles configured to apply coolant to the inside surface of welded pipes to remove heat from the welded pipes, illustrated in accordance with another embodiment of the present patent application;

[00168] FIG. 124 and 125 illustrate a perspective view and a front view of a heat exchanger element or a heat sink element of a coolant system according to another embodiment of the present patent application;

[00169] FIG. 126-128 illustrate a perspective view of a system configured to facilitate placement of a coolant system within and/or removal of a coolant system from a pipe, in accordance with another embodiment of the present patent application;

[00170] FIG. 129 illustrates a partial perspective view of a cooler system with a plurality of rollers configured to engage the interior surface of one or more tubes and a drive motor configured to drive the rollers to move the frame assembly of the cooler assembly illustrated in accordance with with another embodiment of the present patent application;

[00171] FIG. 130 illustrates a perspective view of a cooler system according to another embodiment of the present patent application;

[00172] FIG. 131 illustrates a plan view of an engine power supply being moved by a cooler system frame assembly in accordance with another embodiment of the present patent application;

[00173] FIG. 132 illustrates a heat exchanger of a refrigerant system in contact with the inner surface of welded pipes to remove heat from the welded pipes in accordance with another embodiment of the present patent application;

[00174] FIG. 133 and 134 illustrate a perspective view of a cooler system according to another embodiment of the present patent application;

[00175] FIG. 135 and 136 illustrate a perspective view and partial cross section of a cooler system in accordance with another embodiment of the present patent application;

[00176] FIG. 136A illustrates a perspective view of an ultrasonic inspection station capable of inspecting a weld between welded metal pipes in accordance with an embodiment of the present patent application;

[00177] FIG. 136B illustrates a method showing a pipeline deployment procedure according to an embodiment of the present patent application;

[00178] FIG. 136C and 136D illustrate a schematic view of an S-lay and J-lay pipe procedure according to an embodiment of the present patent application;

[00179] FIG. 136E illustrates S-shaped and J-shaped pipe unwinding from a barge in accordance with an embodiment of the present patent application;

[00180] FIG. 137A illustrates a system for facilitating verification or operation of a field system in accordance with another embodiment of the present patent application;

[00181] FIG. 137B illustrates communication links between the remote computer system, the field system's field computer system, and other components of the field system, in accordance with another embodiment of the present patent application;

[00182] FIG. 137C illustrates communication links between a remote computer system and components of a field system without a field computer system, in accordance with another embodiment of the present patent application;

[00183] FIG. 138 illustrates a flow diagram of a method for facilitating, through a field system, field verification and performing physical operations based on such verification, in accordance with another implementation of the present patent application;

[00184] FIG. 139-142 illustrate a flow diagram of a method for facilitating, via a computer system, field verification and performing physical operations based on such verification, in accordance with other embodiments of the present patent application;

[00185] FIG. 143 illustrates an example of a pipeline according to another embodiment of the present patent application;

[00186] FIG. 144 illustrates a welding station according to another embodiment of the present patent application;

[00187] FIG. 145 illustrates a plurality of welding stations according to another embodiment of the present patent application;

[00188] FIG. 146 illustrates a schematic diagram of a system with multiple welding stations connected to communicate with multiple control stations and collect data logs in accordance with another implementation of the present patent application;

[00189] FIG. 147 illustrates a schematic diagram of a system with multiple welding stations connected to communicate with multiple control stations and collect data logs in accordance with another implementation of the present patent application;

[00190] FIG. 148 illustrates a schematic diagram of a welding station communicatively connected to a network via a Wi-Fi connection in accordance with another embodiment of the present patent application;

[00191] FIG. 149 illustrates a schematic diagram of a plurality of manufacturing sites connected with the ability to communicate with a cloud server via a wide area network (Internet) in accordance with another embodiment of the present patent application;

[00192] FIG. 150 illustrates a schematic diagram of a plurality of welding stations communicatively connected to intermediate computing devices (leaders, inspectors, engineers) which, in turn, are communicatively connected to a cloud server via the Internet in accordance with another embodiment of this patent. applications;

[00193] FIG. 151 illustrates a schematic diagram of a plurality of welding stations communicatively connected to an intermediate computer system (engineer, technician, and quality specialist terminals) via a wireless (eg, Wi-Fi) communication channel in accordance with another embodiment of the present patent application;

[00194] FIG. 152 illustrates a schematic diagram of a plurality of welding stations communicatively connected to a computer system via a wireless (eg, Wi-Fi) communication channel in accordance with another embodiment of the present patent application;

[00195] FIG. 153 illustrates a schematic diagram of a plurality of welding stations communicatively connected to a plurality of intermediate computer systems (engineer, quality inspector and technician terminals) which in turn are communicatively connected to a cloud server in accordance with another embodiment of the present patent application;

[00196] FIG. 154 illustrates an example of a graphical user interface (GUI) for the "Home Screen" of a cloud-based universal data logging (uLog) application implemented by a computer system in a welding station, an intermediate computer system, or a cloud server in accordance with another embodiment. this patent application;

[00197] FIG. 155 illustrates an example GUI for the "Real-time Logging" screen of a cloud-based Universal Data Logging (uLog) application displaying voltage versus time at one welding station according to another embodiment of the present patent application;

[00198] FIG. 156 illustrates an example GUI for the "Get Log" screen of a cloud-based universal data logging (uLog) application displaying welding data parameters, including welding event types, time, zone, weld advance speed, weld wire advance speed. in accordance with another embodiment of the present patent application;

[00199] FIG. 157 illustrates an example GUI for the "Summary Report" screen of a cloud-based universal data logging (uLog) application displaying various welding parameters, including welding time, welding station ID, welding arc voltage, and so on, according to another embodiment of the present patent application;

[00200] FIG. 158 illustrates an example of a GUI for the Save Data in Log screen of a cloud-based universal data logging (uLog) application displaying various parameters according to another embodiment of the present patent application;

[00201] FIG. 159 illustrates an example GUI for the Analytics screen of a cloud-based universal data logging (uLog) application, displaying two icons for selecting the type of analytic report to run (e.g., chart, moving average) in accordance with another implementation of this patent. applications;

[00202] FIG. 160 illustrates an example GUI for the "Welding Parameters" screen of a cloud-based universal data logging (uLog) application displaying two option options for selecting the type of function to be performed according to another embodiment of the present patent application;

[00203] FIG. 161A is a schematic representation of an example of a coil capable of winding a welding wire according to another embodiment of the present patent application;

[00204] FIG. 161B is a schematic side view of a transducer sleeve capable of measuring coil weight in accordance with another embodiment of the present patent application;

[00205] FIG. 161C illustrates another side view of the transducer sleeve showing the location of the elements of the transducer or strain gauge/gauge for measuring the pressure generated by the mass of the coil when the coil is mounted on the hub in accordance with another implementation of the present patent application;

[00206] FIG. 162 illustrates a schematic arrangement in which a filler wire in a spool mounted on a bushing is drawn by a wire feed motor assembly 82 onto a welder (not shown), in accordance with another embodiment of the present patent application;

[00207] FIG. 163 is a flowchart showing a process of comparing the measured mass and the estimated weight determined based on the wire feed speed according to another embodiment of the present patent application;

[00208] FIG. 164A and 164B illustrate an enlarged side cross section of an engine assembly in accordance with another embodiment of the present patent application;

[00209] FIG. 165 illustrates a welding system configuration diagram showing the internal communications of various system components in accordance with another embodiment of the present patent application;

[00210] FIG. 166 illustrates an overview of a non-destructive testing system in accordance with another embodiment of the present patent application;

[00211] FIG. 167 illustrates a generalized implementation of a non-destructive testing system in accordance with another implementation of the present patent application;

[00212] FIG. 168 illustrates an implementation of ultrasonic testing of a non-destructive testing system in accordance with another implementation of the present patent application;

[00213] FIG. 169 illustrates an implementation of an X-ray inspection of a non-destructive inspection system according to another embodiment of the present patent application;

DETAILED DESCRIPTION OF THE INVENTION

[00214] FIG. 1A and 1B illustrate flow diagrams of a method 1000 for welding together pipe sections or segments 1022 (eg, 1022a and 1022b, as illustrated in FIG. 2) of conduit 1024 (as illustrated in FIG. 2). For example, Fig. 1A illustrates a high level flow diagram of a method 1000, and FIG. 1B illustrates a more detailed flow diagram of a method 1000.

[00215] FIG. 2 illustrates a cross section of a welded joint 1026 connecting pipe segments 1022 (eg, 1022a and 1022b) to conduit 1024. Pipe segments 1022 (eg, 1022a and 1022b) may be referred to interchangeably herein as pipes or pipe segments. In one embodiment of the invention, weld 1026 is a complete girth weld joining pipe segments 1022 (eg, 1022a and 1022b) joined in a circle. In one embodiment of the invention, the weld 1026 may be referred to as a circular seam or butt weld. In one embodiment, as described in more detail below, pipe segments 1022a and 1022b are welded together at their beveled ends.

[00216] In one embodiment, the first pipe segment 1022a and the second pipe segment 1002b are at least 30 feet long. In one embodiment, the first pipe segment 1022a and the second pipe segment 1002b are at least 31.5 feet long. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are at least 33 feet long. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are at least 34.5 feet long. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are at least 36 feet long.

[00217] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have an outside diameter of 24 inches or less. In one embodiment of the invention, the outer diameter of the pipe segment may also be referred to as the outer diameter of the pipe segment.

[00218] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have a nominal outer diameter of 24 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an outside diameter of 24.1875 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an outside diameter of 23.8125 inches or less.

[00219] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have an outside diameter of 22.8 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have an outside diameter of 21.6 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an outside diameter of 20.4 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an outside diameter of 19.2 inches or less.

[00220] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an outside diameter of 26 to 28 inches.

[00221] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are made of metal. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b are made of carbon steel. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b are made of alloy steel. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b are made of low alloy steel. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b are made of stainless steel. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b may be made from a material according to the American Petroleum Institute (API) 5L grade X52 specification (for example, a minimum yield strength of 52,000 psi and a minimum tensile strength of 66,000 pounds / sq. inch). In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b may be made of material according to API 5L grade X60 specification (e.g., minimum yield strength 60,000 psi and minimum tensile strength 75,000 psi) .

[00222] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b may be wholly or partially made of a corrosion resistant alloy (CRA). In one embodiment, the corrosion resistant alloy may comprise both iron-based alloys, such as various grades of stainless steel, and nickel-based alloys (eg, commonly known by the trade name "Inconel").

[00223] In one embodiment, some KSS materials may require shielding gas on both sides of the weld. In one embodiment of the invention, then, the purge and test system 7001 (as will be described in more detail with respect to Figs. 86-100) can be used within the pipes 1022a, 1022b to provide a purge gas chamber within (in the area of the contact surface) the pipes to be welded , and an external welding system 7500 (as illustrated in FIG. 97) can be used on the outside of pipes 1022a, 1022b. In one embodiment, the external welding system 7500 is configured to provide shielding gas outside (eg, at the joint) of the pipes to be welded.

[00224] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are made from the same material. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b are made from different materials.

[00225] In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b can be made of bimetallic materials, wherein the inside of the pipe segment is FCC material, and the outside of the pipe segment can be made of either carbon steel or made of KSS material other than the material of the inner part.

[00226] In one embodiment of the invention, as illustrated in FIG. 2G, the first pipe segment 1022a and the second pipe segment 1022b comprise a metal interior of the pipe 5244 surrounded by an insulator/coating 5246. metal part of pipe 5244.

[00227] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b may be externally coated with a corrosion resistant material/coating if the first pipe segment 1022a and the second pipe segment 1022b are used in a hostile environment (e.g., sea/ salt water/ocean, chemicals, etc.). In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b may be coated on the outside with a wear resistant material/coating. In one embodiment of the invention, the first pipe segment 1022a and the second pipe segment 1022b may be coated on the outside with an insulating material/coating. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b may be internally coated with a corrosion resistant material/coating, abrasion resistant material/coating, an insulating coating/material, or a combination thereof. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b may be coated on the outside and inside with a corrosion resistant material/coating, a wear resistant material/coating, an insulating coating/material, or a combination thereof.

[00228] In one embodiment of the invention, as illustrated in FIG. 2A and 2B, end 1038a of pipe 1022a is welded to second end 1038b of pipe 1022b. In one embodiment, end 1038a of pipe 1022a has an internal bevel 5228 and an external bevel 5230. In one embodiment, end 1038b of pipe 1022b has an internal bevel 5232 and an external bevel 5234. In one embodiment, of the invention, as will be understood from the description below, the layer of the root pass in the weld metal is located in the IBR region defined by the first internal bevel of the weld 5228 and the second internal bevel of the weld 5232, if the internal welding system 5004 is used to apply the layer of the weld pass weld root inside pipes 1022a, 1022b.

[00229] In one embodiment, the outside bevels 5230 and 5234 may comprise, respectively, first outside bevels 5230a and 5234a and second outside bevels 5230b and 5234b. In one embodiment of the invention, the first outer bevels of the groove 5230a and 5234a are beveled at an angle EB ₁ with respect to the axis NN perpendicular to the longitudinal axis AA of the pipe segments 1022a, 1022b. In one embodiment of the invention, the angle EB ₁ is 5°.

[00230] In one embodiment, the second outer bevels 5230b and 5234b are chamfered at an angle EB ₂ with respect to the axis NN. In one embodiment of the invention, the angle EB ₂ is greater than the angle EB ₁ . In one embodiment of the invention, the angle EB ₂ is 45°.

[00231] In one embodiment, the outer bevels 5230 and 5234 may comprise a single bevel. In one embodiment, the outside bevels 5230 and 5234 may comprise a single continuous J-shaped surface.

[00232] In one embodiment, the internal bevels 5228 and 5232 are chamfered at an angle IB with respect to the axis NN. In one embodiment of the invention, the angle IB is 37.5°. In one embodiment of the invention, the internal bevels 5228 and 5232 may have a length B, measured along the axis NN, from the respective inner surfaces of the pipe 5130 and 5132. In one embodiment, the length B, measured along the axis NN, from the respective internal surfaces pipe 5130 and 5132 is 0.05 in.

[00233] In one embodiment, the outer bevels 5230 and 5234 and the inner bevels 5228 and 5232 may be separated from each other by a non-bevelled surface. In one embodiment of the invention, the non-chamfered surface may have a segment NB measured along the axis NN. In one embodiment of the invention, the length NB, measured along the axis NN, is 0.05 inches. In one embodiment of the invention, the non-chamfered surface is optional and the outer bevels 5230 and 5234 and their respective inner bevels 5228 and 5232 can be adjacent to (and touching) each other.

[00234] In one embodiment, the internal bevels 5228 and 5232 of pipe segments 1022a, 1022b may have the same bevel angle. In one embodiment, the outer bevels 5230 and 5234 of pipe segments 1022a, 1022b may have the same bevel angle(s). In another embodiment of the invention, the chamfer angle of the internal bevels of the groove 5228 and 5232 of the pipe segments 1022a, 1022b may be different. In another embodiment, the bevel angle(s) of the outer bevels 5230 and 5234 of the pipe segments 1022a, 1022b may be different.

[00235] In one embodiment of the invention, the dimensions B of the internal bevels of the weld groove, the size NB of the surface on which the chamfers, and the angle of the chamfers IB, EB ₁ and EB ₂ may differ and depend on the thickness T of the pipe segments 1022a, 1022b.

[00236] In one embodiment, end 1038a of pipe 1022a and end 1038b of pipe 1022a are joined to form a weld bead 5236 formed therebetween. In one embodiment, the weld bead 5236 may have a V-shaped cross section. In one embodiment of the invention, end 1038a of pipe 1022a and end 1038b of pipe 1022b are designed and prepared to have a J-shaped configuration so that the weld bead formed by joining end 1038a of pipe 1022a and end 1038b of pipe 1022b together has U-shaped configuration. In another embodiment of the invention, the shape of the welding edge depends on the welding parameters or welding conditions.

[00237] As illustrated in FIG. 2, in one embodiment of the invention, the weld metal 1034 is configured to connect the first pipe segment 1022a and the second pipe segment 1022b. In one embodiment, the weld metal 1034 may comprise Inconel or an Inconel alloy. In one embodiment of the invention, the weld metal 1034 may contain a material having a higher strength than the pipe material. In one embodiment of the invention, the composition of the weld metal 1034 may differ in composition from the pipe material. For example, in one embodiment, the weld metal may comprise Inconel or an Inconel alloy, and the material of the first pipe segment 1022a and second pipe segment 1022b may comprise stainless steel.

[00238] In one embodiment, the weld metal 1034 and/or the weld 1026 comprises a plurality of weld pass layers 1014, 1016, 1018, and 1020. For example, in one embodiment, the plurality of weld pass layers 1014, 1016, 1018 and 1020 may include a root pass 1014, a hot pass 1016, one or more layers of fill pass 1018, and a cover pass layer 1020, as will be described in more detail below. The layer(s) of the weld passage may be referred to interchangeably herein as the layer(s) of the passage. In one embodiment, the weld pass (e.g., root pass, hot pass, fill pass(s), facing pass) may be a single pass of the welding tool or welding system along the weld 1026. In one embodiment, a weld bead or weld is formed as a result of each pass of a weld.

[00239] In one embodiment of the invention, as illustrated in FIG. 1A, 1B, and 2, a method 1000 for welding pipe sections or segments 1022a and 1022b together typically includes a root pass procedure 1002, a hot pass procedure 1004, a fill and cover pass procedure 1006, a weld inspection procedure 1008, a procedure a heating pass 1010 and a coating procedure 1012. In one embodiment, the fill pass and facing pass procedure 1006 may comprise one or more weld fill pass procedure 1006a and a weld facing pass procedure 1006b. In one embodiment, method 1000 is typically a multi-pass weld or multi-layer weld procedure that includes, for example, a root pass procedure 1002, a hot weld pass procedure 1004, and a fill and cover pass procedure. 1006.

[00240] In one embodiment, one or more weld passes (e.g., root pass, hot pass, fill pass(s), cladding pass) of the multi-pass or multi-layer weld method 1000 can be made with the same welding system or tool at different times. In one embodiment of the invention, the weld passes may be performed sequentially by the same system or tool. For example, in one embodiment, the root pass and hot pass procedures may be performed sequentially by the internal welding system 5004 (as will be described in more detail below) within the pipes. In one embodiment of the invention, the fill and liner pass procedures may be performed sequentially by the external welding system 7500 on the outside of the pipes.

[00241] In one embodiment, the internal welding system 5004 is typically configured to weld pipe segments 1022a and 1022b within conduit 1024, and the external welding system 7500 is typically configured to weld pipe segments 1022a 1022b outside conduit 1024 In one embodiment, the weld performed by the internal welding system 5004 produces a K-shaped weld bead or layer, and the weld performed by the external weld system 7500 produces a J-shaped weld bead or layer.

[00242] In one embodiment, the hot, fill, and clad pass procedures may be performed sequentially by the external welding system 7500 outside the pipes, with only the root pass procedure performed by the internal welding system 5004 (as will be described in more detail below) inside the pipes. .

[00243] In one embodiment of the invention, one or more weld passes (e.g., root pass, hot pass, fill pass(s), facing pass) of the multi-pass or multi-layer weld method 1000 may be performed by different welding systems or instruments at the same or different times. In one embodiment of the invention, the weld passes may be performed successively by different welding systems or tools.

[00244] In one embodiment of the invention, each of the hot, fill, or clad pass procedures is performed in its respective welding booth outside of the pipes. In one embodiment of the invention, the welding booth is a relatively small chamber, approximately 12 feet wide, 10 feet long and 8 feet high, in which an external welding system is installed and moved from one weld to another weld by means of a tail platform. The welding booth is typically a light metal frame covered with thin sheet metal. The welding booth has a special floor designed to pivot upwards, allowing the welding booth to lower onto the pipes and then turn back for easy access to the pipe. In one embodiment of the invention, each of the one or more fill pass procedures is performed in a different welding booth, each containing an external welding system.

[00245] In one embodiment, the root pass procedure 1002 is the first welding procedure of the multi-pass or multi-layer weld method 1000. In one embodiment, the root pass procedure 1002 is performed by the internal welding system 5004. welding power.

[00246] In one embodiment, the root pass procedure 1002 then performed by the internal welding system 5004 takes 1.03 minutes. In one embodiment of the invention, the cycle time for the root pass procedure is 4 minutes (this time is calculated from the moment when the drive rod or halyard 5034 is set to auto move mode). In one embodiment, the total pass procedure cycle time for root welding (performed by the 5004 internal welding system) is 13.15 minutes (including 2.30 minutes for the spool/wire change procedure) and the average root pass procedure cycle time seam (performed by the internal welding system 5004) is 4.42 minutes.

[00247] In one embodiment, the root pass procedure 1002 is performed by the external welding system 7500. embodiment, the root pass procedure 1002 is performed by the external welding system 7500 using end clamps. In one embodiment, the root pass procedure 1002 is performed by the external welding system 7500 using the internally located clamps 7050, 7052. and checks 7001).

[00248] In one embodiment, the root pass procedure 1002 forms the root pass layer 1014. In one embodiment, as illustrated in FIG. 1A and 1B, the root pass layer 1014 is the first weld bead or layer in the multi-run or multi-layer weld method 1000. In one embodiment of the invention, the root pass layer is also referred to as a root seal bead or layer. In one embodiment, the root pass procedure 1002 is performed by gas shielded metal arc welding (GMAW). In one embodiment, the root pass procedure 1002 is performed by gas shielded tungsten arc welding (GTAW). In one embodiment of the invention, the root pass procedure 1002 is performed by short circuit metal arc welding (GMAW-S). In one embodiment, the root pass procedure 1002 is performed by other welding processes, as will be understood by those skilled in the art.

[00249] In one embodiment, hot pass procedure 1004 is the second welding procedure of method 1000 for performing a multi-pass or multi-layer weld. In one embodiment, the hot pass procedure 1004 is performed by an internal welding system 5004. In one embodiment, the hot pass procedure 1004 may be performed by an end internal welding system 3001 containing an integral weld power system.

[00250] In one embodiment, the hot pass procedure 1004 is performed by an external welding system 7500. In one embodiment, the hot pass procedure 1004 is performed by an external welding system using internally located clamps. In one embodiment of the invention, the clamps located inside can be standard clamps or clamps for purge and control. In another embodiment of the invention, the hot pass procedure 1004 is performed by a manual welder. In such an embodiment of the invention, the ends of the pipe have a configuration containing a 30° groove.

[00251] In one embodiment of the invention, the subsequent hot run procedure 1004 with the external welding system (in the welding booth) and from the side of the trench can take 1.06 minutes. In one embodiment of the invention, the hot pass procedure 1004 then performed by an external welding system (in the welding booth) and from the work side can take 58 seconds. In one embodiment of the invention, the duration of the hot run procedure cycle is 2.38 minutes (this time is calculated from the moment the hot run welding booth is installed on the pipe). In one embodiment of the invention, the total cycle time for three cycles of the hot pass procedure performed by the external welding system in the welding booth is 11.35 minutes, and the average cycle time for the hot pass procedure performed by the external welding system in the welding booth is 3.34 minutes .

[00252] In one embodiment, the hot pass procedure 1004 forms the hot pass weld layer 1016. In one embodiment, as illustrated in FIG. 2, the hot pass layer 1016 is the second weld bead or layer applied in the multi-pass or multi-layer weld method 1000. In one embodiment, the hot pass procedure 1004 immediately follows the root pass procedure 1002. In one embodiment, the hot pass procedure 1004 is performed by metal shielded metal arc welding (GMAW). In one embodiment, the hot pass procedure 1004 is performed by gas shielded tungsten arc welding (GTAW). In one embodiment of the invention, the hot pass procedure 1004 is performed by gas-shielded metal arc welding in short circuit (GMAW-S). In one embodiment of the invention, the hot pass procedure 1004 is performed by other welding processes, as will be understood by those skilled in the art.

[00253] In one embodiment, one or more of the fill pass procedures 1006a and the facing pass procedures 1006b, the fill and cover pass procedures 1006 are performed by the external welding system 7500. In one embodiment, the fill and cover pass procedure 1006 is performed at multiple stations. In another embodiment of the invention, the filling and facing pass procedure 1006 is performed by a manual welding machine. In such an embodiment of the invention, the ends of the pipe have a configuration containing a 30° groove.

[00254] In one embodiment, one or more fill pass procedures 1006a follow (or are performed after) the hot pass procedure 1004. In one embodiment, one or more fill pass procedures 1006a form the fill pass layer(s) of the weld 1018 The fill pass layer(s) 1018 is configured to fill the weld bevel and strip substantially flush with the surface of the pipe segments 1022a and 1022b of conduit 1024. seams may vary. In one embodiment, the number of fill pass procedures 1006a in the multi-pass or multi-layer weld method 1000 may depend on the thickness of the pipe segments 1022a and 1022b of conduit 1024 being welded together.

[00255] In one embodiment, the fill pass procedures 1006a are performed by gas shielded metal arc welding (GMAW). In one embodiment, the fill pass procedures 1006a are performed by gas shielded tungsten arc welding (GTAW). In one embodiment, the fill pass procedures 1006a are performed by gas-shielded pulsed metal arc welding (GMAW-P). In one embodiment of the invention, fill pass procedures 1006a are performed by other welding processes, as will be appreciated by those skilled in the art.

[00256] In one embodiment, the facing pass procedure 1006b is the last or final welding procedure of the multi-pass or multi-layer weld method 1000. In one embodiment, the facing pass procedure 1006b follows (or is performed after) the fill pass procedure(s) 1006a. In one embodiment of the invention, as illustrated in FIG. 2, the fill pass layer 1020 is a weld bead or layer applied after the fill pass procedure 1006a. In one embodiment of the invention, the cladding pass procedure 1006b may also be referred to as the overlapping pass procedure. In one embodiment, the liner pass procedure 1006b generates the liner pass layer of the weld 1020. In one embodiment, as illustrated in FIG. 2, the liner weld layer 1020 is the final or final weld bead applied in the multi-run or multi-layer weld method 1000. In one embodiment of the invention, the layer of facing weld 1020 substantially protrudes above the surface of pipe segments 1022a and 1022b of conduit 1024.

[00257] In one embodiment, the cladding pass procedure 1006b is performed by gas shielded metal arc welding (GMAW). In one embodiment, the cladding pass procedure 1006b is performed by gas shielded tungsten arc welding (GTAW). In one embodiment of the invention, the fill pass procedure 1006a is performed by gas-shielded pulsed metal arc welding (GMAW-P). In one embodiment, the facing pass procedure 1006a is performed through other welding processes, as will be understood by those skilled in the art.

[00258] In one embodiment, the root pass procedure 1002 is only the pass procedure of the multi-pass or multi-layer weld method 1000 performed by the internal welding system 5004, while the hot pass procedure 1004 and the filling pass procedure 1006 are performed using an external welding systems 7500.

[00259] In another embodiment, both the root pass procedure 1002 and the hot pass procedure 1004 of the multi-pass or multi-layer weld method 1000 are performed by the internal welding system 5004, while the fill and cover pass procedure 1006 is performed using an external system. welding 7500.

[00260] In yet another embodiment of the present invention, the root pass procedure 1002, the hot pass procedure 1004, and the fill pass procedure 1006 are performed using an external welding system 7500. In one embodiment, purge and control clamps are used inside the pipes 1022a, 1022b, with the external welding system 7500 performing the root pass procedure 1002, the hot pass procedure 1004, and the fill and cover pass procedure 1006.

[00261] FIG. 2G-2I illustrate a cross section of conduits 1024 with welded joints 1026 formed therebetween.

[00262] FIG. 2G illustrates a cross section of conduit 1024 with a weld 1026 formed therebetween. For example, weld 1026 in FIG. 2G comprises a root pass layer 1014 and a hot pass layer 1016 formed by an internal welding system 5004 inside the pipes 1022a, 1022b, with one or more fill pass layers 1018 and a facing pass layer 1020 formed by an external welding system 7500 outside the pipes 1022a, 1022b. .

[00263] The individual weld pass layers (eg, root pass layer 1014, hot pass layer 1016, fill and cover pass layers 1018 and 1022) are also clearly visible in FIG. 2. The boundary 1032 between the weld metal 1034 and the pipe material 1036 can be easily and clearly seen in FIG. 2. In one embodiment of the invention, the shape of the boundary 1032 (as illustrated as line ABCDE) is characteristic of the pipeline 1024 being welded (e.g., through the root pass procedure 1002 and/or the hot pass procedure 1004) within the pipeline 1024.

[00264] In one embodiment, when both the root pass procedure 1002 and the hot pass procedure 1004 of the multi-pass or multi-layer weld method 1000 are performed by the internal welding system 5004 within conduit 1024, the location of the layer of the root pass The weld 1014 and the hot pass layer 1016 are interchanged (for example, compared to a weld in which the root pass procedure is performed by the internal welding system 5004 inside the conduit 1024 and the hot pass procedure 1004 is performed by the external welding system outside the conduit 1024). In one embodiment of the invention, as illustrated in FIG. 2 and 2G, the hot pass layer 1016 is located closer to the inner longitudinal axis A-A of the welded first and second pipes 1022a and 1022b than the root pass layer 1014.

[00265] In one embodiment, the hot pass layer 1016 of the weld metal 1034 has at least a corresponding portion 5238 located closer to the longitudinal axis A-A than the inner surface 5130, 5132 of the welded pipes 1022a and 1022b, in the region 5240 and 5242 welded pipes 1022a and 1022b directly adjacent to the weld metal 1034 on the opposite side of the weld metal 1034. In one embodiment of the invention, as illustrated in FIG. 2 and 2G, when both the root pass procedure 1002 and the hot pass procedure 1004 of the multi-pass or multi-layer weld method 1000 are performed by the internal welding system 5004 within the conduit 1024, the neck region 1028 of the weld joint 1026 is formed away from the inner walls 5130 , 5132 pipeline 1024.

[00266] In one embodiment of the invention, the root pass layer 1024 is located in the internal bevel 5228, 5232 of the first and second pipe 1022a and 1022b, and the hot pass layer 1016 is located on top of the root pass layer 1014 (i.e. , closer to the inner longitudinal axis A-A). In one embodiment, the internal welding system 5004 is built and installed to perform more than one weld pass within the conduit 1024. In one embodiment, the internal welding system 5004 is built and installed to actuate in the radial direction so that the welding system 5004 may adjust the height of the welding torch 5502 between two passes (eg, between the root pass procedure 1002 and the hot pass procedure 1004).

[00267] In one embodiment, the additional weld pass layer(s) may be overlaid on top of the hot pass layer 1016 and located closer to the inner longitudinal axis A-A of the welded first and second pipe 1022a, 1022b than the hot pass layer 1016. For example, , in one embodiment of the invention, one or more layers of the fill pass 1018 may be formed by the internal welding system 5004 so that one or more layers of the fill pass 1018 are superimposed on the layer of the hot pass 1016 and located closer to the internal longitudinal axis A-A of the welded first and of the second pipe 1022a, 1022b than the hot pass layer 1016. For example, in one embodiment of the invention, one or more fill pass layers 1018 and facing pass layers 1020 may be formed by an internal welding system 5004 such that one or more fill pass layers 1018 and layers of the facing pass 1020 were superimposed on the hot pass layer 1016 and located closer to the inner longitudinal axis A-A of the welded first and second pipes 1022a, 1022b than the hot aisle layer 1016.

[00268] In another embodiment of the invention, one or more layers of fill passage 1018 and a layer of facing passage 1020 are applied in the internal chamfer 5230, 5234 of the first and second pipes 1022a and 1022b, and may be formed by an external welding system 7500 on the outside of the pipeline 1024.

[00269] FIG. 2H illustrates a cross-sectional view of conduit 1024 with welded joint 1026 formed therebetween. For example, welded joint 1026 in FIG. 2H comprises a root pass layer 1014 formed by an internal welding system 5004 within the pipes 1022a, 1022b, wherein the hot pass layer 1016, one or more fill pass layers 1018, and the facing pass layer 1020 are formed by the external weld system 7500 outside the pipes 1022a, 1022b. In one embodiment, a root pass layer 1014 is applied in the internal bevel 5228, 5232 of the first and second pipe 1022a and 1022b. In one embodiment, a hot pass layer 1016, one or more fill pass layers 1018, and a facing pass layer 1020 are applied in the outer bevels 5230, 5234 of the first and second pipe 1022a and 1022b.

[00270] FIG. 2I illustrates a cross-sectional view of conduit 1024 with welded joint 1026 formed therebetween. For example, welded joint 1026 in FIG. 2I includes a root pass layer 1014, a hot pass layer 1016, one or more fill pass layers 1018 and 1020 formed by an external welding system 7500 on the outside of pipes 1022a and 1022b. In one embodiment, a root pass layer 1014, one or more hot pass layers 1016, one or more fill pass layers 1018, and a facing pass layer 1020 are applied in the outer bevels 5230, 5234 of the first and second pipe 1022a and 1022b.

[00271]In one embodiment of the invention, after the weld 1026 is performed, the weld 1026 is inspected during the weld inspection procedure 1008. In one embodiment, the weld inspection procedure 1008 is performed after the fill and cover pass procedure 1006. weld inspection procedures 1008. In one embodiment, a significant amount of heat is generated during welding procedures (eg, procedures 1002, 1004, and 1006). In one embodiment of the invention, the weld test procedure 1008 is performed at an operating temperature less than the highest weld temperature. In one embodiment of the invention, the weld 1026 may be cooled prior to the weld inspection procedure 1008 by the internal cooling system 2010 or 6500 (as described more like below). In one embodiment, the weld inspection procedure 1008 may comprise any type of non-destructive testing/weld inspection 1026.

[00272] In one embodiment, the weld inspection procedure 1008 may comprise automated ultrasonic testing (AUT). In one embodiment of the invention, automated ultrasonic welding testing 1026 can be used for both onshore and offshore pipeline welding applications. In one embodiment of the invention, the AUT is configured to be used in a mass production environment. In one embodiment of the invention, the AUT is configured to be used to detect and size weld defects.

[00273] In one embodiment of the invention, automated ultrasound testing is performed by an OUT scanning system (eg, 6801, as illustrated in Fig. 136A). In one embodiment of the invention, the AUT scanning system comprises an ultrasonic transducer system. In one embodiment of the invention, the OUT scanning system may be portable. In one embodiment of the invention, the AUT scanning system may also comprise a data acquisition system operatively coupled to the ultrasound transducer system. In one embodiment, the ultrasonic transducer system may include an emitter configured to send, for example, ultrasonic signals (eg, wave pulses) within the pipe segments 1022a and 1022b and/or the circumferential seam 1026 therebetween. In one embodiment of the invention, ultrasonic signals or pulses are sent at a frequency of 1 Hz to 20,000 Hz. In one embodiment of the invention, the frequency of the ultrasonic waves can range from 0.5 MHz to 23 MHz.

[00274] In one embodiment, the ultrasonic signals or pulses sent by the emitter are configured to reflect off boundaries where the density of the annular seam 1026 varies. In one embodiment, the ultrasonic sensor system may comprise a receiver configured to receive/detect reflected impulses. In one embodiment of the invention, the receiver is configured to measure the intensity of the reflected pulses and generate an electrical signal proportional to the intensity of the reflected pulses. In one embodiment, the transmitter and receiver of an ultrasonic transducer system may have a plurality of elements or components. In one embodiment of the invention, the ultrasonic sensor system can be activated selectively to detect ultrasonic pulses at a given location.

[00275] In an aqueous 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 of the invention, time-of-flight diffraction (ToFD) ultrasonic weld inspection may be used when a plurality of weld grooves are defined.

[00276] In one embodiment, the AUT of the weld inspection procedure may include full coverage of the pulse echo ultrasonic weld inspection. In one embodiment of the invention, pulsed echo ultrasonic testing technologies use phased array (PA) probes in combination with ToFD testing to obtain very accurate measurements of weld defects. In one embodiment of the invention, welds are broken down into zones (zonal selectivity), which are evaluated separately, and the results are collected in a comprehensive weld analysis. In one embodiment of the invention, linear and sectoral scanning provide excellent weld inspection. In one embodiment of the invention, ToFD ultrasonic weld inspection can be used to fully cover the pulse echo ultrasonic weld inspection.

[00277] In yet another embodiment, the weld inspection procedure 1008 may comprise radiographic testing. In one embodiment of the invention, radiographic testing is performed by a radiographic system. In one embodiment of the invention, the radiographic system includes an emitter configured to emit radiographic radiation into the pipe segments 1022a and 1022b, and an annular seam 1026 therebetween. In one embodiment of the invention, the intensity of the radiographic radiation may be attenuated by the material of the pipe segments 1022a and 1022b and the circumferential seam 1026 between them. In one embodiment, the radiographic system includes a receiver configured to measure the intensity of radiographic radiation passing through the material of the pipe segments 1022a and 1022b and the circumferential seam 1026 therebetween.

[00278] In one embodiment of the invention, the weld inspection procedure 1008 may include a gamma ray and X-ray inspection in close proximity. In one embodiment, the weld inspection procedure 1008 may comprise magnetic particle inspection (MPI) or paint penetrating inspection (DPI). In one embodiment, the weld inspection procedure 1008 may comprise any other non-destructive testing (NDT), such as, but not limited to, guided wave (MFL) ultrasonic testing, eddy current testing, hardness testing, magnetic flux leakage (MFL) testing, steeloscopy , corrosion mapping study, etc. In one embodiment, non-destructive testing (NDT) can generally mean any test capable of identifying weld defects without damaging the pipes and/or the weld between them.

[00279] As illustrated in FIG. 2G, in one embodiment, as described above, each pipe segment 1022a, 1022b comprises an inner metal portion 5244 surrounded by an outer protective coating (e.g., insulating material) 5246. In one embodiment, the ends 5248 and 5250 of weldable pipe segments 1022a , 1022b have a protruding inner metal part.

[00280] In one embodiment, after the weld inspection procedure 1008, the outer protective coating is applied back to the weld joint 1026. 118) adhered to the outer surface 5254 of the inner metal part of the pipe 5244, thus insulating the previously protruding ends of the pipes 5248, 5250 of the pipes 1022a, 1022b.

[00281] In one embodiment, to facilitate the application of an outer protective coating or insulator, the weld 1026 and the surrounding portions of the pipe segments 1022a and 1022b of conduit 1024 are heated to a predetermined coating temperature. In one embodiment of the invention, the protruding ends 5248, 5250 of the welded pipes 1022a, 1022b are heated. In one embodiment of the invention, the predetermined coating temperature is the temperature required to apply the outer protective coating or insulator. In one embodiment of the invention, the predetermined coating temperature is set to provide good adhesion or adherence between the outer protective coating or insulator and the pipe 1024.

[00282] In one embodiment, the heating procedure 1010 is performed after the weld inspection procedure 1008. In one embodiment, the induction preheat procedure may be used to heat the protruding ends 5248, 5250 of welded pipes 1022a, 1022b of conduit 1024 in preparation for use protective material(s) or insulator.

[00283] In one embodiment, the heating routine 1010 is performed by the heating system 5304 (which is illustrated and explained in FIGS. 115A and 115B). In one embodiment of the invention, the heating system may comprise an electrical heating system. In one embodiment, the heating system may include a microwave induction coil configured to instantly heat the protruding ends 5248, 5250 of welded pipes 1022a, 1022b of conduit 1024 to a predetermined coating temperature. In one embodiment, the heating system is also configured to adjust the temperature of the protruding ends 5248, 5250 of the welded pipes 1022a, 1022b of conduit 1024 to maintain a suitable coating temperature. In one embodiment, the heating system may include a feedback heating system to allow the heating system to reach and maintain a desired coating temperature, and a temperature sensor operatively associated with the feedback system. In one embodiment of the invention, the temperature sensor may be a contact or non-contact temperature sensor. In one embodiment of the invention, the feedback heating system may include one or more sensors configured to determine other parameters of the heating procedure - heating time, etc.

[00284] In one embodiment, the coating procedure 1012 is performed immediately after the heating procedure 1010. In one embodiment, the coating procedure 1012 is performed in a coating booth (for example, similar in design to a welding booth) having in its consisting of a coating head constructed and assembled to apply/spray/apply the insulator/coating/epoxy mixture to the projecting ends 5248, 5250 of welded pipes 1022a, 1022b of conduit 1024. In one embodiment, the coating head performs a coating procedure in less than a minute. In one embodiment of the invention, the coating head completes the coating procedure in 50 seconds.

[00285] In one embodiment, an insulator/coating is applied to the heated projecting ends 5248, 5250 of welded pipes such that the insulator/coating 5246A (as illustrated in Fig. 118) adheres to the outer surface 5254 of the inner metal part of the pipe, insulating, thus, the previously protruding ends of pipes 5248, 5250 of pipes 1022a, 1022b.

[00286] In one embodiment, a coating is applied to the outer surfaces or portions of pipe segments 1022a and 1022b surrounding weld 1026 to provide an insulating barrier that prevents or minimizes corrosion at the welded portions.

[00287] In one embodiment, the coating may comprise a polypropylene coating. In one embodiment of the invention, the coating may comprise a polyethylene coating. In one embodiment of the invention, the coating may comprise a polyurethane coating. In one embodiment of the invention, the coating may contain a heat insulating (for example, from heat loss during heating) coating. In one embodiment of the invention, the coating may contain an anti-corrosion coating. In one embodiment of the invention, the coating may comprise a wear resistant coating. In one embodiment of the invention, the coating may comprise a bonded epoxy (FBE) coating. In one embodiment of the invention, the coating may comprise a bonded epoxy (FBE) coating along with a double base layer of chemically modified polypropylene (CMPP) or polyethylene (CMPE). In one embodiment of the invention, immediately thereafter, a layer of chemically modified polypropylene (CMPP) or polyethylene (CMPE) is followed by the application of a polypropylene (PP) or polyethylene (PE) film. In one embodiment, the coating may comprise a multi-component liquid coating (MCL) (eg, MCL coatings based on urethane and epoxy). In one embodiment of the invention, the coating may comprise weld insulation (FJC).

[00288] In one embodiment, the coating may comprise injection molded polypropylene. In such an embodiment of the invention, conduit 1024 is preheated to 180° C. before being coated with injection molded polypropylene.

[00289] In one embodiment, automated equipment may be used to apply coating materials to the weld 1026. In one embodiment, the coating supply system may comprise an injection molded coating system, as illustrated and described in detail with respect to Fig. 117A and 117B. In one embodiment of the invention, the coating supply system may comprise a flame spray coating system. In one embodiment of the invention, the insulator/coating may be applied to the protruding portions of the weld using a spray gun. In one embodiment of the invention, the spraying device is configured to spray the insulating material onto the protruding section of the pipe in the region of the welds. In one embodiment of the invention, a spray device is illustrated and described with respect to FIG. 116A-116B.

[00290] In one embodiment, an abrasive cleaning procedure may be performed to prepare conduit 1024 for coating. In one embodiment, an abrasive cleaning procedure may be performed prior to the heating procedure 1010. In one embodiment, the oxidized pipe weld is sandblasted to remove all contaminants.

[00291] In one embodiment, the coating system may include a feedback coating system to allow the coating system to obtain the desired coating on conduit 1024 and one or more sensors operatively associated with the feedback coating system. In one embodiment of the invention, one or more sensors are configured to determine the following parameters of the coating procedure - heating time, heating temperature, coating material temperature, coating material volume, etc.

[00292] In one embodiment, method 1000 may include other procedures that are not illustrated in FIG. 1A. In one embodiment of the invention, these other procedures of the method 1000 are illustrated and explained in relation to FIG. 1b.

[00293] In one embodiment, method 1000 may include a pipe preparation procedure 1040, a pipe alignment procedure 1042, a weld check procedure 1044, a repair procedure 1046, a cooling procedure 1048, and a pipeline deployment procedure 1050. In one embodiment, each of these procedures is optional.

[00294] In one embodiment, the pipe preparation procedure 1040 is performed before the root pass procedure 1002. In one embodiment, the pipe preparation procedure 1040 is performed before the pipe alignment procedure 1042.

[00295] In one embodiment, the pipe preparation procedure 1040 may comprise a cutting procedure 1040a. In one embodiment, cutting procedure 1040a is performed to prepare the edge or ends of pipe segments 1022a, 1022b for welding. In one embodiment of the invention, during the cutting procedure 1040a, the pipe segments 1022a and 1022b being welded together are cut to the desired dimensions. In one embodiment of the invention, the cutting procedure 1040a may be performed at the manufacturing site.

[00296] In one embodiment of the invention, the method may comprise a pipe-laying procedure in which the pipes are distributed in accordance with the design (before the joining/welding procedure). In one embodiment of the invention, each pipe segment connection has a specific location in the pipeline. The laying team makes sure that each piece of pipe is placed where it should be. The inspectors check the assigned pipe numbers to make sure the connections are in the correct order.

[00297] In one embodiment, the method may comprise a bending procedure in which pipes are bent to conform to the terrain of the pipeline route. In one embodiment of the invention, pipes are inserted into a pipe bending machine and then a mandrel is positioned in the pipe. The mandrel is built and mounted to apply pressure inside the pipe to prevent buckling when bent. The operator positions the pipe and performs the bend. After bending, the pipe is removed from the pipe bending machine. After the bending procedure, each part of the pipe is installed in place.

[00298] In one embodiment, the pipe preparation procedure 1040 may comprise a chamfering procedure 1040b. In one embodiment of the invention, the chamfering procedure 1040b is performed to prepare the edge or ends of the pipe segments 1022a, 1022b for welding. In one embodiment of the invention, during the chamfering procedure 1040b, the ends of the pipe sections or segments 1022a and 1022b being welded together are cut at an angle to the desired dimensions. In one embodiment, the desired bevels can be machined at the ends of the pipe segments 1022. In one embodiment, a pipe end machine is inserted into the pipe and secured to the pipe (by lifting the internal clamp shoes). In one embodiment of the invention, the chamfering procedure 1040b may take 10 seconds. In one embodiment of the invention, the operator can manually check the formed chamfer using the corner gauge 5801 illustrated in FIG. 2C-2F. Fig. 2C-2E illustrate, respectively, a front view, a perspective view, and a side view of an angle gauge 5801, wherein FIG. 2F illustrates an enlarged view of detail A in FIG. 2C. In one embodiment of the invention, bevelling procedures 1040a, 1040b may be performed at the manufacturing site.

[00299] In one embodiment of the invention, the standard groove depth for field welding within a pipe is 0.050 inches. In one embodiment, the weld bead is about 3 millimeters high, so the weld bead protrudes from the surface by 0.05 to 0.07 inches. To perform two weld passes (eg, root pass and hot pass), in one embodiment, the groove can be cut to a depth of 0.150 to 0.170 inches.

[00300] In one embodiment, the pipe alignment procedure 1040 is performed before the root pass procedure 1002. In one embodiment, the pipe alignment procedure 1042 is performed in between the pipe preparation procedure 1040 and the root pass procedure 1002. In one embodiment of the invention, a preheat procedure may be performed prior to the welding procedure (eg, prior to the root pass procedure) to heat the pipe to over 100°C in order to evaporate all moisture from the pipe surface.

[00301] In one embodiment of the invention, as illustrated in FIG. 2G, the procedure for aligning pipe 1042 may include presenting second pipe 1022a at second end 1038b of first pipe 1022b and aligning weld ends 1038a, 1038b of first and second pipe 1022a, 1022b. In one embodiment of the invention, the internal welding system 5004 may include a feedback system (for example, using a measurement sensor 5056, one or more processors 5140, orientation motors 5030, 5074, external platform 5330, 6010A, 6010B, internal clamps 5144, 5144 , 7050, 7052, as will be explained in more detail below), configured to determine whether the ends 1038a, 1038b of the first and second pipes 1022a, 1022b are properly aligned. The term "motor" as commonly used herein means any type of electromechanical motor, such as an electric motor, hydraulic motor, pneumatic motor.

[00302] In one embodiment, an additional weld inspection procedure 1044 may be performed in between the hot pass procedure 1004 and the fill and cover pass procedure 1006. In one embodiment, the additional weld inspection procedure 1044 may comprise radiographic testing. In one embodiment of the invention, radiographic testing is performed by a radiographic system. In one embodiment, the x-ray testing system includes an emitter configured to emit x-rays into pipe segments 1022a and 1022b and the root pass and hot pass layers formed therebetween. In one embodiment, the intensity of the x-ray radiation may be attenuated by the material of the pipe segments 1022a and 1022b, as well as the root pass and hot pass layers 1014, 106 formed between them. In one embodiment, the x-ray system includes a receiver configured to measure the intensity of radiographic radiation passing through the material of the pipe segments 1022a and 1022b and the layers of root pass and hot pass 1014, 1016 formed therebetween. radiation in the immediate vicinity.

[00303] In one embodiment, the repair procedure 1046 is performed after the weld inspection procedure 1008, and before the heating and coating procedures 1010 and 1012. In one embodiment, the repair procedure 1046 is configured to repair any weld defects that discovered during the 1008 weld inspection procedure.

[00304] The weld repair procedure described herein may be one of various types of procedures. In one embodiment of the invention, an additional welding operation is performed over the previous weld to correct any defect in the weld. In another embodiment of the invention, a defective weld can be ground or, if desired, completely cut off (manually or automatically) before performing a subsequent repair operation.

[00305] In one embodiment of the invention, after the heating and coating procedures 1010 and 1012, the pipeline 1024 is allowed to cool to the required temperature before additional processing steps that may be implemented (for example, before wrapping the connected pipe segments or moving / placing pipe segments in water or some other suitable location on land). In one embodiment, the cooling procedure 1048 is performed after the coating procedure 1012. In one embodiment, the cooling procedure 1048 is performed by the cooling system 2010, 2110, 2210, 65000 (as illustrated and described in relation to FIGS. 104-112B and 119- 136), which are designed to remove heat from the welded pipes in such a way as to reduce their temperature to the allowable temperature of the effective winding. For example, the pipeline temperature must be within a predetermined temperature (e.g., 50 to 70 °C) to perform a winding procedure, an S-lay procedure, etc. In one embodiment, the cooling system may be an indoor system cooling, configured to cool the welded pipes inside the conduit 1024.

[00306] In one embodiment of the invention, the welded pipes can be cooled by air flow for a certain time. In one embodiment of the invention, the welded pipes can be cooled by spraying or pouring liquid over the outside of the insulation/coating on the pipeline. In one embodiment of the invention, the procedure for spraying or pouring liquid can be performed in one or more stations.

[00307] In one embodiment, the cooling procedure 1048 is performed for, for example, a barge welding procedure, a pipe string welding procedure at an onshore pipe welding depot, and a main pipeline welding procedure at an onshore pipe welding depot. In one embodiment, the onshore main pipeline welding procedure and the offshore string welding procedure may not comprise a separate cooling procedure.

[00308] In one embodiment, the pipeline deployment/descent procedure 1050 is performed after the coating procedure 1012. In one embodiment, the pipeline deployment/descent procedure 1050 is performed after the cooling procedure 1048.

[00309] In one embodiment, the pipeline deployment procedure 1050 may comprise a winding procedure 1050a, an S-lay procedure 1050b, or a pipeline lowering procedure 1050c.

[00310] In one embodiment, the winding procedure 1050a is configured to wind the pipeline onto a ship that transports the pipeline to its final destination or location. In one embodiment of the invention, the pipeline temperature must be within a predetermined temperature (eg, 50 to 70°C) to perform the winding procedure 1050a. In one embodiment of the invention, a predetermined temperature (eg, 50 to 70°C) is set to prevent any damage during the winding procedure 1050a.

[00311] In one embodiment, the S-lay pipe procedure is an offshore pipe-lay procedure in which the pipeline is lowered into the sea in a horizontal position. In one embodiment of the invention, during the S-shaped pipe-lay procedure, the pipeline collides with the end of the ship in an S-curve. In one embodiment of the invention, the pipeline temperature must be within a predetermined temperature (eg, 50 to 70°C) to perform the S-lay procedure 1050b. In one embodiment, a predetermined temperature (eg, 50 to 70°C) is set to prevent any damage during the S-lay procedure 1050b.

[00312] The coiling procedure, the S-laying procedure, and the J-laying procedure are described in detail with respect to FIG. 136B-E.

[00313] In one embodiment, the pipeline lowering procedure 1050c is configured to position/lower the pipeline into a pre-dug trench.

[00314] In one embodiment of the invention, the state/conditions of pipeline welding can be classified into five categories, called: onshore main pipeline welding procedure, onshore end welding procedure, onshore pipe welding depot main pipeline welding procedure, pipeline strand welding procedure at the onshore pipe welding base and the welding procedure on the barge.

[00315] The onshore main pipeline welding procedure is illustrated in FIG. 3. The procedure for welding the main pipeline on land is usually carried out at ground level and adjacent to the pre-dug trench in which the pipeline will be located. In one embodiment of the invention, above ground pipelines are welded together in sections, for example, up to 1 mile in length. Welding stations for ground welding are located next to each other. The pre-weld and post-weld procedures of the land-based welding process are separated from the actual welding procedure so that the pre- and post-weld procedures can be performed at their own speed. After the pipeline segments are welded together, they are lowered into a pre-dug trench.

[00316] The procedure for welding the pipeline strings is illustrated in FIG. 4. The procedure for welding pipeline strings on land is usually carried out in a previously dug trench in which the pipeline will be located. In other words, sections or segments are cut to the correct length and welded together in a pre-dug trench.

[00317] The main pipeline welding procedure at the onshore pipe welding depot is illustrated in FIG. 5. The procedure for welding the main pipeline at the onshore pipe welding base is usually carried out in an environment close to the factory. All steps of the welding procedure of the main pipeline at the onshore pipe welding base take place within a continuous production process, approximate and corresponding to the factory conditions. For example, pipes are welded, inspected and coated along an assembly line to form a pipe string (eg reaching, in some cases, 7 kilometers). Scourges of pipes are stored until they are coiled on a ship for transport to their final destination. In other words, when the ship/barge is away from the onshore pipe base, the welded pipes are stored in long sections. The strings of pipe are wound on large spools on barges (typically in a J-lay) and unwound when the barge reaches the job site.

[00318] The procedure for welding pipeline strings at an onshore pipe welding depot is illustrated in FIG. 6. The pipeline string welding procedure at an onshore pipe base is used to join pre-assembled pipeline sections or segments together as they will be coiled onto the ship/vessel that will typically transport the pipeline to its final destination. The joint cools after coating, which slows down the winding speed. All procedures for welding the pipeline strings at the onshore pipe welding base are performed at the same station.

[00319] The barge welding procedure is illustrated in FIG. 7. The welding procedure on the barge is usually carried out under near-factory conditions on board the floating base. All actions of the welding procedure on the barge are usually performed within a continuous production process that approximates and corresponds to factory conditions. The pipeline is placed at its final destination when separated from the ship.

[00320] Each of these pipeline welding locations may comprise one or more of the procedures described with respect to FIG. 1A and 1B. One or more of the systems described in this patent application (for example, 5004 internal welding system, 3001 internal string welding system, 7001 purge and check system, 7500 external welding system, and 2010 internal cooling system) can be used in the work procedures of such welding locations. pipeline.

[00321] For example, as shown in FIG. 3, the onshore main pipeline welding procedure begins with a pipe preparation procedure in which a bevel adapted to the weld is machined at each end of the pipes. This is done by a preparation team that works a short distance ahead of the welding team. After the pipe preparation procedure, the root pass procedure is performed. In one embodiment, the root pass procedure is performed by the internal welding system 5004. In one embodiment, the root pass procedure is performed by the external weld system 7500 using the internal clamp(s) 7050, 7052. when welding the root of the seam, the hot pass procedure is performed. The hot pass procedure can be performed by either the external welding system or the 5004 internal welding system.

[00322] In one embodiment, both the hot pass procedure and the root pass procedure are performed by the internal welding system 5004. In another embodiment, only the root pass procedure is performed by the internal welding system 5004, with the procedure hot pass is performed by an external welding system 7500.

[00323] In one embodiment, the filling and facing pass procedure is performed after the hot pass procedure. In one embodiment, the fill and cover pass procedure is performed by the external welding system 7500. In one embodiment, the fill and cover pass procedure is performed at multiple stations.

[00324] After the fill and cover pass procedure, a weld inspection procedure is performed. For example, ultrasonic, radiographic, or magnetic testing of the weld area can be used for verification. Any defects found during the weld inspection procedure are repaired during the weld repair procedure. Welded pipes are coated with a weldable epoxy coating. The weld-on epoxy is applied to the (heated) protruding end of the welded pipe so that the weld-on epoxy adheres to the outer surface of the inside of the pipe. The coating procedure is carried out by an independent team that works after the repair team. The loan pipeline is lowered into a previously dug trench. The pipeline lowering procedure can be performed by an independent team that works ahead of the coating team.

[00325] As illustrated in FIG. 4, the procedure for welding pipeline strings on land begins with the procedure for preparing the pipe. The required length of the pipe is not known in advance, so the overlay is intended for the procedure of welding pipeline strings on land. Once the pipes are in the trench, one pipe is cut to correct length and the required chamfer is machined at the end of the pipe. After the pipe preparation procedure, the root pass procedure is performed.

[00326] In one embodiment, the root pass procedure is performed by the internal string welding system 3001. In another embodiment, the root pass procedure is performed by the pipe string clamping system using the external welding system 7500. B In another embodiment of the invention, the root pass procedure is performed by a hand-held welder using externally placed clamps.

[00327] After the root pass procedure, a hot pass procedure is performed. In one embodiment, the hot pass procedure is performed by the internal string welding system 3001. In another embodiment, the hot pass procedure is performed by the external weld system 7500. In another embodiment, the hot pass procedure is performed by a hand-held welding machine.

[00328] In one embodiment, both the hot pass procedure and the root pass procedure are performed by the internal string welding system 3001. In another embodiment, only the root welding pass procedure is performed by the internal string welding system 3001 , while the hot pass procedure is performed by the external welding system 7500.

[00329] The filling and facing pass procedure is performed after the hot pass procedure. In one embodiment, the fill and cover pass procedure is performed by an external welding system 7500. In another embodiment, the fill and cover pass procedure is performed by a manual welder. The filling and lining pass procedure is carried out outside the pipes. After the fill and cover pass procedure, the weld inspection procedure is performed. For example, ultrasonic, radiographic, or magnetic testing of the weld area can be used for verification. The weld inspection procedure is carried out by an independent team that works in front of the welding team. Any defects found during the weld inspection procedure are repaired during the weld repair procedure. The repair procedure is carried out by an independent team that works in front of the team performing the inspection. Welded pipes are coated with a weldable epoxy coating. The weld-on epoxy is applied to the (heated) protruding end of the welded pipe so that the weld-on epoxy adheres to the outer surface of the inside of the pipe. The coating procedure is carried out by an independent team that works after the repair team.

[00330] As illustrated in FIG. 5, the welding procedure of the main pipeline at the onshore pipe welding depot begins with a pipe preparation procedure in which the necessary chamfer is mechanically performed on the ends of the pipe. After the pipe preparation procedure, the root pass procedure is performed. In one embodiment, the root pass procedure is performed by the internal welding system 5004. In another embodiment, the root pass procedure is performed by the purge and check system with the external welding system 7500. when welding the root of the seam, it is carried out with internal clamps using an external welding system.

[00331] After the root pass procedure, a hot pass procedure is performed. In one embodiment, the hot pass procedure is performed by the internal welding system 5004. In another embodiment, the hot pass procedure is performed by the external welding system 7500.

[00332] In one embodiment, both the hot pass procedure and the root pass procedure are performed by the internal welding system 5004. In another embodiment, only the root pass procedure is performed by the internal welding system 5004, with the procedure the hot pass procedure is performed by the external welding system 7500. In yet another embodiment of the invention, the root pass procedure is performed by the external welding system 7500 using the internal purge clamps 7001, while the hot pass procedure is performed by the external welding system 7500.

[00333] The X-ray weld inspection procedure is performed after the hot pass procedure. The X-ray weld inspection procedure is optional.

[00334] The fill and cover pass procedure is performed after the hot pass procedure and the X-ray weld inspection procedure. In one embodiment of the invention, the filling and facing pass procedure is performed by an external welding system. In one embodiment of the invention, the filling and facing pass procedure is performed at a plurality of stations.

[00335] After the fill and cover pass procedure, a weld inspection procedure is performed to perform a weld inspection of the weld. For example, ultrasonic, radiographic, or magnetic testing of the weld area can be used for verification. Any defects found during the weld inspection procedure are repaired during the weld repair procedure. Welded pipes are coated with injection molded polypropylene. The injection molded polypropylene coating is applied to the (preheated to 180°C) protruding ends of the pipe so that the injection molded polypropylene coating adheres to the outer surface of the inside of the pipe. After the coating procedure, a cooling procedure is performed. It is allowed to cool the pipes with air flow for a certain time.

[00336] As illustrated in FIG. 6, the pipeline string welding procedure at the onshore pipe welding depot begins with the pipe preparation procedure, in which the necessary chamfer is mechanically performed on the pipe ends. After the pipe preparation procedure, the root pass procedure is performed. In one embodiment, the root pass procedure is performed by the internal string welding system 3001. In another embodiment, the root pass procedure is performed by the purge clamping system 7001 with the external welding system 7500. In another embodiment, of the invention, the root pass procedure is performed by internal clamps using an external welding system.

[00337] After the root pass procedure, a hot pass procedure is performed. In one embodiment, the hot pass procedure is performed by the internal string welding system 3001. In another embodiment, the hot pass procedure is performed by an external welding system.

[00338] In one embodiment, both the hot pass procedure and the root pass procedure are performed by the internal string welding system 3001. In another embodiment, only the root pass procedure is performed by the string welding system 3001.

[00339] The X-ray weld inspection procedure is performed after the hot pass procedure. The X-ray weld inspection procedure is optional.

[00340] The filling and facing pass procedure is performed after the hot pass procedure. In one embodiment of the invention, the filling and facing pass procedure is performed by an external welding system. In one embodiment of the invention, the filling and facing pass procedure is performed at a plurality of stations.

[00341] After the fill and cover pass procedure, a weld inspection procedure is performed to perform a weld inspection of the weld. For example, ultrasonic, radiographic, or magnetic testing of the weld area can be used for verification. Any defects found during the weld inspection procedure are repaired during the weld repair procedure. Welded pipes are coated with injection molded polypropylene. The injection molded polypropylene coating is applied to the (preheated to 180°C) protruding ends of the pipe so that the injection molded polypropylene coating adheres to the outer surface of the inside of the pipe. After the coating procedure, a cooling procedure is performed. In one embodiment of the invention, the pipes may be cooled by pouring or spraying water on the outer surface of the insulation. In another embodiment of the invention, the pipes may be cooled by an internal cooling system. In one embodiment of the invention, the pipes may be wound onto the ship after the cooling procedure. In one embodiment of the invention, the temperature of the pipes must be in the range of 50 to 70°C during the winding procedure in order to prevent any damage during the winding process. In one embodiment of the invention, all procedures of the pipeline string welding sequence at the onshore pipe welding depot are performed at the same location.

[00342] As illustrated in FIG. 7, the procedure for welding the pipeline strings on the barge begins with the pipe preparation procedure, in which the necessary bevel is mechanically performed on the ends of the pipe. After the pipe preparation procedure, the root pass procedure is performed. In one embodiment, the root pass procedure is performed by the internal welding system 5004. In another embodiment, the root pass procedure is performed by the purge clamping system 7001 with the external welding system 7500. In another embodiment, the root pass procedure is performed by internal clamps using an external welding system 7500.

[00343] After the root pass procedure, a hot pass procedure is performed. In one embodiment of the invention, the pipes are advanced to perform the hot pass procedure after the root pass procedure has been performed. In one embodiment, the hot pass procedure is performed by the internal welding system 5004. In another embodiment, the hot pass procedure is performed by an external welding system.

[00344] In one embodiment, both the hot pass procedure and the root pass procedure are performed by the internal welding system 5004. In another embodiment, only the root pass procedure is performed by the internal welding system 5004. X-ray suture is performed after the hot pass procedure. The X-ray weld inspection procedure is optional.

[00345] The fill and cover pass procedure is performed after the hot pass procedure and the X-ray weld inspection procedure. In one embodiment of the invention, the filling and facing pass procedure is performed by an external welding system. In one embodiment of the invention, the filling and facing pass procedure is performed at a plurality of stations.

[00346] After the fill and cover pass procedure, a weld inspection procedure is performed to perform a weld inspection. For example, ultrasonic, radiographic, or magnetic testing of the weld area can be used for verification. Any defects found during the weld inspection procedure are repaired during the weld repair procedure. Welded pipes are coated with injection molded polypropylene. The injection molded polypropylene coating is applied to the (preheated to 180°C) protruding ends of the pipe so that the injection molded polypropylene coating adheres to the outer surface of the inside of the pipe. After the coating procedure, a cooling procedure is performed. In one embodiment of the invention, the pipes may be cooled by pouring or spraying water on the outer surface of the insulation. In one embodiment of the invention, the cooling procedure is performed at a plurality of stations. In another embodiment of the invention, the pipes may be cooled by an internal cooling system. In one embodiment of the invention, the pipes face the end of the vessel in an S-shaped configuration. In one embodiment of the invention, the temperature of the pipes must be in the range of 50 to 70° C. during the S-Lay procedure to prevent any damage during the S-Lay procedure.

[00347] In one embodiment, a field system 5000 is provided for welding two pipes 1022a, 1022b. As used herein, the term "field system" is a general term intended to refer to the system(s) described herein as a whole, and/or any of the subsystems per se. For example, "field system" may refer to a combination of an internal inspection system, an external welder, an internal pipe cooler, and a non-destructive ultrasonic inspection system, together with a remote uLog processing system (eg, a 13704 remote computer system). In another example, "field system" may refer to, for example, a separate internal welding system, a separate internal inspection system, a separate internal cooling system, a separate welding machine for welding pipe strings. In other words, "field system" may refer to, for example, the internal welding system 5004 separately, the internal inspection system 7001 separately, the internal cooling system 6500 separately, the pipe welding machine 3001 separately.

[00348] As illustrated in FIG. 8, 9, 10-1, 10-2, and 10-3, in one embodiment of the invention, each pipe segment 1022a or 1022b has a longitudinal axis as indicated by arrow AA. As will become clear from the description below, the field system 5000 is configured to support and adjust the position and/or orientation of a plurality of pipe segments 1022a, 1022b until both pipe segments 1022a, 1022b are aligned along the same longitudinal axis A-A, and one end of each of the pipe segments 1022a, 1022b will not abut at the junctions. Fig. 9 illustrates an enlarged view of the field system 5000 in FIG. 8, in which the edges form a contact surface 5002 (also known as a "fit" connection). In one embodiment, the field system 5000 includes an internal welding system 5004 that applies a weld to an internal contact surface 5002 from within the fitted pipe segments 1022a, 1022b. To apply a weld to the inner surface of the joint 5002, the inner welding system 5004 is rolled in through the end of one of the pipe segments 1022b, as illustrated in FIG. 10-1. Then, the second pipe segment 1022a is placed and adjusted until both segments 1022a, 1022b are properly aligned. In one embodiment, the internal welding system 5004 applies a weld (e.g., GMAW) from within the pipe segments 1022a, 1022b to the side surface or mating surface of the pipe segment 1022a, 1022b and into the v-shaped a gap formed by the bevel/bevel of the two pipe segments 1022a, 1022b (another cross-sectional shape other than a v-gap may be used).

[00349] FIG. 9A illustrates a partial cross section of conduit 1024 showing the perfect alignment of weld head 5502 of internal welding system 5004 with respect to internal grooves 5228 and 5232 (along longitudinal axis A-A of pipes 1022a, 1022b). In the illustrated embodiment, pipes 1022a, 1022b are perfectly aligned with each other and do not have any stagger (i.e., height difference between pipe bevels 1022a, 1022b after pipe alignment).

[00350] In one embodiment of the invention, the field system 5000 may include external clamps 5302 used to externally fix the pipes together (external to the pipes). In one embodiment of the invention, the outer clamps 5302 have rods across the weld, and welding can be performed in manual mode. In one embodiment, the outer jaws 5302 may be hydraulically actuated or may be mechanically actuated (eg, using a hand lever). For example, in one embodiment, the outer clips 5302 may be tip-to-tone clips, as illustrated in FIG. 7A and 7B.

[00351] In one embodiment, the internal welding system 5004 is connected to an external structure/system (i.e., external to the pipes 1022a, 1022b to be welded) via a tether 5034 (as illustrated in FIG. 10-1). In one embodiment of the invention, the external system is a remote uLog processing system. In one embodiment, the tether 5034 may be in the range of 40 to 80 feet (eg, for a pipe that is 40 to 80 feet long). In one embodiment of the invention, the halyard 5034 may be referred to as a "drive link". In one embodiment of the invention, the drive rod/tether 5034 may be rigidly connected to the internal welding system 5004. In other words, the drive rod/tether 5034 is a permanent element of the internal welding system 5004. In one embodiment of the invention, the tether 5034 includes a structural tubular element, protecting all cables, wires and hoses (for example, which connect the external structure/system and the internal 5004 welding system) from damage.

[00352] In one embodiment of the invention, when the internal welding system 5004 moves from one pipe joint (weld) to the next pipe joint (weld), the tether 5034 disconnects at the DP disconnect point (as illustrated in FIG. 10-2). This detachment facilitates the placement of the new/incoming pipe segment 1022a in position relative to the first pipe 1022b. Fig. 10-2 illustrate that the cables, hoses, and wires (e.g., that connect the outer structure/system and the inner welding system 5004) at the end of each drive rod/tether 5034 are disconnected and that the new/incoming pipe segment 1022a is positioned in relation to the first pipe 1022b.

[00353] As illustrated in FIG. 10-3, in one embodiment of the invention, after the incoming pipe 1002a is positioned relative to the first pipe 1002b, the tether 5034 can protrude/pull out of the incoming pipe 1002a by a distance HP. In one embodiment of the invention, the distance HP that the tether 5034 can protrude/pull out of the incoming pipe 1002a is in the range of 1 to 5 feet.

[00354] The tether 5034 is typically used to supply fluid (compressed air), transmit electrical signals, and/or transmit communication signals between the external structure/system and the internal welding system 5004. contains a drive rod or halyard.

[00355] For example, tether 5034 may include a welding power line configured to supply power to the welding torches. In one embodiment, the tether 5034 includes three weld power lines to independently power the three associated welding torches in the internal welding system 5004. welding system 5004.

[00356] In one embodiment of the invention, the tether 5034 may contain communication lines configured to communicate with the measurement sensor 5056, the control camera 5112 and / or other electronic modules (for example, to start or stop welding) of the internal welding system 5004. In one embodiment of the invention, communication with the internal welding system 5004, including communication with the measurement sensor 5056, control camera 5112, and/or other electronic components of the internal welding system 5004, can be performed wirelessly. It should be understood that if a plurality of welding torches are provided, then a plurality of measurement sensors/lasers 5056 are also provided.

[00357] In one embodiment, the tether 5034 may include a fluid supply line configured to provide compressed air to the internal welding system 5004. In one embodiment, the tether 5034 may include other (separate) power lines configured to suppress electricity for 5116 batteries to recharge them. In one embodiment of the invention, a separate power supply line for recharging the 5116 batteries is optional. In one embodiment, the cable 5034 may include a separate power line configured to supply power to one or more electronic modules and/or motors of the internal welding system 5004. In another embodiment, a separate power line is optional.

[00358] In one embodiment, the internal welding system 5004 is used for pipes having an internal diameter of 26 to 28 inches with a pipe wall thickness of 0 to 1 inch. In this regard, the internal welding system 5004 is configured to fit a hole size of 24 to 28 inches. In one embodiment of the invention, the internal welding system 5004 is used for pipes having an internal diameter of 24 inches or less with a pipe wall thickness of 0 to 1 inch. In one embodiment of the invention, the internal welding system 5004 is used for pipes having an outside diameter of 24 inches or less. In one embodiment of the invention, the internal welding system 5004 is used for pipes having an outside diameter of 26 to 28 inches.

[00359] FIG. 10A illustrates an internal welding system 5004 being constructed, sized and placed in pipes having an internal diameter of 26 inches with a wall thickness of 1 inch. For example, in one embodiment, the outer diameter of the skeleton structure of the internal welding system 5004 is 23.32 inches for pipes with an ID of 26 inches (with a wall thickness of 1 inch). For example, for a 26" ID pipe (with a wall thickness of 1"), the outer diameter of the frame structure (not having its own wheels) of the 5004 internal welding system is 23.32 inches.

[00360] FIG. 10B illustrates an internal welding system 5004 being built, sized and placed in pipes having an internal diameter of 24 inches with a wall thickness of 1 inch. For example, in one embodiment, the outer diameter of the skeleton structure of the internal welding system 5004 is 21.32 inches for pipes with an ID of 24 inches (with a wall thickness of 1 inch). For example, for a pipe with an ID of 24 inches, the outside diameter of the frame structure (not having its own wheels) of the 5004 internal welding system is 21.32 inches.

[00361] In one embodiment of the invention, the diameter of the frame of the internal welding system 5004 may depend on the ability of the internal welding system to pass through pipe bends. In one embodiment of the invention, the standard minimum pipe bend radius is 30 times D, where D is the outer or outside diameter of the pipe. In other words, the radius of the turning axis of the pipe is 30 times the outer or outside diameter of the pipe. For example, for a 26" OD or OD pipe, the minimum bend radius required to pass the 5004 Internal Weld System is 780" (i.e. (26") x 30). For example, for pipe with a 24" OD or OD, the minimum bend radius required to pass the 5004 internal weld system is 720" (i.e. (24") x 30). In one embodiment of the invention, the length of the frame of the internal welding system 5004 is limited by its placement.

[00362] In one embodiment of the invention, as illustrated in FIG. 1°C and 10D, field system 5000 may include a platform 5330 for transporting and moving the first pipe 1022a and the second pipe 1022b. In one embodiment of the invention, the platform 5330 is configured to bring the second pipe 1022a from the second 1038b end of the first pipe 1022b after the frame of the internal welding system 5004 is installed on the second end of the first pipe 1022b. In one embodiment of the invention, the platform 5330 may be referred to as a "docking module" (LUM).

[00363] In one embodiment of the invention, if necessary, to hold pipes 1022a, 1022b can be used multiple platforms. For example, if the pipe 1022a, 1022b is small and flexible, at least four platforms may be used, spaced along the entire length of the pipe 1022a, 1022b. If the pipe 1022a or 1022b is large and rigid, only two platforms can be used along the entire length of the pipe 1022a, 1022b.

[00364] In one embodiment of the invention, two platforms can be used to transport and move the pipe such that each platform is installed at the end of the pipe. In one embodiment of the invention, three platforms are used to transport and move the pipe such that two platforms are installed at the ends of the pipe and one platform is installed in the central part of the pipe section. In one embodiment of the invention, the centrally placed platform is configured to provide only support and no connectivity. In one embodiment of the invention, the platform 5330 used for the incoming pipe 1022a can be fully configured to transport, move and lead the incoming pipe 1022a to the second end of the first pipe 1022b (after the frame assembly of the internal welding system 5004 is installed on the second end of the first pipe 1022b) and realign the incoming pipe 1022a if the pre-weld profile data indicates a need for adjustment.

[00365] In one embodiment, the platform 5330 may include a set of actuated rollers 5332 external to the tubes 1022a, 1022b. In one embodiment, the rollers 5332 of the platform 5330 may be referred to as "outer pivots". In one embodiment of the invention, the outer surface 5346 and/or 5348 (as illustrated in Fig. 2G) of the first pipe 1022a and/or the second pipe 1022b come into movable contact with the outer(s) rotary(s) element(s) 5332, which assists in adjusting the relative position of tubes 1022a, 1022b based on instructions from one or more processors 5140.

[00366] In one embodiment, the platform 5330 includes a fixed frame 5334 configured to be rigidly connected to a surface (eg, base), a first movable frame 5336 movable to position the pipe in a horizontal plane, and a second movable frame 5338 , made with the possibility of positioning the pipe in a vertical plane.

[00367] In one embodiment of the invention, platform 5330 may be hydraulically actuated. For example, hydraulic cylinders 5340 located on the sides of the platform 5330 may be configured to move the second movable frame 5338. In one embodiment, the hydraulic cylinder(s) 5342 located under the platform 5330 may be configured to move the first movable platform 5336. In one embodiment of the invention, the movement of the platforms 5330 (placed at both ends of the pipes) can be coordinated to adjust the linear movement of the pipe 1022a or 1022b in all three directions (up-down, left-right, back-forward) and adjust the angular movement of the pipe 1022a or 1022b in two directions (tilt in the vertical and horizontal plane)).

[00368] In one embodiment, platform 5330 is operatively coupled to one or more processors 5140. In one embodiment, platform 5330 is wirelessly or wired connected to one or more processors 5140 such that if data The pre-weld profile detects a need for adjustment, hydraulic cylinders 5340 and 5342 are actuated to move and realign the incoming pipe 1022a based on the pre-weld profile data. In one embodiment, the externally placed rollers 5332 may be operatively linked and controlled by one or more processors 5140 via a first movable frame 5336 and a second movable frame 5338.

[00369] In one embodiment of the invention, the platform 5300 may be powered electrically. For example, Fig. 73 illustrates electrically powered platforms 6010A and 6010B. In one embodiment, the platform rollers 6010A and 6010B may be driven by motors to move the pipe 1022a or 1022b linearly and/or angularly. In one embodiment of the invention, platforms 6010A 6010B may include motors operatively associated with a ball screw to move the first movable frame and/or the second movable frame.

[00370] In general, when aligning pipes for a welding procedure, two alignment errors may occur, for example, pipe corner alignment error and pipe positioning error. As illustrated in FIG. 10E, a corner alignment error results in a gap 5344 on one side of the pipe. As illustrated in FIG. 10F, a positioning error results in a step transition, ie, a ridge on one side (eg, 1022b) and a trough on the other side (eg, 1022a).

[00371] In one embodiment, platforms 5330 or platforms 6010A and 6010B are used in pipeline alignment and welding procedures on land. Under offshore pipeline installation conditions, both angular alignment and position errors can be corrected by transmitting control signals from one or more processors 5140 to platform 5330 or platforms 6010A and 6010B (to control the respective rollers 5332). Thus, one or more processors 5140 are configured to adjust the relative position between the pipes (to correct for their alignment errors) by controlling the platform 5330 or the platforms 6010A and 6010B. In one embodiment of the invention, one or more processors 5140 are configured to actuate the platform 5330 to move the first pipe 1022a and the second pipe 1022b relative to each other based on the pre-weld profile data to change the contact surface area 5136 between the pipes 1022a, 1022b before welding operations based on instructions from one or more 5140 processors.

[00372] In one embodiment of the invention, pipes 1002a, 1002b can be aligned with a faucet and clamp (internal or external). In one embodiment of the invention, clamps can be built and mounted to align two pipes 1022a, 1022b both horizontally and vertically. In one embodiment of the invention, the crane is configured to control the axial position and two angles (tilt in the vertical and horizontal planes).

[00373] In one embodiment of the invention, as illustrated in FIG. 11, the internal welding system 5004 includes a frontmost section 5006, a center section 5008, and a drive section 5010.

[00374] In one embodiment, the frame members of the frontmost section 5006, center section 5008, and drive section 5010 may collectively be referred to as the frame assembly or frame assembly of the internal welding system 5004. In one embodiment, the frame or frame assembly of the internal welding system 5004 may be configured to support all components of each of the sections: the frontmost section 5006, the center section 5008, and the drive section 5010. 12), the front frame section 5068 (as illustrated in Fig. 23), and the frame drive section 5278 (as illustrated in Fig. 32A). In one embodiment of the invention, the frame or frame assembly of the internal welding system 5004 is configured to be placed inside the pipes 1022a, 1022b.

[00375] In one embodiment, the frontmost section 5006 is the section where external cables, wires and hoses from an external system/structure (external to the pipes being welded) are connected. In one embodiment of the invention, the frontmost section 5006 is configured to accommodate all of the components that provide the weld, as described in more detail below. In one embodiment of the invention, the central section 5008 is configured to align the pipe segments 1022a, 1022b and perform welding procedures. In one embodiment of the invention, the drive section 5010 is configured to move the internal welding system 5004 from one pipe connection to the next pipe connection. In one embodiment of the invention, the drive section 5010 is also configured to accommodate batteries, compressed air and shielding gas, which are part of the internal welding system 5004 required for operation.

[00376] In one embodiment of the invention, some components of the internal welding system 5004 are placed in such a way that half of the components are placed in the frontmost section 5006, and the remaining components are placed in the central section 5008. In one embodiment of the invention, some components of the internal welding system 5004 placed in one of three sections of the internal welding system 5004, but connected to the other three sections of the internal welding system 5004. welding 5004.

[00377] FIG. 12 illustrates an enlarged view of the forwardmost section 5006 of the inner welding system 5004. In one embodiment, the forwardmost section 5006 of the inner welding system 5004 includes a hitch 5012, the forwardmost electronic module 5014, a slip ring 5016, a front clamp control valve 5018, a feed assembly wire 5020, forward position sensor 5022, adjustable rails 5024, frontmost frame section 5026, idlers 5028, front rotation motor 5030, and front rotation clutch 5032. In one embodiment, the frontmost electronic module 5014 may include one or more processors 5014 In one embodiment, the front clamp control valve 5018, the forward position sensor 5022, and the forward rotation motor 5030 may be operatively coupled to one or more processors 5140.

[00378] FIG. 13-22 illustrate a view of the various components of the frontmost section 5006 of the internal welding system 5004. For example, FIG. 13 illustrates the coupler 5012, FIG. 14 illustrates a front rotating clutch 5032, FIG. 15 illustrates the front slip ring 5016, FIG. 16 illustrates the frontmost frame section 5026, FIG. 17 illustrates adjustable rails 5024, FIG. 18 illustrates guide rollers 5028, FIG. 19 illustrate a front rotation motor 5030, FIG. 20 illustrates the front clamp control valve 5018, FIG. 21 illustrates forward position sensor 5022, and FIG. 22 illustrates the wire feed assembly 5020, respectively.

[00379] FIG. 11A illustrates a view of a tether 5034 in which an internal welding system 5004 is configured to connect to a first end 5035 of the tether 5034, and an operator control system 5039 configured to connect to a second end 5037 of the tether 5034. In one embodiment, the first end 5035 of the tether 5034 is connected to the hitch 5012 by the frontmost section 5006 of the internal welding system 5004. In one embodiment of the invention, communication (of the internal welding system 5004) with the Ulog system is configured to be organized through one or more processors, or modules in the operator control system 5039 In one embodiment of the invention, the operator control system 5039 is placed external to the pipes 1022a, 1022b to be welded.

[00380] In one embodiment, the frontmost frame section 5026 is built and assembled to house/support all of the components of the frontmost section 5006 of the internal welding system 5004. In one embodiment, the frontmost frame section 5026 is built and mounted to provide attachment point for all components in front of the 5004's internal welding system and to protect these components from damage. In one embodiment of the invention, the frontmost frame section 5026 is built and assembled to guide new pipe segments to align with previous/existing segments. In one embodiment of the invention, the forwardmost section 5026 may be made of steel or other materials, as will be appreciated by those skilled in the art.

[00381] In one embodiment, the forwardmost frame section 5026 is constructed and assembled to include a cone-shaped nose cone allowing the internal welding system 5004 to move easily in new pipe segments while joining/welding new pipe segments to previous/ existing pipe segments. In one embodiment of the invention, the nose cone of the forwardmost frame 5026 may serve as an alignment structure, configured to help align the second tube 1022b with respect to the first tube 1022a. In one embodiment, the cone-shaped nose cone is configured to extend outwardly from the second end of the first tube 1022a to help align the second tube 1022b with the first tube 1022a.

[00382] In one embodiment of the invention, as illustrated in FIG. 12, the forwardmost frame section 5026 includes a sensor 5352 configured to detect the end of the pipe when the frame of the internal welding system 5004 returns to the pipe opening after welding the previous pipe. In one embodiment of the invention, the sensor 5352 may be configured to be movable along with the frame of the internal welding system 5004. In one embodiment of the invention, the sensor 5352 is operatively coupled to or connected to one or more processors 5140.

[00383] In one embodiment, the sensor 5352 may be a rotary switch. For example, a rotary switch may have a downwardly protruding rod or wire offset towards the inner surface of the pipe and configured to advance against the inner surface of the pipe until it reaches the edge of the pipe and extend downward after reaching the edge of the pipe to actuate rotary switch, thus detecting the end of the pipe. For example, when the frontmost frame section 5026 reaches the end of the pipe, a portion of it will extend outward from the pipe to receive the next pipe to be welded, with the wire configured to extend outward from its normal position to detect the end of the pipe. In another embodiment of the invention, the sensor 5352 may be a linear motion sensor configured to be operatively coupled to the wheels/rollers of the internal welding system 5004 to determine the distance that the internal welding system 5004 travels and use this information to determine/detect the end of a pipe of known length. .

[00384] In one embodiment of the invention, the sensor 5352 is configured to detect the contact surface area 5136 between the pipes 1022a, 1022b. In one embodiment of the invention, one or more processors 5140 are configured to control drive motors 5124 to move the frame of the internal welding system 5004 through at least one of the pipes 1022a, 1022b until the sensor 5352 detects the area of the contact surface 5136. In In one embodiment of the invention, the sensor 5352 is configured to detect the placement of the internal welding system 5004 in the area of the contact surface between the two pipes 1002a, 1002b. In one embodiment, the sensor 5352 may be a measurement sensor 5056. In one embodiment, the sensor 5352 may be a laser. In one embodiment of the invention, the sensor 5352 may be a control chamber 5112. In one embodiment of the invention, the measurement sensor 5056 and/or the control chamber 5112 is configured to also perform the measurement functions of the sensor 5352.

[00385] In one embodiment of the invention, as illustrated in FIG. 12, the end 5208 of the frontmost frame section 5026 is configured to connect to the flange portion 5210 (as illustrated in FIG. 23) of the front clamp 5142 of the center section 5008. In one embodiment, the end 5208 of the frontmost frame section 5026 is configured to connect to flange portion 5210 of the front clamp 5142 of the center section 5008 using fasteners such as bolts 5212 (as illustrated in Fig. 23).

[00386] The front rotating sleeve 5032 in the frontmost section 5006 is illustrated in FIG. 12 and 14. A rotatable coupling is generally a coupling or joint constructed and mounted to rotate two combined/connected elements. The rotating sleeve is constructed and mounted to provide a seal between the stationary supply channel (pipe or conduit) and the rotating element (drum, cylinder or spindle) to prevent fluid from entering and/or flowing out of the rotating element. Fluids commonly used with rotary couplings include compressed air and purge gas. A rotating coupling typically includes a housing, a shaft, a seal, and a bearing. The bearings and seal are mounted around the shaft. Bearings are used to allow the rotating joint, both the shaft and the housing, to rotate. The seal is built and mounted to prevent fluid (such as compressed air or purge gas) from escaping to the outside through the rotating sleeve during operation. During operation, the rotating sleeve clamps onto the inlet valve to engage with the outlet valve. At this time, the fluid passes into the rotating sleeve from its source and is held within the rotating sleeve during its movement. This fluid leaves the rotating sleeve when it crosses the valve opening during rotation, and more fluid enters the rotating sleeve again on the next rotation.

[00387] In one embodiment of the invention, the front rotating sleeve 5032 is configured to allow compressed air to flow through it. In one embodiment of the invention, the front rotary sleeve 5032 (eg, described in relation to Fig. 25) is constructed and mounted to receive compressed air from the rear rotary sleeve 5072 (for example, through the rear slip ring 5080, the rotary hub 5078 and the front slip ring 5016 ). The rear rotary coupling has substantially the same components and operates in substantially the same manner as the front rotary coupling 5032 and therefore is not illustrated in the same detail as the front rotary coupling 5032.

[00388] In one embodiment, a front rotary sleeve 5032 is constructed and mounted to transfer a portion of the received compressed air to the front clamp control valve 5018 (to actuate and control the front clamp 5142) via the valve 5204. In one embodiment, the front a rotating sleeve 5032 is constructed and installed to transfer the remainder of the received compressed air to the compressor or external cylinder of the air supply system 5029 (as illustrated in Fig. 70) to replenish the system (for example, filling the cylinder with compressed air) via valve 5204. In one embodiment of the invention , the remainder of the resulting compressed air is supplied to the compressor or cylinder of the air supply system 5029 (as illustrated in Fig. 70) through the front rotary coupling 5032.

[00389] In one embodiment of the invention, as illustrated in FIG. 70, two valves 5115 and 5117 are configured to be closed at the start of a replenishment procedure. During the refill procedure, pressurized air from the 5029 air supply bottle passes through valves 5115, 5117 and 5204 to the front rotary coupling 5032, from the front rotary coupling 5032 to the rear rotary coupling 5072, and then through valves 5198,5196, 5194 and 5113 to compressed air bottle 5128 to replenish compressed air bottle 5128 with compressed air. In one embodiment, the pressure throughout the fluid path (or fluid transmission line) between the external cylinder of the air supply system 5029 and the compressed air cylinder 5128 is maintained at the pressure in the cylinder during the refill procedure.

[00390] In one embodiment of the invention, the front rotary sleeve 5032 in the forwardmost section 5006 is also configured to allow compressed air from the halyard 5034 to enter the wire feed assembly 5020, which is rotatably mounted on the rotary hub 5078 of the center section 5008.

[00391] The front slip ring 5016 in the frontmost section 5006 is illustrated in FIG. 12 and 15. The slip ring is an electromechanical device (electrical connection) built and assembled to transfer electrical power and communication signals from a stationary structure to a rotating structure. The slip ring can be used in any electromechanical system that requires free continuous rotation during the transmission of energy and/or data signals. The slip ring contains a stationary structure (contact brush) that rubs against the outer diameter of the rotating structure. As the rotating structure completes a revolution, an electrical current or signal is conducted through the stationary structure to the rotating structure making the connection. The stationary structure may be a graphite or metal contact (brush) and the rotating structure may be a metal ring. If more than one electrical circuit is required, additional ring/brush assemblies are placed in series along the axis of rotation. Both the brushes and the rings are stationary, while the other components are rotating.

[00392] In one embodiment, the front slip ring 5016 is configured to transmit communication signals from the frontmost electronic module 5014 to the wire feed module 5046 of the wire feed assembly 5020. In one embodiment, the front slip ring 5016 is also configured to provide transmission of (welding) energy and transmission of communication signals from the 5034 tether to the 5004 internal welding system.

[00393] In one embodiment of the invention, as illustrated in FIG. 12 and 17, adjustable guides 5024 are built and mounted to improve the alignment of pipe segments 1022a, 1022b. In one embodiment of the invention, adjustable guides 5024 are built and mounted to accommodate different pipe sizes. In one embodiment of the invention, adjustable guides 5024 are also built and mounted to protect the center section 5008 from impact with the incoming pipe segment 1022b. In one embodiment, the adjustable rails 5024 of the internal welding system 5004 are built and mounted to adjust their extension slightly more than the clamp shoes folded (i.e., the clamp shoes 5157 in their folded position), but extend less than the extended ones. clamp shoes (i.e. clamp shoes 5157 in their extended position).

[00394] In one embodiment of the invention, as illustrated in FIG. 12 and 18, guide rollers 5028 are built and mounted to prevent the incoming pipe segment 1022b from binding on the sidewalls of the frontmost section 5006. In one embodiment, guide rollers 5028 are built and mounted to accommodate different pipe sizes. In one embodiment of the invention, the guide rollers 5028 are passive elements.

[00395] In one embodiment of the invention, as illustrated in FIG. 12, the forwardmost electronic module 5014 includes communication connections to the tether 1034 and to the front slip ring 5016. For example, in one embodiment, the forwardmost electronic module 5014 is configured to transmit power and communication signals to and from the tether 5034, and with the ability to transmit power and communication signals to and from the front slip ring 5016.

[00396] In one embodiment, the forwardmost electronics module 5014 is also configured to control the front rotation motor 5030 and the front clamp control valve 5018. In one embodiment, the forwardmost electronics module 5014 is further configured to receive signals from the forward provisions 5022.

[00397] The forward rotation motor 5030 in the forwardmost section 5006 is illustrated in FIG. 12 and 19. In one embodiment, the front rotation motor 5030 is electrically synchronized with the rear rotation motor 5074 located in the center section 5008 (described below). In one embodiment of the invention, both rotation motors 5030 and 5074 are configured to rotate the pivot hub 5078 of center section 5008 while leaving the front and rear clamps 5142 and 5144 stationary.

[00398] In one embodiment, the front rotation motor 5030 may include an outboard gear (due to design constraints). For example, in one embodiment, the front rotation motor 5030 has an electric motor comprising a rotor, a rotation shaft rotated by the rotor, and an external gear reducer 5021a supported by and comprising external teeth on the rotation motor shaft. The outer gear 5021a can be engaged with an external gear 5021b also having external teeth. The opposite end of the external gear reducer 5021b also has external teeth 5021c. The outer teeth 5021c of the outer/drive gearbox are built and mounted to engage with the inner teeth 5023 (as illustrated in Fig. 19) formed on the inner annular surface of the driven (ring) element of the wire feed unit gearbox 5020 to transmit torque from the front rotation motor 5030 to wire feed assembly 5020. In one embodiment of the invention, outer/drive gear outer gear teeth 5021c are built and mounted to engage with inner gear teeth 5023 formed on the driven (ring) gear member 50212 of wire feed assembly 5020 using a gear train design (see 19 ) to transmit torque from the front rotation motor 5030 to the wire feed unit 5020.

[00399] In one embodiment of the invention, as illustrated in FIG. 12 and 20, the front clamp control valve 5018 is configured to receive pressurized air from the stationary portion of the front rotating sleeve 5032.

[00400] In one embodiment, the front clip control valve 5018 is operatively coupled to receive control signals from the front electronics module 5014. In one embodiment, the front clip control valve 5018 is configured to supply compressed air to actuate and operate the front clamp 5142 when it receives signals from the frontmost electronic module 5014.

[00401] In one embodiment of the invention, as illustrated in FIG. 12 and 21, the forward position sensor 5022 may be a proximity sensor and a wheel angle sensor with a special profile. In one embodiment of the invention, a wheel angle sensor is built and mounted to be rotatably mounted on a wire feed assembly 5020 that rotates with the pivot hub 5078.

[00402] In one embodiment, the forward position sensor 5022 is operatively coupled to the front electronics module 5014 to send control signals. In one embodiment, the forward position sensor proximity sensor 5022 may be configured to send control signals to the front electronics module 5014 when the sensor is at the highest point on the wheel angle sensor. In one embodiment, the forwardmost electronics module 5014 is configured to use signals received from the forward position sensor 5022 to detect the orientation of the forwardmost section 5006 relative to the remainder of the internal welding system 5004 (e.g., pivot hub 5078).

[00403] In one embodiment of the invention, as illustrated in FIG. 12, 22, 22A, and 22B, the 5020 wire feed assembly contains a 5036 wire spool holder, a 5038 wire straightener, a 5040 welding wire bowden tube, a 5042 shielding gas control valve, a 5044 wire feed system, an electronic feed module wire 5046; and a wire feed frame 5048. In one embodiment, an example of a wire spool 5272 is illustrated in FIG. 22A. In one embodiment, the wire straightener 5038, shield gas control valve 5042, and wire feed system 5044 may be operatively associated with one or more processors 5140. In one embodiment, the electronic wire feed module 5046 may include one or more processors. 5140.

[00404] In one embodiment, the wire feed assembly 5020 is built and assembled to house the wire spools 5272, wire spool holders, wire straighteners, wire feed system, and shield gas control valves for each of the three illustrated welding torches. 5520 in the center section 5008 of the 5004 internal welding system. In the illustrated embodiment, the 5020 wire feed assembly includes three 5036 wire spool holders, three 5038 wire straighteners, three 5040 welding wire bowden tubes, three control valves shielding gas 5042 and three wire feed systems 5044 associated with the three illustrated welding torches 5502 in the central section 5008 of the internal welding system 5004. welding wire, welding wire/electrode spool gas control valves and wire feed systems in the 5004 internal welding system may vary depending on the number of welding torches.

[00405] In one embodiment, the 5272 welding wire spool is 7 (7/8) inches in size and weighs 10 pounds. In one embodiment of the invention, the size of the electrode or welding wire is 0.03 inches. In one embodiment of the invention, the electrode or weld wire is made of carbon steel. In one embodiment, the electrode or welding wire is manufactured from ER70S-6 carbon steel for inert gas welding, for example, from Chicago Electric Welding Systems. In one embodiment, the electrode or welding wire is designed for use with various shielding gas mixtures, such as 100% carbon dioxide (CO ₂ ), a mixture of 75% argon and 25% CO ₂ , or a mixture of 98% argon and 2% O _{2 .}

[00406] In one embodiment, the wire feed assembly 5020 is constructed and mounted to couple to the pivot assembly 5078 of the center section 5008 such that the rotation of the wire feed module 5020 is directly transmitted by the front rotation motor to the pivot hub 5078. In one embodiment of the invention , the wire feed assembly 5020 is built and mounted to mount (using fasteners) on the pivot hub 5078 of the center section 5008. wire 5020 and swivel hub 5078.

[00407] In one embodiment, the frame of the wire feed unit 5048 is constructed and mounted hollow to allow power, communication signals, shield gas, welding wire/electrodes, motor control signals, and compressed air to flow in, out, and pass through it.

[00408] In one embodiment of the invention, as illustrated in FIG. 22, a wire spool holder 5036 is constructed and mounted to receive and hold wire/electrode spools (not illustrated) used by the internal welding system 5004. In one embodiment, the wire spool holder 5036 may include a stop member 5220 configured with the ability to fix a coil for welding wire / electrode on it.

[00409] In one embodiment, the stop member 5220 may be removably placed on the shaft 5226 of the filler wire holder 5036 using a stop 5222 attached to the stop member 5220. The stop 5222 may include a smaller diameter area and a larger diameter area. In one embodiment of the invention, the stopper receiving hole may be provided on a shaft 5226 having the shape of a conventional closed circle cross-section with a side hole 5224 extending outward from the shaft 5226. diameter, and an area of larger diameter are inside the area of the receiving hole of the stopper, having a cross-sectional shape in the form of a conventional closed circle. When the larger diameter area is placed in the stopper receiving hole, the shaft 5226 covers the larger diameter area that cannot pass through the side hole 5224, locking the stopper member 5220 to the shaft 5226 by engaging between the stopper 5222 and the stopper receiving hole. Alternatively, when the stopper 5222 is positioned such that the smaller diameter area is entirely covered by the stopper receptacle, the stopper member 5220 can be freely removed from the shaft 5226 as the smaller diameter area can pass through the side hole 5224. Embodiments of the Invention, the stopper member 5220 can be fixed with a locking screw on the shaft 5226 of the wire spool holder 5036 with the possibility of removal.

[00410] The welding wire or electrode that exits from the welding wire/electrode spools can be bent with respect to it. In one embodiment, the wire straightener 5038 is configured to correct permanent bending and alignment of the filler wire (eg, by winding the filler wire in reverse). The straight configuration of the filler wire facilitates the passage of the filler wire through the Bowden tube (guide) 5040 for the filler wire. In addition, feeding the straight welding wire to the 5502 welding torch results in tighter welds. In one embodiment of the invention, a wire straightener 5038 is optional.

[00411] In one embodiment, a 5040 welding wire bowden tube (guide) is constructed and installed to guide the welding wire/electrode from the 5044 welding wire feed system to the 5502 welding torch. ) for 5040 welding wire is attached at both ends. In one embodiment, the filler wire is sheathed in a Bowden tube (guide) for 5040 filler wire.

[00412] In one embodiment, a 5044 filler wire feed system is built and installed to draw the filler wire through the wire straightener 5038 from the 5272 filler spool and push the filler wire through the 5040 filler wire bowden tube (guide) to the filler wire. burner 5502.

[00413] In one embodiment, the wire feed system 5044 is configured to be automatically controlled to deliver the required amount of wire to the welding torch 5502. In one embodiment, the wire feed system 5044 may include a motor and two gears configured to drawing the welding wire through the wire straightener 5038 from the 5272 welding wire spool and pushing the welding wire through the 5040 welding wire Bowden tube (guide) to the 5502 welding torch. comprise a rotation angle sensor configured to measure the number of engine revolutions. In one embodiment, the wire feed system motor(s) 5004 is operatively coupled to one or more processors 5140. This information is used by one or more processors 5140 to determine the amount of wire fed to the welding gun 5502 and to adjust the amount of welding wire sold to the welding torch 5502. In one embodiment, as the rotary hub 5078 rotates, the welding wire/electrode is fed to the torch 5502 by the wire feed assembly 5020.

[00414] In one embodiment, the shield gas control valve 5042 is configured to control the flow rate of the shield gas supply to the welding torch through the shield gas supply line. In one embodiment of the invention, each welding torch 5502 has a corresponding shielding gas valve 5042 connected to it.

[00415] In one embodiment, the shielding gas is stored in the drive section 5010 and is supplied to the wire feed assembly 5020 by a shielding gas hose/line for distribution to one or more welding torches 5502. In one embodiment, the shielding gas control valve 5042 configured to receive shielding gas from the rear swivel sleeve 5072 (for example, through the rear slip ring 5080 and swivel hub 5078).

[00416] In one embodiment, the shield gas valve 5042 is operatively coupled to receive control signals from the electronic wire feed module 5046. In one embodiment, the shield gas control valve 5042 is configured to supply shield gas to an associated welding torch when it receives signals from the 5046 electronic wire feed module.

[00417] In one embodiment, the wire feed electronics module 5046 is configured to send and receive electrical power and transmit communication signals through the forward slip ring 5016 to the forwardmost electronics module 5014. In one embodiment, the wire feed electronics module The 5046 is configured to send and receive electrical power and transmit communication signals through the rearward slip ring 5080 to the forwardmost electronics module 5064.

[00418] In one embodiment of the invention, the electronic wire feed module 5046 is configured to control all motors and valves mounted on the pivot hub 5078 of the center section 5008. For example, the electronic wire feed module 5046 is configured to control the wire feed system, the axial movement of the welding torch 5502, radial movement of the welding torch 5502, side tilt movement of the welding torch 5502 and/or shielding gas. In other words, the electronic wire feed module 5046 is operatively coupled to the shield gas control valve(s) 5042 to control the flow and supply of shield gas to the welding torch(s) 5502.

[00419] In one embodiment, the electronic wire feed module 5046 is operatively coupled to the welding torch thrust motor 5550 to control the axial movement of the welding torch 5502. In one embodiment, the electronic wire feed module 5046 is operatively coupled to the welding gun radial motor 5512 to control the radial movement of the welding torch 5502. In one embodiment, the electronic wire feed module 5046 is operatively coupled to the side tilt motor of the welding torch 5588 to control the side tilt movement of the welding torch 5502. In one embodiment, the axial movement of the welding torch 5550 , the welding torch radial motor and the 5588 side tilt motor, either individually or collectively referred to as "welding torch motor(s").

[00420] In one embodiment of the invention, the electronic wire feed module 5046 is configured to communicate with and control the measurement sensor 5056, as well as the inspection camera 5112, mounted on the rotary hub 5078. In one embodiment of the invention, the measurement sensor 5056 is carried by the node frame of the internal welding system 5004. In one embodiment of the invention, the control chamber 5112 is carried by the frame assembly of the internal welding system 5004.

[00421] In one embodiment, the measurement sensor 5056 may include a measurement laser, a 3D inspection camera, an ultrasonic sensor inspection system, an electrical capacitance measurement probe, and any other measurement sensors as will be understood by those skilled in the art.

[00422] FIG. 23 and 24 illustrate a front view and a cross section of the center section 5008 of the internal welding system 5004. In one embodiment of the invention, as mentioned above, the frontmost part of the frame 5026 of the frontmost section 5006 is connected to the front clamp 5142 of the center section 5008, and the wire feed assembly 5020 rotatably connected to the 5078 pivot hub.

[00423] In one embodiment, the center section 5008 of the internal welding system 5004 includes a front clamp 5142 (or a first pipe engagement device 5052), a probe 5056, a welding head assembly or torch module 5500, a rear clamp 5144 (and a second pipe engagement device 5054), 5062 rear clamp control valve, 5064 center section electronics, 5066 sole rollers, 5068 center section frame, 5070 adjustable rails, 5074 rear rotation motor, 5076 rear position sensor, 5078 pivot hub, and 5080 rear slip ring.

[00424] In one embodiment, front clamp 5142 (or first pipe engagement device 5052), sensor 5056, welding head assembly or torch assembly 5500, rear clamp 5144 (and second pipe engagement device 5054), rear clamp control valve 5062 , rear rotation motor 5074, rear position sensor 5076 is operatively coupled to one or more processors 5140. In one embodiment, camera 5112 is operatively coupled to one or more processors 5140. one or more 5140 processors. The term "pipe engagement device" as used herein means a clamp that is rigidly fixed to the surface of the pipe, or an internal seal configured to form a gas seal against the inner surface of the pipe, or a combination of the aforementioned clamp and seal . For example, in one embodiment, the first pipe engagement device 5052 may be a first clamp 5142, a first seal 5146, or a combination thereof. In one embodiment, the second pipe engagement device 5054 may be a second clamp 5144, a second seal 5148, or a combination thereof. In one embodiment of the invention, the first and second pipe engagement devices 5052 and 5054 are carried by the frame assembly of the internal welding system 5004.

[00425] FIG. 25-31 illustrate a view of the various components of the central section 5008 of the internal welding system 5004. For example, FIG. 25 illustrates a rear rotating clutch 5072, FIG. 26 illustrates the rear slip ring 5080, FIG. 27 illustrates the frame of the center section 5068 and adjustable rails 5070, FIG. 28 illustrates shoe rollers 5066, FIG. 29 illustrates the 5062 rear clamp control valve, FIG. 30 illustrates the front clip 5142, and FIG. 31 illustrates the rotary module 5078, respectively.

[00426] The rear rotating sleeve 5072 in the center section 5008 is illustrated in FIG. 23, 24, and 25. In one embodiment, the structure and operation of the rear rotary coupling 5072 is similar to the front rotary coupling 5032, and therefore the structure and operation of the rear rotary coupling 5072 is not described in detail herein except for the differences noted above.

[00427] In one embodiment of the invention, the rear rotating sleeve 5072 is configured to pass through it a stream of compressed air and a stream of shielding gas (or purge gas). In one embodiment of the invention, the rear rotary coupling 5072 in the center section 5008 is configured to connect the compressed air flow from the compressed air cylinder 5128 (as illustrated in Fig. 32A and B) of the drive section 5010 through the rotary hub 5078 of the center section 5008 to the front rotating sleeve 5032. In one embodiment, the rear rotating sleeve 5072 in the center section 5008 is also configured to connect the shield gas cylinder 5114 (as illustrated in FIGS. 32A and 32B) in the drive section 5010 to the shield gas control valve 5042 in the supply assembly. wire 5020 of the frontmost section 5006.

[00428] In one embodiment, a rear rotary coupling 5072 is constructed and assembled to transfer the received portion of compressed air to the rear clamp control valve 5062 (to operate the rear clamp 5144). In one embodiment of the invention, the rear rotary sleeve 5072 is built and mounted to transfer the remainder of the received compressed air to the front rotary sleeve 5032 (for example, through the rear slip ring 5080, the rotary hub 5078 and the front slip ring 5016). In one embodiment of the invention, the remainder of the resulting compressed air is fed into the front rotary sleeve 5032 and passes through the rear rotary sleeve 5072.

[00429] In one embodiment, the front and rear rotating sleeves 5032 and 5072 of this patent application may be one of the commercially available types of sleeves called "Series 012 2 Pass Threaded Shaft Unions" manufactured by "Rotary Systems, Inc." In another embodiment, implementation of the invention, the front and rear rotary couplings of the present patent application may be any rotary couplings, as will be understood by experts in this field of technology.

[00430] In one embodiment, the structure and operation of the rear slip ring 5080 is similar to the front slip ring 5016, and therefore the structure and operation of the rear slip ring 5080 is not described in detail herein, except for the differences noted above.

[00431] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 26, the rear slip ring 5080 in the center section 5008 is configured to transmit communication signals between the wire feed electronics module 5046 and the center section electronics module 5064.

[00432] In one embodiment, the back and front slip ring 5016 and 5080 of this patent application may be one of the commercially available rings called AC6275 manufactured by Moog, Inc. In one embodiment, the front and back slip ring 5016 and 5080 of this patent application may have a current rating of 50 amps. In another embodiment of the invention, the front and rear slip ring of the present patent application may be any rotating sleeves, as will be understood by experts in the art.

[00433] In one embodiment of the invention, as illustrated in FIG. 23 and 24, the center section electronics module 5064 in the center section 5008 contains communication cables leading to the wire feed assembly 5020 through the rear slip ring 5080 and communication cables leading to the drive section 5010. In one embodiment, the center section electronics module 5064 in The center section 5008 is configured to control the rear rotation motor 5074 and receive signals from the rear position sensor 5076. In one embodiment, the center section electronics module 5064 in the center section 5008 is also configured to control the rear clamp valve 5062.

[00434] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 27, center section frame 5068 is built and assembled to house/support all components of center section 5008 of internal welding system 5004. In one embodiment, center section frame 5068 is built and assembled to provide mounting points for all components, located in the central section 5008 and to protect these components from damage. In one embodiment of the invention, the frame of the center section 5068 is also built and mounted to connect the drive section 5010 through a universal joint, allowing the internal welding system 5004 to rotate in curved pipes. In one embodiment of the invention, the frame of the center section 5068 may be made of steel or other materials, as will be appreciated by those skilled in the art.

[00435] In one embodiment, the frame end 5214 of the center section 5068 is configured to connect to the flange portion 5216 of the rear clamp 5144. In one embodiment, the frame end 5214 of the center section 5068 is configured to couple to the flange portion 5216 of the rear clamp 5144 using fasteners such as bolts 5218.

[00436] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 27, the 5070 Adjustable Guides are built and mounted to help center the 5004 Internal Weld System when installing the 5004 Internal Weld System in a pipe. In one embodiment of the invention, adjustable rails 5070 are also built and mounted to protect the center section 5008 from being hit by the end of a pipe segment. In one embodiment of the invention, adjustable guides 5070 are built and mounted to accommodate different pipe sizes.

[00437] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 28, sole rollers 5066 are constructed and mounted to hold the mass of center section 5008. seam. In one embodiment of the invention, the sole rollers 5066 are constructed and mounted to adjust the angle of the shoe to facilitate the movement of the inner welding system 5004 in a straight line in the pipe. In one embodiment of the invention, shoe rollers 5066 are built and mounted to adjust in height to suit different pipe sizes. In one embodiment of the invention, the shoe rollers 5066 are passive elements.

[00438] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 29, the 5062 Rear Clamp Control Valve is built and mounted to receive compressed air from the stationary part of the 5072 Rear Rotary Sleeve.

[00439] In one embodiment, the back clamp control valve 5062 is operatively coupled to receive control signals from the center section electronics module 5064. In one embodiment, the back clamp control valve 5062 is configured to supply compressed air for actuation and operation. rear clamp 5144 when it receives signals from the center section electronics module 5064.

[00440] In one embodiment of the invention, as illustrated in FIG. 24, the rear position sensor 5076 may be a proximity sensor and a wheel angle sensor with a special profile. In one embodiment of the invention, the wheel angle sensor is built and mounted to rotatably mount on the 5078 steering hub.

[00441] In one embodiment, the rear position sensor 5076 is operatively coupled to provide control signals to the center section electronics module 5064. For example, in one embodiment, the rear position sensor proximity sensor 5076 may be configured to send control signals to the center section electronics. center section module 5064 when the sensor is at the highest point on the wheel angle sensor. In one embodiment, the center section electronics module 5064 is configured to use signals received from the forward position sensor 5076 to detect the orientation of the center section 5008 relative to the remainder of the internal welding system 5004 (eg, pivot hub 5078).

[00442] The rear rotation motor 5074 in the center section 5008 is illustrated in FIG. 24. In one embodiment of the invention, the rear rotation motor 5074 is electrically synchronized with the front rotation motor 5030 such that the rotation motors 5030 and 5074 together are configured to rotate the pivot hub 5078 of the center section 5008 while holding the front and rear clamps 5142 , 5144 stationary. In one embodiment of the invention, rotation motors 5030 and 5074 are configured to rotate the welding torch 5502 in a circle (360° rotation) along the contact surface 5136. In one embodiment of the invention, rotation motors 5030 and 5074 are configured to direct the research beam of radiation , are also configured to drive the welding torch 5502 through at least 360° about the axis of the pipe AA, so as to perform a continuous rotary pass when welding the root of the weld.

[00443] In one embodiment, the front rotation motor 5030 and the rear rotation 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 coupled to one or more processors 5140.

[00444] In one embodiment, the front rotation motor 5074 has an electric motor comprising a rotor, a rotating shaft rotated by the rotor, and a drive gear supported by and containing teeth on the rotating shaft. The teeth on the drive gear are constructed and mounted to mesh with the teeth formed on the driven gear member 5079 of the pivot hub 5078 to transmit torque from the rear rotation motor 5074 to the pivot hub 5078.

[00445] In one embodiment, the rotary hub 5078 is built and mounted to rotate during welding, during pre-weld and post-weld scanning procedures. In one embodiment of the invention, the rotary hub 5078 is located between the first and second clamps 5142 and 5144. Since the first and second clamps 5142 and 5144 are not physically connected to each other, the front rotation motor 5030 and the rear rotation motor 5074 at each end of the rotary hub 5078 synchronized to keep the two pipes 1022a, 1022b from moving relative to each other. In one embodiment, the two pipe engagement devices 5142, 5144 can rotate relative to each other by rotating the front rotation motor 5030 and the rear rotation motor 5074, for example, at different speeds and/or in different directions. In one embodiment of the invention, only when the front rotation motor 5030 and the rear rotation motor 5074 rotate at the same speed in the same direction, the welding torch 5502 and the measurement sensor 5056 rotate along the contact surface 5136 between the pipes 1022a, 1022b (for example , without moving the pipe hooks 5142, 5144).

[00446] In one embodiment, the center portion 5077 of the pivot hub 5078 includes slots/holes through which shielding gas hoses, bowden tubes (guides), welding power cables, motor cables, measurement sensor cables, and camera cables are designed to pass. .

[00447] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 30, the 5142 front clamp has a hollow configuration. In one embodiment, the opening 5082 through the center of the front clamp 5142 is built and mounted large enough to allow all necessary cables and hoses to pass through. In one embodiment of the invention, the opening 5082 of the front clamp 5142 is also built and mounted to allow for the use of structural elements necessary to hold the mass of the front half of the internal welding system 5004, as well as to maintain the alignment of the two halves/segments of the pipe 1022a, 1022b of the weld. In one embodiment, the front and rear clamps 5142, 5144 are built and mounted to mount on the pivot hub 5078, such as with preloaded angular contact bearings 5108, 5098 for rigidity.

[00448] In one embodiment, the inner surface 5130, 5132 of the first pipe 1022a and/or the second pipe 1022b engages and is controlled by the first clamp 5142 and the second clamp 5144, respectively, to adjust the relative positioning of the pipes based on instructions from one or more processors 5140. In one embodiment of the invention, adjustment of the relative positioning of pipes 1022a, 1022b is achieved without disengaging the first pipe engaging device 5144 from the inner surface 5132 of the first pipe 1022b and without disengaging the second pipe engaging device 5142 from the inner surface 5130 of the second pipe 1022a. This can be done because the rotation motors 5030 and 5074 are configured to rotate the tubes 1022a, 1022b without disengaging the tube engagement devices 5144, 5142 as described in this patent application.

[00449] In one embodiment of the invention, as illustrated in FIG. 23, 24, and 30, 5142 front clamp typically contains 5084 piston, 5086 cylinder, 5088 bushing, 5090 clamp shoe pins, 5092 levers, 5094 shaft, 5096 hub, 5098 front bearing, 5100 spider, 5102 housing, front disc 5104, rear disc 5106, rear bearing 5108, and bushing 5110. In one embodiment, the rear bearing 5108 and front bearing 5098 are configured to hold the pivot hub 5078. In one embodiment, the rear clamp 5144 has the same structure, configuration, and the principle of operation as described above in relation to the front clamp 5142 and thus the structure, configuration and operation of the rear clamp 5144 is not described in detail in this document.

[00450] In one embodiment, the front clip 5142 is configured to lock one of the tubes 1022a, 1022b, and the second clip 5144 is configured to lock the second of the tubes 1022a, 1022b. In one embodiment of the invention, one of the clamps 5142, 5144 may be referred to as the "first clamp" and the other of the clamps 5142, 5144 may be referred to as the "second clamp". In one embodiment of the invention, the clamps 5142, 5144 of the internal welding system 5004 may either individually or collectively be referred to as the "brake system" of the internal welding system 5004, which holds the frame of the internal welding system 5004 in position within the pipe 1022a, 1022b. In one embodiment, the front and back clamps 5142, 5144 are radial clamps that engage the inner surface 5130, 5132 of the pipes 1022a, 1022b, respectively, to hold the inner welding system 5004 from moving. The operation of the front and rear clamps 5142 and 5144 will be described in more detail below.

[00451] In one embodiment, the internal welding system 5004 includes a first pipe engagement device 5052, a second pipe engagement device 5054, a measurement sensor 5056, one or more processors 5140; and a welding torch 5502. In one embodiment of the invention, the measurement probe 5056, the control chamber 5112, the welding torch 5502, and the welding head assembly 5500 are rotatably mounted on the rotary hub 5078. The structure, configuration, and principle of operation of each of the listed elements - the first engagement device pipe 5052, second pipe engagement device 5054, measurement sensor 5056, inspection chamber 5112, welding torch 5502, and welding head assembly 5500 are described in more detail with respect to FIG. 30 and 33-59 and their respective descriptions.

[00452] FIG. 32A and 32B illustrate an enlarged and plan view of the drive section 5010 of the internal welding system 5004. In one embodiment, the drive section 5010 of the internal welding system 5004 includes shielding gas cylinders 5114, batteries 5116, drive section electronics module 5118, pneumatic valves 5120 , drive wheels or rollers 5122, drive motors 5124, brakes 5126, and compressed air bottle 5128. In one embodiment, pneumatic valves 5120 comprise a brake valve 5190 and a drive wheel valve 5192 (both illustrated in FIG. 70). In one embodiment, the drive section 5010 of the internal welding system 5004 includes a drive section frame 5278. In one embodiment, the drive section frame 5278 may be made of steel or other materials, as will be appreciated by those skilled in the art.

[00453] In one embodiment, drive section electronics module 5118 may comprise one or more processors 5140. In one embodiment, pneumatic valves 5120 (brake valve 5190 and drive wheel valve 5192) and drive motors 5124 may be operatively linked to one or more 5140 processors.

[00454] In one embodiment of the invention, the drive section 5010 may be connected to the center section 5008 through a universal connection 5123 and elastic elements 5125.

[00455] In one embodiment, the compressed gas cylinders 5114 are built and installed to contain the shielding gas required by the welding torches 5502. coupling 5072 in the center section 5008.

[00456] In one embodiment, the batteries 5116 are lithium ion batteries. In one embodiment, the batteries 5116 are configured to power all electronic components as well as the electric drive motors 5124 of the internal welding system 5004. For example, in one embodiment, the batteries 5116 are configured to power the electronic module of the center section 5064 , the frontmost section electronics module 5014, the drive section electronics module 5118, and the wire feed electronics module 5046. In one embodiment, the batteries 5116 may be operatively coupled to one or more processors 5114.

[00457] In one embodiment, the batteries 5116 are also configured to power the 5512 radial welding torch motor, 5588 tilt welding torch motor, 5550 axial welding torch motor, 5044 wire feed system motors, 5030 and 5074 front and rear rotary motors. , and drive motors 5124. In one embodiment, the batteries 5116 are configured without the ability to power the welding system with electrical energy. In one embodiment, the batteries 5116 are configured to supply electrical power only to the drive section electronics module 5118 and to the drive motors 5124, while electrical power to the remaining motors and electronic modules of the internal welding system 5004, including the radial welding torch motor 5512, the motor 5518 Tilt Welding Torch Motor, 5550 Axial Torch Motor, 5044 Wire Feed Motors, 5030 and 5074 Front and Rear Rotary Motors, 5064 Center Section Electronic Module, 5014 Frontmost Section Electronic Module, and 5046 Wire Feed Electronic Module, derive electrical power from external power supplies via drive rod/halyard 5034.

[00458] In one embodiment, drive motors 5124 are configured to drive rollers or wheels 5122 to move the frame assembly (including first pipe engagement device 5052, second pipe engagement device 5054, welding torch 5502, measurement sensor 5056) of the internal welding system 5004 , from one end of the pipe 1022a, 1022b to the second end of the pipe 1022a, 1022b along the inner surface 5130, 5132 of the pipe 1022a, 1022b. In one embodiment, the drive motors 5124 of the drive section 5010 are configured to move the body of the internal welding system 5004 through the conduit 1004 after each weld is completed. In one embodiment, the drive motors 5124 of the drive section 5010 are configured to accelerate and decelerate the internal welding system 5004 in conduit 1004.

[00459] In one embodiment of the invention, the power supply is attached to the frame assembly of the internal welding system 5004 and is configured to power the drive motors 5124. In one embodiment, the drive motors 5124 of the drive section 5010 are powered by electricity. In one embodiment, the drive motors 5124 of the drive section 5010 are powered by batteries 5116.

[00460] In one embodiment, the drive rollers 5122 are configured to engage with the inner surface 5130, 5132 of one or more tubes 1022a, 1022b. In one embodiment, the drive rollers 5122 are operatively coupled to the drive motors 5124 of the drive section 5010. air from a compressed air bottle 5128. In one embodiment of the invention, the drive rollers 5122 are made of elastomeric materials or rubber.

[00461] In one embodiment, the drive rollers 5122 are configured to move the internal welding system 5004 through the conduit 1004 after each weld is made. In one embodiment of the invention, the internal welding system 5004 may include drive rollers 5122 configured to support the frame or frame assembly of the internal welding system 5004 during rotation. For example, in one embodiment of the invention, the internal welding system 5004 includes four active drive wheels. In other words, two drive wheels on each side rotated 180°. In one embodiment of the invention, the number of drive wheels may vary. In one embodiment, the drive rolls 5122 may have treads on them to increase traction as the internal welding system 5004 moves through the pipeline.

[00462] In one embodiment of the invention, two of the four drive rollers 5122 can be directly connected to and controlled by respective drive motors 5124. In one embodiment, the other two drive rollers 5122 may be connected to the engine driven drive wheels via a chain drive 5111 and driven by the engine driven drive wheels.

[00463] In one embodiment, drive rollers 5122 are built and mounted to drive the welding system 5004 within the pipes 1022a, 1022b until the welding system 5004 reaches a predetermined position. In one embodiment of the invention, drive rollers 5122 are built and mounted to be pressed against the inner surface of the pipe by a pneumatic cylinder.

[00464] In one embodiment, the brakes 5126 are configured to be actuated by a pneumatic cylinder 5133 that is operatively connected to the pneumatic valves 5120 to obtain compressed air from the compressed air cylinder 5128. In one embodiment, the brakes 5126 are internally 5004 welding systems are designed for emergency use. For example, brakes 5126 may be used when the drive motor 5124 of the drive section 5010 cannot decrease the speed of the internal welding system 5004 for some reason. For example, brakes 5126 may be used on slopes to keep the internal welding system 5004 from rolling into or out of the conduit 1004, depending on the direction of the slope. In one embodiment of the invention, the brakes 5126 are configured to be controlled in both automatic and manual modes.

[00465] In one embodiment, the brakes 5126 may also be used to hold the frame of the internal welding system 5004 in place within the pipes during welding procedures, a pre-weld scan procedure, and/or a post-weld scan procedure. For example, the brakes 5126 may be configured to lock the body of the internal welding system 5004 into position within the pipes from movement during welding procedures, a pre-weld scan procedure, and/or a post-weld scan procedure.

[00466] In one embodiment, an air tank 5128 is built and installed to store the air needed to operate the brakes 5126, drive rollers 5122, and front and rear clamps 5142, 5144. In one embodiment, the air tank The 5128 is built and mounted to be connected to the 5030 lanyard by a front and rear rotating coupling 5032, 5072 so that the compressed air bottle 5128 can be refilled when needed.

[00467] In one embodiment, pneumatic valves 5120 are constructed and mounted to control air to two pneumatic cylinders configured to actuate and actuate brakes 5126 and drive rollers 5122, respectively.

[00468] In one embodiment, the drive section electronics module 5118 is configured to forward communication signals to the center section electronics module 5064. In one embodiment, the center section electronics module 5118 is also configured to control the drive motors 5124 and two pneumatic valves 5120.

[00469] In one embodiment of the invention, one or more processors 5140 are configured to control drive motors 5124 to move the frame of the internal welding system 5004 through at least one of the pipes 1022a, 1022b until the sensor 5352 detects the area of the contact surface 5136 between pipes 1022a, 1022b. In one embodiment of the invention, one or more processors 5140 are configured to control the brake system of the internal welding system 5004 to fix the frame of the internal welding system 5004 in a certain position within the pipes 1022a, 1022b from moving, which determines the position of the measuring sensor 5056 in relation to the contact area. surface 5136 to allow the measurement sensor 5056 to detect the profile of the area of the contact surface 5136 between the pipes 1022a, 1022b.

[00470] FIG. 33 illustrates a view of the center section 5008 of the internal welding system 5004 located inside the pipe segments 1022a, 1022b, where some components of the center section 5008 are not illustrated for clarity. For example, illustrated are front and rear clamps 5142, 5144, pivot hub 5078, weld head assembly 5500, measurement probe 5056, and inspection chamber 5112 in FIG. 33.

[00471] In one embodiment, the two pipe welding field system 5000 includes a computer system 5138 to facilitate the welding. In one embodiment, computer system 5138 includes one or more processors 5140 communicatively coupled to welding system 5004. In one embodiment, computer system 5138 and its one or more processors 5140 can be communicatively coupled to welding system 5004 (and one or more of its components) through one or more wired or wireless communication channels. By way of example, the wired links may comprise one or more Ethernet links, a coaxial link, an optical fiber link, or other wired links. As another example, the wireless links may comprise one or more Wi-Fi links, a Bluetooth link, short range communication (NFC) links, cellular links, or other wireless links. In one embodiment of the invention, one or more components of the welding system 5004 may be connected to communicate with each other via one or more of the aforementioned wired or wireless communication channels. In one embodiment, it may be useful to use one or more wireless communication channels to allow one or more processors 5140 or one or more components of the 5004 welding system to communicate with each other to reduce the number of communication cables in the 5004 welding system to reduce risk potential cable entanglement resulting in delays or damage to other components of the 5004 welding system. laser, inspection camera or other measurement devices), welding torch, or other components of the 5004 welding system.

[00472] 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 may include a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronic processing of information.

[00473] As used herein, the term "one or more processors" should be understood to mean a single embedded processor, local to a particular system or component described herein, external and local to a particular system or component described herein. in this document, or located remotely from a particular system or component described in this document. In addition, the connection between one or more processors may be wired or wireless. Additionally, the term "one or more processors" can also mean a plurality of embedded and local processors, a plurality of individual and local processors, a plurality of remotely located processors, or any combination of embedded (and local), individual (and local), and remote processors. With respect to embedded processors, embedded processors refer to processors that physically move (i.e., are physically connected and move) with a particular system or component. With respect to individual processors, this means processors that are local to the manufacturing site and communicate wirelessly with embedded electronic components. Individual processors are also referred to as electronic components that are associated with an embedded system (eg, via a drive link) and are local to the manufacturing site. Viewed in a different light, if the processor moves with the drive link, it should also be considered an "embedded" processor.

[00474] In one embodiment, the first pipe engagement device 5002 is configured to engage with the first pipe inner surface 5130, allowing the first pipe engagement device 5052 to be fixed relative to the first pipe 1022a. In one embodiment, the second pipe engaging device 5054 is configured to engage with the inner surface 5132 of the second pipe 1022b, allowing the second pipe engaging device 5054 to be fixed to the second pipe 1022b.

[00475] In one embodiment of the invention, the measurement sensor 5056 is located between the first pipe engagement device 5052 and the second pipe engagement device 5054, and is configured to emit a research beam of radiation. In one embodiment of the invention, one or more sensor motors are operatively coupled to the sensor 5056 to guide the research radiation beam along the contact surface 5136 between the tubes 1022a, 1022b. In one embodiment, the front and rear rotation motors 5030 and 5074 may be referred to individually or collectively as a "sensor motor". In one embodiment, the front and rear rotation motors 5030 and 5074 are configured to rotate the measurement sensor 5056 along the contact surface 5136. In one embodiment, the measurement sensor 5056 is configured to generate signals based on the profile of the contact surface 5136 between the pipes 1022a , 1022b. In one embodiment of the invention, the contact surface 5136 is an annular contact surface. In one embodiment of the invention, the area of the contact surface 5136 is the inner surface of the tubes 1022a, 1022b in the area of the tubes 1022a, 1022b located near where the weld will be performed.

[00476] In this document, the term "contact surface area" means the internal surfaces of the pipes to be welded in the area and, additionally, in the immediate vicinity, where the weld metal is located. The area of the contact surface contains at least part or, additionally, the entire internal groove of the seam of both pipes to be welded, if such a groove of the seam is provided. In one embodiment of the invention, the area of the contact surface contains all beveled edges, and also extends beyond the beveled edges, if such beveled edges are provided.

[00477] In one embodiment of the invention, the wheels 5028 on the frontmost section 5006 of the internal welding system are built and mounted to keep the clamps from seizing on the inner surfaces of the pipe. The less the 5028 wheel extends, the easier it is for the internal welding system to adjust to pipe bends. In one embodiment of the invention, the wheels 5028 can be adjusted. In one embodiment, the wheels 5028 may not be adjustable. In one embodiment of the invention, spring-loaded wheels or sole rollers 5066 (as illustrated in Fig. 23) on the rear clamp 5144 and adjustable wheels 5276 (as illustrated in Fig. 32A) on the rear of the drive section 5008 are built and mounted so that the axle The symmetry of the clamp was about 0.25 inches below the axis of symmetry of the pipe. With this configuration, when the clamps expand against the inner surface of the pipe, the expander holds the clamp over the wheels instead of forcing the wheels against the inner walls of the pipe.

[00478] Embodiments of the invention, the "pipe engagement device" includes a clamp that securely engages the surface of the pipe. The clamp, for example, may include one or more shoes or other support elements configured to securely engage the surface of the pipe to prevent movement of said pipe. In another embodiment of the invention, the "pipe engagement device" comprises a seal that seals the engagement with the inner surface of the pipe in such a way as to prevent gas from passing through it. Such a seal may include, for example, an inflatable bladder, an elastic element, or other engineering structures that engage with the inner surface of the pipe to prevent gas from passing through it. Such a seal can be used to remove oxygen from the area of the pipe to be welded in order to prevent or reduce oxidation resulting from the welding process. In yet another embodiment of the invention, the pipe engaging device comprises a combination of a clamp and a seal, or one or more clamps and/or one or more seals.

[00479] In one embodiment, the first pipe engagement device 5052 includes a first clip 5142 and the second pipe engagement device 5054 includes a second clip 5144.

[00480] In one embodiment, the first pipe engagement device 5052 includes a first seal 5146 and the second pipe engagement device 5054 includes a second seal 5148.

[00481] In one embodiment, the second seal 5148 and the second clip 5144 may be referred to as the rear seal 5148 and the rear clamp 5144, respectively. In one embodiment, the first seal 5146 and the first clamp 5142 may be referred to as the front seal 5146, respectively. and front clamp 5142.

[00482] In one embodiment, the first pipe engagement device 5052 includes a clamp 5142 and the second pipe engagement device 5054 includes a clamp 5148. In one embodiment, the first pipe engagement device 5052 includes a seal 5146 and the second pipe engagement device 5054 includes clamp 5144.

[00483] In one embodiment, the first pipe engagement device 5052 includes a clamp 5142 and a seal 5146, and the second pipe engagement device 5054 includes a clamp 5144 and a seal 5148. In one embodiment, the first pipe engagement device 5052 includes a clamp 5142 and a seal 5146, and the second pipe engagement device 5054 includes a clamp 5144. In one embodiment, the first pipe engagement device 5052 includes a clamp 5142 and a seal 5146, and the second pipe engagement device 5054 comprises a seal 5148. In one embodiment, the first pipe engagement device 5052 includes a clamp 5142, and a second pipe engagement device 5054 includes a clamp 5144 and a seal 5148. In one embodiment, the first pipe engagement device 5052 includes a seal 5146 and the second pipe engagement device 5054 includes a clamp 5144 and a seal 5148.

[00484] In a configuration where there is a seal on one side of the 5056 gauge and 5112 test chamber and a clamp on the other (opposite) side of the 5056 gauge and 5112 test chamber, a high pressure purge gas is directed into the area between the clamp and the seal. Purge gas from the area between the clamp and the seal can leak through the small gap between the pipes being welded, and can also exit the pipes at the side of the 5056 gauge and 5112 test chamber where there is no seal and just a clamp. This additional configuration prevents overpressure in the area between the clamp and the seal (for example, compared to a design having two seals, one each on the side of the 5056 transmitter and the 5112 chamber), without a purge gas pressure regulator, and/ or a separate overpressure relief valve in the area between clamp and seal. Continuous supply of high pressure purge gas to the area between the clamp and the seal is designed to reduce the oxygen level in the area adjacent to the welding torch during the welding operation.

[00485] In another embodiment of the invention, for this reason, the first and second seals may additionally have openings to prevent overpressure in the purge gas chamber formed between the first and second seals. In another embodiment of the invention, one or both of the seals, when an inflatable chamber is used for sealing, can be partially filled with air to provide a predetermined or calculated gap around them, allowing the purge region to exit at the required speed.

[00486] If two purge seals 5146, 5148 are used, inert gas is introduced into the purge chamber between them. However, it should be understood that purge seals 5146, 5148 do not necessarily (and generally do not) create a perfect seal. The inert gas exits, for example, through the gap between the two pipes 1022a, 1022b to be welded. Inert gas can also escape around seals 5146, 5148, which are not necessarily ideal. Of course, during welding operations, the gap between the pipes 1022a, 1022b is slightly closed and sealed. As a result, the pressure in the purge chamber between the pipes 1022a, 1022b may increase when creating a weld between the pipes 1022a, 1022b. For this reason, a pressure sensor inside the purge chamber is used to detect pressure inside the purge chamber and generate signals for one or more 5140 processors, which in turn are transmitted to one or more valves and / or one or more regulators, controlling or regulating, as well as Thus, the pressure of the purge gas inside the purge chamber to prevent overpressure. Excessive pressure inside the purge chamber will apply more than the specified outward gas pressure through the gap between the pipes being welded and can potentially change the result of the weld. In various embodiments of the invention, only individual seals 5146, 5148 are used to create a chamber that is sealed on one side only. However, this design provides for a suitable purge chamber, mostly devoid of oxygen, and also prevents the possible formation of overpressure. In such an embodiment, the inert purge gas will exit not only through the gap between the pipes, but also through the end of the pipe, which is not sealed, and, therefore, more gas can be consumed compared to the double seal implementation.

[00487] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first clamp 5142 and the second clamp 5148. In other words, both the first clamp 5142 and the second clamp 5148 are located on opposite sides with respect to the axis of symmetry of the measuring sensor 5056 and the control chamber 5112.

[00488] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first seal 5146 and the second clamp 5144. In other words, both the first seal 5146 and the second clamp 5144 are located on opposite sides with respect to the axis of symmetry of the measuring sensor 5056 and the control chamber 5112.

[00489] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first clamp 5142 and the second clamp 5144. In other words, both the first clamp 5142 and the second clamp 5144 are located on opposite sides with respect to the axis of symmetry of the measuring sensor 5056 and the control chamber 5112.

[00490] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first seal 5146 and the second seal 5148. In other words, both the first seal 5146 and the second seal 5148 are located on opposite sides with respect to the axis of symmetry of the measuring sensor 5056 and the control chamber 5112.

[00491] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first seal 5146, the first clamp 5142, the second clamp 5144 and the second seal 5148. In other words, the first seal 5146 and the second clamp 5142 are located on one side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112, and the second clamp 5144 and the second seal 5148 are located on the other side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112.

[00492] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first seal 5146, the first clamp 5142 and the second seal 5148. In other words, the first seal 5146 and the first clamp 5142 is located on one side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112, and the second seal 5148 is located on the other (opposite) side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112.

[00493] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first seal 5146, the second seal 5148 and the second clamp 5144. In other words, the second seal 5148 and the second clamp 5144 is located on one side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112, and the first seal 5146 is located on the other (opposite) side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112.

[00494] In one embodiment of the invention, the measurement sensor 5056 and the control chamber 5112 are configured to be located along the axis of symmetry (with respect to the axis of the pipe) between the first seal 5146, the first clamp 5142 and the second clamp 5144. In other words, the first seal 5146 and the first clamp 5142 is located on one side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112, and the second seal 5144 is located on the other (opposite) side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112.

[00495] In one embodiment of the invention, the measuring sensor 5056 and the control chamber 5112 are arranged along the axis of symmetry (with respect to the axis of the pipe) between the first clamp 5142, the second seal 5148 and the second clamp 5144. In other words, the second seal 5148 and the second clamp 5144 is located on one side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112, and the first clamp 5142 is located on the other (opposite) side of the axis of symmetry of the measurement sensor 5056 and the control chamber 5112.

[00496] In one or more embodiments of the invention, since the measurement sensor 5056 is located between the clamps 5142, 5144, it is possible to extract profile data between the clamps 5142, 5144 after the clamps 5142, 5144 are locked in place. For this reason, the measuring probe 5056 may continue to scan and detect the profile of the area of the contact surface 5136 during the welding operation. This may be advantageous in some applications because the area of contact surface 5136 may change slightly by welding the two pipes 1022a, 1022b, due to the fact that the weld itself may change the area of contact surface 5136 in other areas that have not yet been welded. In this regard, the measuring sensor 5056 allows to detect and determine any changes in one or more characteristics of the contact surface area 5136 on the fly or in real time in the areas of the contact surface area 5136 close to the areas to be welded. Additionally, since the measuring sensor 5056 is located between clips 5142, 5144, pre-weld profile data can be retrieved from the contact surface area 5136 after application of clamp force by clamps 5142, 5144. The clamp force of clamps 5142, 5144 itself can change the contact surface area 5136. between the ends of the pipe and/or relative height offset between the ends of the pipe in certain (or all) areas of the area of the contact surface 5136. change correct cr the angled shape of the first tube to be welded and/or the second clamp may change the correct round shape of the second tube to be welded). In one embodiment of the invention, for example, the clamp shoes for any of the clamps 5142, 5144 are arranged symmetrically and evenly spaced circumferentially around the inner surface of the pipe to be engaged. Additionally, the outermost surface of each clamp shoe may be equidistant from the central axis of the clamp. The distance between each clamp shoe can be set to be slightly larger than the inside diameter of the pipe. In such a case, if each clamp shoe extends to its maximum position, clamp clamping force 5142, 5144 is used to slightly change the deviation from the roundness of the pipe, compared to a more rounded pipe. Until full clamping force is applied by both clamps 5142, 5144, the profile of the area of the contact surface 5136 cannot yet be fully determined, since a change in shape is possible. The 5136 gauge described in this document can be used to determine the profile after using a pipe clamp.

[00497] In one or more embodiments of the invention, since the measurement sensor 5056 and/or the control chamber 5112 are located between two seals, the measurement sensor 5056 and/or the control chamber 5112 can extract profile data from the gap between the seals 5146, 5148 after how the seals 5146, 5148 will engage the inner surface 5130, 5132 of the pipes 1022a, 1022b to be welded. For this reason, the measuring sensor 5056 may continue to scan and detect the profile of the area of the contact surface 5136 before. during and/or after the welding operation, in which the areas between the seals 5146, 5148 are supplied with or filled with purge gas. This may be useful in some applications because the contact surface area 5136 can be inspected by the 5056 probe and/or the 5112 inspection camera before, during, and/or after the welding operation without destroying the seal 5146, 5148. For example, if the probe the 5056 sensor and/or the 5112 control chamber (in conjunction with one or more 5140 processors) will detect(s) that a minor weld change or additional welding operation is needed, such change or additional welding operation can be performed without the need to install a purge chamber in another (e.g., compared to a design where the probe and/or post-weld inspection chamber is located outside the purge chamber and the probe 5056 and/or inspection chamber 5112 is only inserted to check the area of the weld contact surface 5136 after the purge chamber is turned off). Thus, the measuring sensor 5056 can be used to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to detect the profile of the area of the contact surface 5136 between the pipes 1022a, 1022b after the welding operation is performed, and generate post-weld profile data based on the scan, and this data is about The post-weld profile can be obtained and further corrected or another additional weld made based on the post-weld profile data without releasing clips 5142, 5144 and/or seals 5146, 5148.

[00498] In one embodiment, the clamps 5142, 5144 are rotatable. In one embodiment, the clamps 5142, 5144 are rotatable in different directions relative to each other.

[00499] Additionally, as described herein, the present system allows the first clamp and the second clamp 5142, 5144 to rotate relative to each other after they are fixed, respectively, on the first and second inner surface of the pipe 5130, 5132. This may be performed with one or more orientation motors 5030, 5074 driving one or both clamps 5142, 5144 as described herein. Such relative rotation of tubes 1022a, 1022b may be in response to pre-weld profile data detecting that a better angular match between tube ends is available, and may be accomplished by rotation of relative rotation of one or both clamps 5142, 5144. Such relative rotation is performed without the need to detach the first and second clamps 5142, 5144, while the measuring probe 5056 remains along the axis of symmetry between the clamps 5142, 5144. After turning the first and/or second tube 1022a, 1022b, a new profile of the area of the contact surface 5136 is created, and the measuring probe 5056 can be used again to scan the area of the contact surface 5136 to obtain new profile data before welding. It should be understood that since none of the clamps 5142, 5144 need to be disconnected to obtain new profile data prior to welding, unnecessary downtime can be avoided. It should be understood that during the relative rotation of the tubes 1022a, 1022b, in one embodiment, the rollers 5332, the outer platform 5330 (6010A, 6010B) can be used (according to the instructions) one or more processors 5140) to work in combination with one or more clamps 5142, 5144 to perform this relative rotation.

[00500] In one embodiment of the invention, clamps 5142, 5144 and seals 5146, 5148 are located inside the pipes 1022a, 1022b to form an internal region/section having a seal. In one embodiment, clamps 5142, 5144 and seals 5146, 5148 are configured to seal opposite sides of the weld.

[00501] In one embodiment, clip 5142 and seal 5146 are activated together, and clip 5144 and seal 5148 are also activated together. In one embodiment of the invention, clamps 5142, 5144 and seals 5146, 5148 are controlled by the same valve.

[00502] In one embodiment, seals 5146, 5148 are activated with clip 5142. In one embodiment, seals 5146, 5148 are activated with clip 5144. In one embodiment, clip 5142 and seal 5146 are activated independently of each other. each other, and the clip 5144 and the seal 5148 are also activated independently of each other. In one embodiment of the invention, a separate seal control system may be configured to control the operation of both seals 5146, 5148, independently of (and separate from) the clamp control system configured to control the operation of both clamps 5142, 5144.

[00503] In one embodiment of the invention, the clip 5144 is located relative to the end of the pipe 1022b. In one embodiment, the clamp 5142 and seal 5146 are then activated together. In one embodiment, when conduit 1022a is positioned relative to conduit 1022b, clamp 5144 and seal 5148 are activated together.

[00504] In one embodiment, the clamps 5142, 5144 are movable between a fully retracted position (as illustrated in Fig. 35B) where the clamps 5142, 5144 are not in contact with the inner surface 5130, 5132 of the pipes 1022a, 1022b and the extended position. (as illustrated in Fig. 35A), where the clips 5142, 5144 are configured to apply clamping force to the inner surface 5130, 5132 of the pipes 1022a, 1022b. In one embodiment, clamps 5142, 5144 are constructed and mounted to engage (contact) pipes 1022a, 1022b and transmit forces that grip and shape pipes 1022a, 1022b.

[00505] In one embodiment, the structure, configuration, and operation of clamps 5142, 5144 are illustrated and explained with respect to FIG. 30 and 33-42. For example, Fig. 33 and 34 illustrate a perspective view and a cross-sectional view of the central section 5008 of the internal welding system 5004 placed inside the pipe segments 1022a, 1022b, while both clamps 5142, 5144 and seals 5146, 5148 engage with the inner surface 5130 and 5132 of the pipe segments. 1022a, 1022b, while some components of the center section 5008 are not illustrated for clarity; Fig. 35 illustrates a central section 5008 of an internal welding system 5004 placed within pipe segments 1022a, 1022b, with only clamps 5142, 5144 (without seals) engaging the inner surface 5130 and 5132 of pipe segments 1022a, 1022b, and , some components of the center section 5008 are not illustrated for clarity; Fig. 36 illustrates a perspective view of a clip shoe 5157 secured to a clip shoe pin 5090 located in the spider 5100; Fig. 37 illustrates a perspective view of the spider 5100; Fig. 38 illustrates a perspective view of the clip shoe pin 5090; and Fig. 39 and 40 illustrate a perspective view of the hub 5096 of clamps 5142 or 5140 with clamp shoe pins 5090 and levers 5092 attached thereto.

[00506] In one embodiment of the invention, as illustrated in FIG. 35C, the clips 5142, 5144 are illustrated in the retracted position to illustrate how the rails 5062, 5070 extend slightly higher. In FIG. 35C welding torches 5502 are illustrated in extended positions. Typically, welding torches 5502 can only be in the extended position after clamps 5142, 5144 are in the extended position.

[00507] In one embodiment of the invention, as illustrated in FIG. 36, the welding system 5004 may include a plurality of first clip shoes 5157 circumferentially evenly spaced independently on their respective spider 5100 and a plurality of second clip shoes 5157 circumferentially evenly spaced independently on their respective spider 5100.

[00508] In one embodiment of the invention, clamp shoes 5157 may have different heights for different pipe sizes and can be finely adjusted, for example, with shims or other adjustments. In one embodiment, the clamp shoes 5157 may be self-centering members. In one embodiment, the clamp shoes 5157 of the internal welding system 5004 are constructed and mounted to have a radial clearance of about 1 inch with the inner surface of the pipe.

[00509] In one embodiment, each clamp shoe 5157 includes pipe surface contacting elements (or surfaces) 5156. In one embodiment, pipe surface contacting elements 5156 are constructed and mounted to engage by friction with the inner 5130, 5132 pipes 1022a, 1022b on both sides of the area of the contact surface 5136, when the clamps 5152, 5154 are extended.

[00510] In one embodiment of the invention, as illustrated in FIG. 30 and 36-38, each clip shoe 5157 is built and mounted to connect to and place on a specific clip shoe pin 5090. In one embodiment, the clip shoe pin 5090 is built and mounted to extend through its corresponding opening 5158 in the spider 5100. spider 5100 in such a way as to allow movement (e.g., radial up and down movement) of the clip shoe pin 5090 in a corresponding hole 5158 in the spider 5100. In one embodiment, the spider 5100 can be any element that is built and mounted, to facilitate movement of the clip shoe fingers 5090 such that the clips 5142, 5144 exert a pressing force on the inner surface 5130, 5132 of the pipes 1022a, 1022b.

[00511] In one embodiment of the invention, as illustrated in FIG. 38, one end 5164 of the clip shoe finger 5090 is attached to the clip shoe 5157 and the other end 5166 of the clip shoe finger 5090 is attached to the lever 5092. lever 5092 into it. In one embodiment, the clip shoe finger end 5166 5090 also includes holes 5170 that are constructed and assembled to receive fasteners 5172 for connecting the lever 5092 to the clip shoe finger end 5166 5090.

[00512] In one embodiment of the invention, as illustrated in FIG. 37, the spider 5100 may include holes 5162 that are built and mounted to allow connection between the clip shoe pin 5090 and the arm 5092. In one embodiment, the holes 5162 of the spider 5100 are also built and mounted to allow the arm 5092 to move. when the clips 5142, 5144 move between the stowed and extended positions. In one embodiment of the invention, the spider 5100 is secured to a respective clip 5142 or 5144.

[00513] In one embodiment of the invention, the lever 5092 is an elongated element with holes made at its ends. In one embodiment, the ends of the arms typically have a rounded configuration to allow movement of the arm 5092 when the clips 5142, 5144 move between their collapsed and extended positions.

[00514] In one embodiment of the invention, as illustrated in FIG. 30, 39 and 40, one end of the lever 5092 is connected to the clip shoe pin 5090 and the other end of the lever 5092 is connected to the hub 5096. lever 5092.

[00515] In one embodiment, the hub 5096 may include cutouts 5174 (as illustrated in FIG. 40) that are constructed and mounted to allow connections between the arms 5092 and the hub 5096. In one embodiment, the cutouts 5174 of the hub 5096 also built and mounted to allow the arms 5092 to move in the cutouts 5174 when the clips are moved between their stowed and extended positions.

[00516] In one embodiment of the invention, as illustrated in FIG. 30, clamp 5152 or 5154 includes a cylinder 5086, a piston 5084, and a shaft 5094. In one embodiment, the piston 5084 is axially movable in the cylinder 5086 and the shaft 5094 supports the piston 5084. In one embodiment, the shaft 5094 moves with the 5084 piston.

[00517] In one embodiment, a hub 5096 is constructed and mounted to couple to a shaft 5094 that is longitudinally moved by an axially reciprocating piston 5084, such as driven by fluid pressure (hydraulic or pneumatic) within a cylinder 5086.

[00518] Clamps 5142, 5144 move from a collapsed position (as illustrated in Fig. 35B), where clamps 5142, 5144 are not in contact with the inner surface 5130, 5132 of pipes 1022a, 1022b, to an extended position (as illustrated in Fig. 35A), wherein clamps 5142, 5144 are configured to apply clamping force to inner surface 5130, 5132 of tubes 1022a, 1022b by activating cylinder 5086 such that piston 5084 moves axially in cylinder 5086. In one embodiment, compressed air from the front rotating sleeve 5032 through the front clamp control valve 5018 enters the channel 5031 (as illustrated in Fig. 30). Compressed air entering the channel 5031 presses the piston 5084 forward to move the clamps 5142, 5144 to their extended position.

[00519] In other words, axial movement of piston 5084 results in axial movement of shaft 5094 coupled to piston 5084. In one embodiment, axial movement of shaft 5094 in turn results in axial movement of hub 5096. In one embodiment, the axial movement of the hub 5096 is translated into a radial movement of the clamp shoe fingers 5090 by their arms 5092. Thus, the radial clamping force is generated by the compressed air fluid pressure driving the piston 5084 which actuates the arms 5092 converting the axial movement of the piston 5084 (by shaft 5094 and hub 5096) into the radial movement of the clamp shoes 5157.

[00520] In one embodiment, the size of the cylinder, the applied fluid pressure, and the dimensions of the various components of the clamps 5142 and 5144 can be varied to control the clamping force applied by the clamps to the inner surface 5130, 5132 of the tubes 1022a, 1022b.

[00521] In one embodiment, the seals 5146, 5148 are typically toroidal or annular in shape to allow the honor of the center section (eg, front clip 5142 or back clip 5144) to pass through. In one embodiment of the invention, the seals 5146, 5148 are built and mounted as radially retractable members. In one embodiment of the invention, seals 5146, 5148 are built and assembled to connect to an air or hydraulic line that transports fluid to seals 5146, 5148 for filling. As the seals 5146, 5148 fill, they are built and mounted to engage the inner surface 5130, 5132 of the pipes 1022a, 1022b, forming a chamber 5150 therebetween, respectively. In one embodiment, after filling, seal 5146 engages inner surface 5130 of pipe 1022a, and after filling, seal 5148 engages inner surface 5130 of pipe 1022b. In one embodiment, after seal 5146 has been filled, 5148 engages on the opposite side of contact surface area 5136. In one embodiment, chamber 5150 is a closed volume that may be referred to as a "purge gas chamber". In one embodiment of the invention, chamber 5150 is built and installed to receive purge gas.

[00522] In one embodiment, the internal welding system 5004 may include a purge gas reservoir configured to provide purge gas between the filled first seal 5146 and the filled second seal 5148 to reduce the oxygen content between the first and second filled seals 5146 and 5148 during welding operation time. In one embodiment, the purge gas may be located in the drive section 5010 of the internal welding system 5004. In one embodiment, the purge gas is configured to prevent oxidation during a welding procedure. In one embodiment of the invention, the purge gas is an inert gas. In one embodiment of the invention, the purge gas may contain argon, helium, nitrogen, or a combination thereof. In one embodiment of the invention, the purge gas contains a combination of argon and CO ₂ .

[00523] In one embodiment, the purge gas is pumped into an internal sealed region formed between the filled first and second seals 5146, 5148. By sealing the internal region against oxygen, oxidation resulting from exposure to very high temperatures during welding can be avoided. process.

[00524] In one embodiment, the internal welding system 5044 may include an oxygen sensor 5176 and a pressure sensor 5178. In one embodiment, the oxygen and pressure sensors 5176 and 5178 are operatively coupled to one or more processors 5140. In one embodiment, , oxygen and pressure sensors 5176 and 5178 are built and mounted to be placed in the pivot hub 5078. In another embodiment of the invention, oxygen and pressure sensors 5176 and 5178 are built and mounted to be placed on the spider 5100 (eg, between clamps).

[00525] In one embodiment, the oxygen sensor 5176 is configured to measure the oxygen content of the purge chamber gas 5150 and send oxygen data indicative of the oxygen content of the purge chamber gas 5150 to one or more processors 5140. In one embodiment of the invention , one or more processors 5140 are configured to acquire oxygen content data, compare the obtained oxygen content data with a predetermined oxygen content value, and generate an oxygen excess alarm in the gas if the oxygen content data is greater than the predetermined oxygen content value . In one embodiment of the invention, based on the excess oxygen signal, the internal welding system 5004 can be configured to open the valve structure to allow purge gas (from the purge gas source/tank) to flow into the purge chamber 5150 until the measured oxygen content will not fall below the preset oxygen content value. In one embodiment of the invention, based on the excess oxygen signal, the internal welding system 5004 can be configured to stop the welding procedure.

[00526] 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 that is indicative of the pressure of the inert gas in the purge chamber 5150 to one or more processors 5140. In one embodiment, of the invention, one or more processors 5140 are configured to receive pressure data, compare the received pressure data with a predetermined pressure value, and generate a signal if the pressure data exceeds the predetermined pressure value. In one embodiment, based on the overpressure signal, the internal welding system 5004 can be configured to open the vent valve structure to release pressure in the purge chamber 5150 until the pressure falls below a predetermined pressure value. In one embodiment of the invention, based on the overpressure signal, the internal welding system 5004 can be configured to stop the welding procedure.

[00527] In one embodiment, the seals 5146, 5148, the purge gas container, the purge gas chamber 5150 formed between the seals 5146, 5148, the oxygen and pressure sensors 5176 and 5178 monitoring the gas in the purge chamber 5150 are optional.

[00528] In one embodiment of the invention, as illustrated in FIG. 33, the internal welding system 5004 includes an inspection chamber 5112 configured to be placed between the first pipe engagement device 5052 and the second pipe engagement device 5054. In one embodiment of the invention, the inspection chamber 5112 is built and mounted to rotatably mount on a pivot hub 5078.

[00529] In one embodiment, inspection camera 5112 is operatively coupled to one or more processors 5140. In one embodiment, inspection camera 5112 is configured to send inspection data before, after, or during a welding operation to one or more processors 5140.

[00530] In one embodiment, the inspection camera data typically comprises image(s) of the weld joint captured by the inspection camera 5112. In one embodiment, the inspection camera 5112 is configured to acquire image(s) of the weld joint during or after a welding operation.

[00531] In one embodiment, inspection camera data typically comprises image(s) of the area of contact surface 5136 between pipes 1022a, 1022b taken by inspection camera 5112. In one embodiment, inspection camera 5112 is configured to acquire an image (i) areas of contact surface 5136 between pipes 1022a, 1022b before or during the welding operation.

[00532] In one embodiment, the inspection camera 5112 may be any type of device capable of taking a snapshot/viewing a snapshot of the contact surface area 5136 between the pipes 1022a, 1022b. In one embodiment of the invention, camera 5112 may be a two-dimensional (2D) camera for visual inspection of a weld or contact surface area 5136 between pipes 1022a, 1022b.

[00533] In one embodiment, the inspection camera 5112 may be a two-dimensional (2D) camera equipped with a charge-coupled semiconductor array (CCD). In one embodiment, one or more processors 5140 associated with inspection camera 5112 may be configured to analyze image(s) captured by inspection camera 5112 to detect any defects present in the weld. In one embodiment of the invention, a visual signal based on such an analysis can be transmitted to the operator's external screen. For example, the 2D camera may be a color camera and a change in color may indicate to the operator that there are defects in the weld. In one embodiment of the invention, the existing changes in the profile may also indicate a defect in the weld.

[00534] In one embodiment of the invention, the inspection camera 5112 is configured to obtain a thermal image (eg, different color areas of the metal) of the weld/section. Then, the thermal image is analyzed to determine what temperature has been reached in the different areas of the weld/site.

[00535] In one embodiment of the invention, the images provided by the monitoring camera 5112 may be color images. In one embodiment of the invention, one or more processors 5140 associated with the control camera 5112 may be configured to analyze the color of each pixel of the acquired image to determine the temperature associated with that pixel.

[00536] Embodiments of the invention, the images provided by the monitoring camera 5112 may be grayscale images. In one embodiment of the invention, one or more processors 5140 associated with the control camera 5112 may be configured to analyze the intensity or brightness of each pixel of the acquired image to determine the temperature associated with that pixel. In one embodiment of the invention, one or more processors 5140 associated with the control camera 5112 may be configured to analyze the pixel properties of the acquired image to determine if the temperature is outside a threshold or predetermined temperature range (and if it is relatively very high or relatively very low) and/or whether there is a large temperature difference between adjacent pixels. In one embodiment of the invention, an abnormal temperature or temperature difference may indicate the presence of a weld defect.

[00537] For example, in one embodiment of the invention, the image can be analyzed to determine whether the area or areas of the weld / section has reached a relatively very high or relatively very low temperature. In one embodiment of the invention, the image may be analyzed to determine if the region or regions of the weld/section has a temperature difference/change. In one embodiment, the temperature of each weld area/section is determined and the temperature of each weld area/section thus determined is compared to a threshold value or predetermined temperature range to determine if the weld area or areas has reached a relatively very high temperature. or relatively very low temperature, and whether the area or areas of the welded joint/section has a temperature difference/change.

[00538] In one embodiment of the invention, the inspection camera 5112 is configured to follow the welding torch 5502 so that the operator can monitor the weld as soon as the welding torch 5502 completes the weld.

[00539] In various embodiments of the invention, the measuring sensor includes a laser, a 3D camera, an ultrasonic and an electrical capacitive sensor. If a laser is used, the type of laser used may be a laser displacement sensor. In one embodiment, the laser may be a high speed/high precision LK-G5000 series of laser displacement sensors manufactured by Keyence. In one embodiment of the invention, the laser may be a microprocessor controlled laser such as the "Smart Laser Sensor SLS-050" manufactured by "Meta Vision Systems Inc."

[00540] In one embodiment of the invention, the measurement sensor may include an emitter for emitting a research beam of radiation, and a receiver for receiving measurement signals of the reflected radiation. In one embodiment of the invention, the sensor receiver comprises a sensor that detects reflected radiation and generates signals based on the reflected radiation. These signals are received by one or more processors. In one embodiment of the invention, the signals contain data and information corresponding to the three-dimensional profile of the area of the contact surface between the welded pipes and can be used, for example, to determine the relative height of adjacent pipe surfaces in the welded area, the relative displacement between pipes, any unevenness in adjacent surfaces of pipes to be welded (for example, in their groove areas). Additionally, since the measuring sensor scans the entire contact surface between the pipes, it is possible to determine a specific contact surface profile in each defined scan area. This information may be used by one or more processors to control the operation of the welding torch to produce a customized/adapted weld that is adapted to the specific structural profile of the pipes to be welded in their contact surface area.

[00541] In one embodiment of the invention, the system 5000 may include housings 5852, 5854 (as illustrated in Fig. 31), which are configured to house and protect, respectively, the measuring sensor 5056 and the control chamber 5112 from flying hot sparks ( spatter) from welding, and/or other fragments that may fly towards the 5056 measuring probe and/or the 5112 control chamber during the welding operation.

[00542] In one embodiment of the invention, the housings 5852, 5854 of the measuring sensor 5056 and/or the control camera 5112 may be made of polycarbonate. In one embodiment, portions of housings 5852, 5854 may be removable to facilitate cleaning (eg, removal of weld spatter or other welding debris) or repair. In one embodiment, housing portions 5852, 5854 may include a camera lens guard or a measurement sensor lens guard. In one embodiment, parts of housings 5852, 5854 of sensor 5056 and or inspection chamber 5112 may be disposable, such that housing parts 5852, 5854 can be easily replaced if clogged with weld spatter or other welding debris. For example, in one embodiment, the control chamber 5112 may include a (rectangular) polycarbonate element in front of its lenses, which can be replaced when clogged/obstructed by welding spatter or other welding debris.

[00543] In one embodiment, the pre-weld test, on-the-fly test, and post-weld test may be performed by the 5056 gauge. In one embodiment, the pre-weld test, on-the-fly test, and post-weld test may be performed by the sensor 5056 and control camera 5112.

[00544] In one embodiment of the invention, the measurement sensor 5056 may include an emitter 5180 for emitting a research beam of radiation, and a receiver 5182 for receiving measurement signals of the reflected radiation. In one embodiment of the invention, the measurement sensor 5056 emits radiation towards the area of the contact surface 5136. In one embodiment of the invention, the receiver 5182 of the measurement sensor 5136 is configured to receive radiation reflected from the surface in the area of the contact surface 5136 and generate electronic signals based on it . In one embodiment of the invention, the receiver or sensor 5182 of the measurement sensor 5056 is configured to receive the reflected signal to recognize the 3D topography of the weld/site. The 5056 measurement sensor may be referred to interchangeably herein as the “measurement laser”.

[00545] In one embodiment of the invention, the measurement sensor 5136 includes a plurality of measurement sensors that transmit radiation towards the area of the contact surface 5136. In one embodiment of the invention, each measurement sensor may include a receiver for receiving radiation reflected from the surface in the area of the contact surface 5136 and generate electronic signals based on it.

[00546] In one embodiment of the invention, the measurement sensor 5056 may include a laser displacement sensor. In one embodiment, the measurement sensor 5056 may comprise a complementary metal oxide semiconductor (CMOS) sensor. In one embodiment of the invention, the measurement sensor 5056 may include Ernostar-type high-definition lenses. In one embodiment of the invention, one or more processors 5140 associated with the measurement sensor 5056 is configured to use a system of triangles to determine the position of the reflected light on the RS-CMOS sensor.

[00547] In one embodiment, the sensor 5056 may receive incoming power from the wire feed electronics 5046. In one embodiment, the wire feed electronics 5046 is configured to receive incoming power from batteries 5116 in the drive section 5010 via a rings 5080. Thus, the 5056 gauge receives its incoming power from the 5116 batteries in the 5010 drive section via the 5080 rear slip ring and the 5046 electronic wire feed module. from system 5004, such as when system 5004 moves from one weld to the next weld.

[00548] In another embodiment of the invention, the sensor 5056 may receive incoming power directly from the halyard/drive rod 5034. incoming power directly from the 5034 halyard/drive rod.

[00549] It should be understood that in some embodiments of the invention, it may be necessary to supply power to the measurement sensor 5056 and/or control camera 5112 and receive data from them. Such power supply and/or data communication from the 5056 measurement sensor and/or the 5112 control chamber may be performed by components, for example, one or more 5140 processors and/or a power source, located outside the pipe engagement device (for example, outside the clamps 5142, 5144 and/or or seals 5146, 5148). In some embodiments of the invention, where power supply and/or data transmission is performed through a wired (as opposed to wireless) communication and/or power channel, such a wired channel may take into account the rotation of the rotary hub 5078, for example, to reduce or prevent twisting and /or entanglement of the wire channel. For this reason, in one example, as described herein, a wire path (which may carry information and/or power) may be provided with (i) a movable portion that moves with the measurement sensor 5056 when the measurement sensor 5056 directs the research radiation along a contact surface area subjected to the rotational force of one or more orientation motors, and (ii) a stationary part that remains fixed while the moving part is moving. The fixed and rotatable parts of the wire duct can be connected by means of the described slip ring, which provides a contact surface between the movable and fixed parts, to enable the transmission of signals from the movable part to the fixed part. It should be understood that either a single wired path (eg, with a plurality of individual wires) or a plurality of wired paths (separate paths for power supply and communication) can be used. Additionally, if the internal power supply is applied to the measuring sensor, then only the communication channel passes through the slip ring. If wireless communication with the measuring sensor is provided, then only the power supply channel passes through the slip ring. If built-in power supply and wireless communication is provided, then wired communication must be provided.

[00550] As described for the wired communication path, it is also necessary to provide inert gas to the axial position between the pipe engagement devices (eg, clamps and/or seals) via a pneumatic duct or line to transport the inert gas. It is also necessary to reduce the twisting and/or entanglement of the pneumatic conduit that otherwise occurs when the 5078 rotary hub is rotated. For this reason, the pneumatic conduit must be provided with a stationary part connected to an inert gas source and a movable part that extends into the rotary hub. , the moving part is connected to the stationary part by means of a rotating coupling. The rotating coupling provides relative rotation between the stationary and moving pneumatic parts.

[00551] In one embodiment of the invention, the measurement sensor 5056 is operatively coupled to the measurement sensor motor for directing the research radiation beam along the contact surface 5136 between the tubes 1022a, 1022b. In one embodiment, sensor 5056 and sensor motor may be operatively coupled to one or more processors 5140. In one embodiment, first and second rotation motors 5030 and 5074 may be collectively referred to interchangeably as sensor motors.

[00552] In one embodiment of the invention, the measuring sensor 5056 is configured to characterize the contact surface area 5136 between the pipes 1022a, 1022b. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may include a gap between the pipes 1022a, 1022b. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may contain a radial displacement (eg, up/down) between the pipes 1022a, 1022b. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may contain geometric parameters at each location of the weld. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may contain chips, grooves or other irregularities of the pipes 1022a, 1022b. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may include changes in the roundness of the pipes 1022a, 1022b. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may contain the contours of the groove of the pipe seam 1022A, 1022b (after alignment of the pipes). In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may contain different color areas of the metal of the weld/section. For example, these color areas are analyzed to determine what temperature is reached in different areas of the weld/area.

[00553] In one embodiment, the sensor 5056 may be configured to characterize the area of contact surface 5136 between the pipes 1022a, 1022b, for example, prior to activating the welding torch 5502 to begin fastening/welding the pipes 1022a, 1022b to each other. For example, the characteristics of the contact surface area 5136 may include the geometry of the pipe groove, the gap between the inner adjacent ends of the pipes 1022a, 1022b (after pipe alignment), the gap between the pipe groove 1022a, 1022b (after the pipe alignment), etc. In one embodiment, the sensor 5056 may be configured to characterize the area of contact surface 5136 between pipes 1022a, 1022b, such as 1022b, during a welding operation in the area of the contact surface prior to application of weld metal thereto. For example, the characteristics of the area of the contact surface 5136 may contain the difference in height between the chamfers of the pipes after they are aligned. In one embodiment of the invention, the characteristics of the area of the contact surface 5136 may contain mismatches in height between adjacent edges of the pipes (for example, at their internal beveled edges). In one embodiment of the invention, the measuring sensor 5056 may be configured to characterize the area of the contact surface 5136 between the pipes 1022a, 1022b, for example, after a welding operation. For example, these characteristics of the area of contact surface 5136 may include characteristics of the formed weld beads, weld shape parameters, for example, mismatch of mating parts, weld bead root, entry angle.

[00554] In one embodiment of the invention, one or more processors 5140 are configured to control the measurement sensor 5056 and motors 5030, 5074 to scan the area of the contact surface 5136 between the pipes 1022a, 1022b.

[00555] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to determine the profile of the area of the contact surface 5136 between the pipes 1022a and 1022b before the welding procedure and generate based on profile data before welding.

[00556] In this document, the term "profile" means a general designation of the physical attributes of the welded area of the contact surface between the pipes. The term "profile data" means data corresponding to the profile that can be extracted from the area of the contact surface. For example, such data can be obtained by scanning the area of the contact surface with a measuring sensor, such as a laser. The profile data contains various types of profile information, these various types of information are referred to herein as "characteristics".

[00557] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the contact surface area 5136 between pipes 1022a, 1022b to determine the profile of the contact surface area 5136 between pipes 1022a and 1022b during a welding procedure in area of the contact surface 5136 before applying a weld to it and generating profile data on the fly. In one embodiment of the invention, one or more processors 5140 are configured to generate signals to control the welding torch 5502 based on on-the-fly profile data. Profile data obtained on the fly is described in more detail below. In this description, the term "on the fly" also means or refers to the concept of "real time", meaning that the measurement or determination is used by one or more processors during the current welding operation to control the welding machine. Of course, due to the sensor, the lag of the welding torch relative to the sensor/measuring laser has a certain value, there is a certain buffer (or a small delay in time) between the acquisition of profile data and the use of such data by one or more processors to control the welding torch.

[00558] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to determine the profile of the area of the contact surface 5136 between the pipes 1022a and 1022b after the welding procedure and generate based on the profile data after welding. Profile data obtained after welding is described in more detail below.

[00559] In one embodiment of the invention, the measurement sensor 5056 is configured to work in conjunction with the welding torch 5502 of the welding system 5004 to determine the profile of the contact surface and/or the profile of the weld metal to deposit the weld metal in the right amount and in the right place on the end face. compound. In one embodiment, the sensor 5056 is configured to probe the weld and send a signal to one or more processors 5140 of the articulated weld head 5502 to control the movement of the weld head 5502 around the entire end joint. More specifically, the welding torch 5502 is configured to follow the measurement sensor by having the welding head control system continuously receive weld profile information from the end connection. The information is then used to continuously adjust the 5502 welding torch to achieve the desired weld structure/profile.

[00560] In one embodiment, the internal welding system 5004 may include a measurement sensor for each welding torch 5502. In one embodiment, the internal welding system 5004 comprises three welding torches 5502 and three associated measurement sensors 5056. In one embodiment, implementation of the invention, the internal welding system 5004 may contain two measurement sensors for each welding torch 5502. In one embodiment of the invention, the number of measurement sensors used in the internal welding system 5004 may vary.

[00561] In one embodiment of the invention, the field system 5000 of the present patent application is an intelligent internal inspection system containing internal automatic control and monitoring systems, including a control chamber 5112, a measurement sensor 5056 and a welding head or torch 5502 between spaced clamps 5142 , 5144, and seal structures 5146, 5148. In one embodiment, the field system 5000 of this patent application is an intelligent internal inspection system comprising an inspection chamber 5112 and a measurement sensor 5056 between spaced clamps 5142, 5144 and seal structures 5146, 5148 In one embodiment of the invention, the field system 5000 of the present patent application is an intelligent internal inspection system containing internal automatic control and monitoring systems, including a 5112 inspection camera, a 5056 measurement sensor, and with brew head or burner 5502 between spaced clamps 5142, 5144.

[00562] In one embodiment, the welding system is attached to the back of the pipe alignment clamp and becomes an integrated analysis tool that minimizes the downtime associated with the use of third party tools. In one embodiment of the invention, both the control chamber 5112 and the measurement sensor 5056 are used to check the weld. In one embodiment of the invention, the inspection camera 5112 is configured to acquire a two-dimensional image of the weld and analyze the color of the weld. Since the color of the weld indicates the temperature of the material that was reached during the welding procedure, the information obtained by the 5112 control camera helps determine if the weld was made correctly. In one embodiment of the invention, the measuring sensor 5056 is configured to analyze the profile of the weld. In one embodiment, the 5056 measurement sensor, in conjunction with a 5112 two-dimensional (2D) color camera equipped with a charge-coupled semiconductor (CCD) array, is configured to perform root inspection immediately after the root pass and hot pass pass procedure. In one embodiment of the invention, the welding system 5004 is configured to provide a profile of the root pass and a primary 2D image illustrating the color change and any geometric imperfections in the layer of the root pass. In one embodiment of the invention, the welding system 5004 is configured to create a permanent record of the root pass layer profile and a visual image that can be stored and played back on the user's electronic device (eg, laptop).

[00563] In one embodiment of the invention, the check performed by the measurement sensor 5056 in conjunction with the color camera 5112 can be used as a reference for the OUT check of the weld. In one embodiment, the test performed by the 5056 gauge in conjunction with the 5112 color camera can be used to perform a pass/fail (pass/fail) test for root pass and hot pass welds. . In one embodiment of the invention, if a root defect is found, the weld is sheared and prepared in the same station long before the defect would be discovered after all passes were deposited, thus preventing significant loss of production time.

[00564] In one embodiment, the internal welding system 5004 includes a feedback system that is configured to be operatively associated with a plurality of sensors and one or more processors 5140. In one embodiment, one or more processors 5140 are configured to analyze data provided by multiple sensors. In one embodiment of the invention, one or a plurality of sensors comprise a temperature sensor configured to provide information about the temperature of the weld and/or monitor the temperature during a welding procedure. In one embodiment of the invention, one or a plurality of sensors comprise a weld metal sensor configured to monitor the weld metal being used during a welding procedure. In one embodiment of the invention, one or a plurality of sensors may include sensors configured to monitor the speed and time of the welding procedure.

[00565] FIG. 41 illustrates a front perspective view of the welding head assembly 5500, with FIG. 42 and 43 illustrate a rear perspective view of the welding head assembly 5500. FIG. 44-46 illustrate a left side perspective view, a right side perspective view, and a cross section of the weld head assembly 5500, with some components of the weld head assembly 5500 not illustrated for clarity.

[00566] In one embodiment, in the illustrated embodiment, the center section 5008 may comprise three welding torches 5502. In another embodiment, the center section 5008 may comprise two welding torches 5502. In yet another embodiment, the center section 5008 may contain one welding torch 5502. In one embodiment of the invention, the number of welding torches may vary.

[00567] In one embodiment, the welding head assembly 5500 includes a welding torch 5502 and a welding torch body assembly 5504. In one embodiment, the welding torch 5502 includes a tip 5503. 5502 and welding torch body assembly 5504) are transported by the frame or frame assembly of the 5004 internal welding system.

[00568] In one embodiment of the invention, the welding torch 5502 is built and mounted to supply or direct the consumable electrode 5507 to the welding area/zone. The consumable electrode wire 5507 is fed from a source (e.g., a reel or spool of wire) through a wire feed system 5044. In one embodiment, the welding torch 5502 is built and mounted for connection to a power source (e.g., a DC power source). In one embodiment, the electric arc between consumable electrode wire 5507 and conduits 1022a, 1022b heats conduits 1022a, 1022b, causing them to melt and form a joint. In one embodiment of the invention, consumable electrode wire 5507 is supplied with shielding gas through the welding torch 5502, which protects the welding procedure from airborne contaminants. In one embodiment, the shielding gas is supplied to the weld area/zone through a nipple that contains the gas cup 5505. In one embodiment, the electrode 5507 can extend beyond the gas cup 5505.

[00569] In one embodiment, the shield gas stored in the drive section 5010 is supplied to the wire feed assembly 5020 by a shield gas hose/line for distribution to one or more welding guns 5502. In one embodiment, the shield gas control valve The 5042 is configured to receive shielding gas from the rear swivel sleeve 5072 (eg, via a rear slip ring 5080, a swivel sleeve 5078, and a front slip ring 5016). In one embodiment, the shield gas control valve 5042 is configured to control the flow rate of the shield gas supply to the welding torch 5502 through the shield gas supply line. In one embodiment of the invention, each welding torch 5502 has a corresponding shielding gas valve 5042 connected to it. In one embodiment, the shield gas control valve 5042 is configured to supply shield gas to the associated welding gun 5502 when it receives signals from the electronic wire feed module 5046.

[00570] In one embodiment of the invention, the welding torch 5502 is configured to be transported by the frame of the internal welding system 5004 and configured to create a weld at the end of the second end of the first pipe 1022a. In one embodiment of the invention, the welding torch 5502 is configured to be positioned internally within the first pipe 1022a and/or the second pipe 1022b to perform an internal welding operation. In one embodiment of the invention, an internally placed welding torch 5502 is mounted on (located on) and connected to a rotary sleeve 5078.

[00571] In one embodiment, the welding torch 5502 may have at least three degrees of freedom. In one embodiment, the articulation degrees of freedom allow the 5502 welding torch to be efficient and effective in filling contact surface profiles where needed.

[00572] Degrees of freedom, as a rule, refers to the freedom of movement of the welding torch 5502 in three-dimensional space. Translational movement or displacement is generally referred to as linear movement or displacement along three mutually perpendicular axes X, Y and Z.

[00573] In one embodiment of the invention, herein the term positioning, as a rule, means translational movement or displacement. In one embodiment of the invention, the positioning may be relative or absolute.

[00574] In one embodiment of the invention, the coordinate system may include: a Y-axis located essentially parallel to the longitudinal axis A-A (as illustrated in Fig. 8) pipes 1022a, 1022b; the X axis perpendicular to the Y axis; and a Z-axis perpendicular to the Y-axis and substantially parallel to the radial axis RR (as illustrated in FIG. 8) of the pipes 1022a, 1022b. For example, translational movement along the X-axis generally means forward and backward movement. Translational movement along the Y-axis generally means moving left and right. Translational movement along the Z-axis generally means movement up and down.

[00575] Rotational movement or displacement generally means rotation about these three mutually perpendicular X, Y, and Z axes. Rotation about the three mutually perpendicular X, Y, and Z axes typically means rotation about the vertical axis (Z axis), rotation around the transverse axis (Y axis) and rotation around the longitudinal axis (X axis). For example, rotational movement around the X-axis generally means oblique movement to the left and right. Rotational movement around the Y-axis generally means oblique movement forward or (reversely) backward. Rotational movement around the Z-axis generally means rotational movement left and right.

[00576] In one embodiment of the invention, in this document, the term orientation, as a rule, means rotational movement or displacement. In one embodiment of the invention, the orientation may be relative or absolute.

[00577] In one embodiment of the invention, at least three degrees of freedom may include two translational movements of the welding torch 5502 along two of the three mutually perpendicular axes X, Y and Z, and one rotational movement of the welding torch 5502 around the same three mutually perpendicular axes X , Y and Z.

[00578] In one embodiment, two translational movements of the welding torch 5502 along two of the three mutually perpendicular axes X, Y, and Z may comprise an up and down movement of the welding torch 5502 and a lateral movement (e.g., left to right) of the welding torch 5502. B In one embodiment, moving up and down the welding torch 5502 may mean a radial movement (i.e., effectively parallel to the radial axis RR of the tubes 1022a, 1022b) of the welding torch 5502, and a transverse movement (from left to right) of the welding torch 5502 may mean axial movement (i.e., in fact, parallel to the longitudinal axis A-A of the pipes 1022a, 1022b) of the welding torch 5502.

[00579] In one embodiment of the invention, one rotational movement of the welding torch 5502 around one of the three mutually perpendicular axes X, Y, and Z may include an oblique forward or (reverse) backward movement of the welding torch 5502.

[00580] In one embodiment of the invention, the welding torch 5502 is mounted to move about the axis of rotation P (as illustrated in Fig. 54, 56 and 58) on or close to the welding tip 5503 of the welding torch 5502, so that the weld pool is created on welding tip 5503, typically coinciding with the axis of rotation P. In one embodiment, the axis of rotation P is located in front of the welding tip 5503. For example, in one embodiment of the invention, the welding torch 5502 is designed to rotate about the axis of rotation P (as illustrated in Fig. 54, 56 and 58), on which the electrode wire 5507 contacts the pipe 1022a, 1022b. In one embodiment, the welding torch 5502 is set to move such that it is pivotally connected about an axis close to the welding torch 5503. In one embodiment, the axis passes through the pivot axis P and is effectively parallel to the longitudinal axis A-A pipes 1022a, 1022b.

[00581] In one embodiment, the welding torch 5502 is operatively coupled to one or more welding torch motors 5596. pipes 1022a, 1022b. In one embodiment of the invention, one or more welding torch motors 5596 are configured to move the welding torch 5502 relative to the first and second pipe engagement devices 5052, 5054 after they are fixed, respectively, relative to the first pipe and second pipe 1022a, 1022b.

[00582] In one embodiment, one or more processors 5140 are configured to control one or more welding torch motors 5596 to control the position and orientation of the welding torch 5502. For example, as described in more detail below, one or more welding torch motors 5596 may comprise 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 an inclined welding torch motor 5588 configured to control the tilted position and orientation of the 5502 welding torch.

[00583] In one embodiment of the invention, the motors 5030 and 5074 are configured to move the welding torch 5502 in a circle around the area of the contact surface 5136 and also to move the measuring sensor 5056 around the area of the contact surface 5136 simultaneously with the welding torch 5502. In one embodiment of the invention , the welding torch 5502 pulls the measurement probe 5056. In one embodiment, the front and rear rotation motors 5030 and 5074 are configured to rotate the rotary hub 5078 and rotate the welding torch 5502, the measurement probe 5056 and the control chamber 5112, which are located on the rotary hub 5078 and connected to it. In one embodiment, the front and rear rotation motors 5030 and 5074 may be referred to interchangeably as annular welding torch motors.

[00584] In one embodiment, one or more processors 5140 is operatively coupled to one or more orientation motors 5030 and 5074 to rotate the first jaw 5142 relative to the second jaw 5144 so as to rotate the first tube 1022a relative to the second tube 1022b based on instructions. from one or more 5140 processors.

[00585] In one embodiment of the invention, the motors 5030 and 5074 are configured to move the welding torch 5502 in a circle around the area of the contact surface 5136 and also to move the inspection chamber 5112 around the area of the contact surface 5136 simultaneously with the welding torch 5502. In one embodiment of the invention , the welding torch 5502 pulls the control chamber 5112. In one embodiment of the invention, the control chamber 5112 pulls the welding torch 5502.

[00586] In one embodiment of the invention, the motors 5030 and 5074 are configured to move the welding torch 5502 in a circle around the area of the contact surface 5136 and are also configured to move both the control chamber 5112 and the measurement sensor 5056 around the area of the contact surface 5136 simultaneously with the welding torch 5502. In one embodiment, the welding torch 5502 pulls the measurement probe 5056 and the inspection chamber 5112. In one embodiment, the welding torch 5502 pulls the measurement probe 5056 and moves the inspection chamber 5112 in front of it.

[00587] In one embodiment, the motors 5030 and 5074 are configured to move the welding torch 5502 in a first direction of rotation during a root pass and move the welding torch 5502 in a second direction opposite the first direction during a hot pass.

[00588] In one embodiment of the invention, the motors 5030 and 5074 are configured to move the welding torch 5502 at least 360° about the pipe axis A-A (as illustrated in Fig. 8) so as to perform a continuous rotary pass during welding seam root. In one embodiment of the invention, a 360° rotation of the welding head 5502 about the axis A-A (around the inner surface of the pipe) is possible, since the welding torch 5502 is mounted on a rotary hub 5078 (i.e., axially rotatable).

[00589] In one embodiment of the invention, one or more welding torch motors 5596 are configured to move the welding torch 5502 in the longitudinal direction (as illustrated in Fig. 48 and 49) inside the pipes 1022a, 1022b, towards the inner surface 5130, 5132 and in the opposite direction from it (as illustrated in Fig. 33), pipes 1022a, 1022b. In one embodiment, one or more welding torch motors 5596 are configured to move the welding torch 5502 at an angle to the weld (as illustrated in FIGS. 56 and 58). In one embodiment of the invention, the motors 5030 and 5074 are configured to move the welding torch 5502 in a circle along the contact surface 5136.

[00590] In one embodiment, the weld head assembly 5500 includes a radial positioning system 5506 configured to allow radial movement of the welding torch 5502, an axial positioning system 5508 configured to allow axial movement of the welding torch 5502, and an oblique positioning system 5510, configured to tilt the welding torch 5502.

[00591] In one embodiment, the torch body assembly 5504 is constructed and assembled to accommodate the welding torch 5502, the axial positioning system 5506, the axial positioning system 5508, and the tilt positioning system 5510. In one embodiment, the torch body assembly 5504 is configured with the ability to protect the components of the 5502 welding torch and various components of its 5506, 5508 and 5510 positioning systems from welding temperature and spatter.

[00592] In one embodiment, the burner body assembly 5504 may include base members 5509 and two side body members 5511 and 5513. , fasteners 5527). In one embodiment, the burner body assembly 5504 may comprise a first body cross member 5522 and an opposing second body body member 5523 constructed and assembled to connect the side body members 5511 and 5513 to each other at the top ends. For example, the first and second transverse elements of the housing element 5522, 5523 can be connected to the side elements of the housing 5511 and 5513 using any suitable fastening mechanism (for example, fasteners 5525).

[00593] In one embodiment of the invention, as illustrated in FIG. 41-46, the welding torch 5502 is set to be moved by the radial positioning system 5506 such that the welding tip 5503 is movable towards and away from the welding surfaces 5130, 5132 of the pipes 1022a, 1022b. In one embodiment of the invention, one or more processors 5140 is configured to control one or more welding torch motors 5512 to adjust the radial distance of the welding tip 5503 within the tubes 1022a, 1022b to the contact surface area 5136.

[00594] In one embodiment, one or more processors 5140 are configured to control one or more welding torch motors 5512 to move the welding tip 5503 radially away from the contact surface area 5136 after the root pass so as to adapt to the weld metal applied in the root weld and allow a hot pass over the root pass within the tubes 1022a, 1022b (closer to the longitudinal axis A-A).

[00595] In one embodiment of the invention, one or more processors 5140 configured to control one or more motors may be part of an electronic wire feed module 5046.

[00596] In one embodiment of the invention, the radial positioning system 5506 is configured to move the welding torch 5502 radially with respect to changing the profile of the pipe shape to adjust the distance from the welding tip to the workpiece (for example, pipe) during multiple passes (for example, a for root welding and hot pass), and for returning back from the pipe 1022a, 1022b when moving the internal welding system.

[00597] In one embodiment, the radial positioning system 5506 is configured to radially move the welding torch 5502 a distance of 1.25 inches. In one embodiment of the invention, the welding torch 5502 is moved by the radial positioning system 5506 between a normal, idle, and raised position. As illustrated in FIG. 43, the welding torch 5502 is raised (to its raised position) by the radial positioning system 5506 so that the welding torch 5502 is located at the correct/required/preset distance from the pipes 1022a, 1022b to perform the welding procedure.

[00598] In one embodiment, the radial positioning system 5506 may include a linear actuator. In one embodiment, the radial positioning system 5506 may include a radial welding torch motor (electric) 5512, a lead screw 5514, and a screw drive nut 5516. In one embodiment, the motor 5512 is configured (e.g., mechanically coupled) to rotate the lead screw 5514. In one embodiment of the invention, the motor 5512 is configured to rotate both clockwise and counterclockwise, resulting in raising or lowering the welding torch 5502, in fact, parallel to the radial axis RR (as illustrated in Fig. 8) of the pipes 1022a, 1022b . In one embodiment, the motor 5512 is directly coupled to rotate the lead screw 5514. In embodiments, the motor 5512 is indirectly coupled, such as through a gear train or gearbox to rotate the lead screw 5514.

[00599] In one embodiment of the invention, the lead screw 5514 includes a mechanically made thread on its outer surface, extending along its entire length. In one embodiment, the helical nut 5516 is constructed and assembled to thread onto the lead screw 5514 and is threaded on its inner surface.

[00600] In one embodiment of the invention, the radial positioning system 5506 includes two vertical guide rods 5518 and 5520 located on both sides and parallel to the lead screw 5514. In one embodiment of the invention, the front vertical guide rods 5518 and 5520 are connected to the base element 5509 burner body assembly 5504 at one end and connected to the first transverse body member 5522 at its second end. In one embodiment, the ends of the front guide bars 5518 and 5520 extend through holes made in the base member 5509 of the welding torch assembly 5504 to connect the front vertical guide bars 5518 and 5520 to the base member 5509 of the torch body assembly 5504. In one embodiment, the ends of the front vertical guide bars 5518 and 5520 pass through holes made in the first body cross member 5522 to connect the front guide bars 5518 and 5520 to the first body cross member 5522.

[00601] In one embodiment of the invention, the end of the lead screw 5514 (opposite the end connected to the motor 5512) is built and mounted to pass through the holes 5534 in the first transverse body member 5522.

[00602] In one embodiment, the radial positioning system 5506 includes two rear vertical guide rods 5600 and 5602 parallel to the lead screw 5514 and two front guide rods 5518 and 5520. In one embodiment, the rear vertical guide rods 5600 and 5602 are connected to the base member 5509 of the burner body assembly 5504 at one end and connected to the second transverse body member 5523 at its second end. In one embodiment, the ends of the rear vertical guide bars 5600 and 5602 extend through holes made in the base member 5509 of the welding torch assembly 5504 to connect the rear vertical guide bars 5600 and 5602 to the base member 5509 of the torch body assembly 5504. In one embodiment of the invention , the ends of the rear vertical guide bars 5600 and 5602 pass through holes made in the second body cross member 5523 to connect the rear vertical guide bars 5600 and 5602 to the second body cross member 5523.

[00603] In one embodiment, the radial positioning system 5506 also includes a transverse radial positioning element 5524 and two vertical radial positioning elements 5526. In one embodiment, two vertical positioning radial positioning elements 5526 are connected to both ends of the transverse radial positioning element 5524. In one embodiment, the transverse radial positioning member 5524 and the two vertical radial positioning members 5526 of the radial positioning system 5506 are movable during radial movement of the welding torch 5502.

[00604] In one embodiment, the transverse radial positioning member 5524 may have protruding ends 5528 configured to engage with the notch or protruding ends of the receiving holes 5530 of two vertical radial positioning members 5526. In one embodiment, after the protruding the ends 5528 of the traverse 5524 pass through the cutouts or projecting receiving holes 5530 of the two vertical radii positioners 5526, the traverse 5524 and the two vertical traverse members 5526 can be securely connected to each other by any suitable fastening mechanism (e.g., fasteners 5532).

[00605] In one embodiment, the radial positioning cross member 5524 includes holes for receiving front vertical guide bars 5518 and 5520 through them. This configuration allows the radial positioning cross member 5524 to slide into position on the front vertical guide bars 5518 and 5520 In one embodiment, the lead screw 5514 is configured to pass through the central hole 5536 of the radial positioning transverse member 5524.

[00606] In one embodiment, the radial positioning system 5506 also includes two rear radial positioning elements 5604 and 5606. In one embodiment, two vertical positioning radial elements 5526 are connected to two rear radial positioning elements 5604 and 5606. In one embodiment, implementation of the invention, the two rear radial positioning elements 5604 and 5606 and the two vertical radial positioning elements 5526 of the radial positioning system 5506 are movable during the radial movement of the welding torch 5502.

[00607] In one embodiment, each rear radial positioning element 5604 and 5606 has ends that are configured to engage with the ends of their respective vertical positioning elements 5526. In one embodiment, after the ends of the rear radial positioning elements 5604 and 5606 with the ends of two vertical positioning elements 5526, each rear element of the radial positioning 5604 and 5606 can be rigidly fixed with its corresponding vertical element of the radial positioning 5526 using a suitable fastening mechanism (for example, fasteners 5608).

[00608] In one embodiment of the invention, the rear radial positioning elements 5604 and 5606 include holes for receiving, respectively, the rear vertical guide rods 5600 and 5602 through them. This configuration allows the rear radial positioning elements 5604 and 5606 to slide into a predetermined position on rear vertical guide bars 5600 and 5602.

[00609] In one embodiment, the helical nut 5516 is interlockable with a portion of the radial positioning transverse member 5524 such that the rotation of the helical nut 5516 is locked along with the lead screw 5514. In other words, the helical nut 5516 is kept from rotation with the lead screw 5514, whereby the screw nut 5516 is configured to move the lead screw 5514 up and down. embodiment of the invention, the lead screw 5514 is configured to pass through the hole of the locked screw drive nut 5516.

[00610] In one embodiment of the invention, two vertical radial positioning elements 5526 are connected to each other using front and rear transverse support elements 5610 and 5612. For example, the front support element 5610 is built and mounted to connect to the front and bottom of the two vertical elements radial positioning 5526 using any suitable fastening mechanism (for example, fasteners 5614). The rear transverse support member 5612 is built and assembled to connect to the rear and bottom of the two vertical positioning radial members 5526 using any suitable fastening mechanism (eg, fasteners 5616).

[00611] In one embodiment, the welding assembly 5500 also includes two vertical positioners 5538 and an upper positioner 5540. In one embodiment, two vertical positioners 5538 are connected to the ends of the upper positioner 5540. In one embodiment, the ends of the top positioning element 5540 are L-shaped. In one embodiment of the invention, the respective connecting portions of the two vertical positioning elements 5538 may comprise a conjugated configuration configured to engage with the L-shaped configuration of the ends of the upper positioning element 5540. In one embodiment of the invention, after engaging the L-shaped configuration of the ends of the upper positioner 5540 with a conjugated configuration of the respective parts of the two vertical positioners 5538, the upper positioner 5540 and the two vertical positioners 5538 can be securely connected to each other using any suitable fastening mechanism (for example, fasteners 5542).

[00612] In one embodiment, the axial positioning system 5508 is configured to allow the welding torch 5502 to move axially to maintain the welding torch 5502 in the groove as the welding torch 5502 is moved around the pipe, and to allow the welding torch 5502 to oscillate within the groove seam, if necessary, fill the groove of the seam.

[00613] FIG. 47 illustrates a welding heater 5502 placed in a normal, centered, axial position. In one embodiment, the axial positioning system 5508 is configured to axially move the welding torch 5502 by +/- 1 inch. For example, as shown in FIG. 48 and 49, the welding torch 5502 is moved by the axial positioning system 5508 +1 inch axially and -1 inch axially, respectively, such that the welding torch 5502 is positioned at the correct/desired/preset distance from the pipe being welded.

[00614] FIG. 50 and 51 illustrate a left side perspective and exploded view of the weld head assembly 5500, with some components of the weld head assembly 5500 not illustrated for clarity. Fig. 52 illustrates a bottom perspective view of the top positioning element 5540 of the welding torch assembly. Fig. 53 illustrates a top elevation view of the welding head assembly 5500, with some components of the welding head assembly 5500 not illustrated for clarity.

[00615] In one embodiment of the invention, as illustrated in FIG. 50-53, the axis positioning system 5508 may be a linear actuator. In one embodiment, the radial positioning system 5508 may include an axial welding torch motor (electric) 5550, a lead screw 5552, and a screw drive nut 5554. In one embodiment, the configuration and operation of each motor 5550, lead screw 5552, and screw nut gears 5554 of the axial positioning system 5508 are similar to the motor 5512, lead screw 5514, and screw nut 5516 of the radial positioning system 5506 and, therefore, are not described in more detail in this document. In one embodiment of the invention, when the lead screw 5552 is turned by the motor 5550, the screw drive nut 5554 extends along the thread.

[00616] In one embodiment of the invention, the axis positioning system 5508 includes two horizontal guide rods 5556 and 5558 located on and parallel to both sides of the horizontally located lead screw 5552. In one embodiment of the invention, each of the horizontal guide rods 5556 and 5558 is connected to top positioning element 5540 at its two ends. In one embodiment, the ends of the horizontal guide rods 5556 and 5558 extend through holes made in the top positioner 5540 to connect the horizontal guide rods 5556 and 5558 to the top positioner 5540. In one embodiment, at least the ends of each horizontal guide rod The 5556 and 5558 comprise a protrusion 5560 configured to fit into a respective protrusion receptacle 5562 provided in a hole on the top positioner 5540 to lock the horizontal guide rods 5556 and 5558 to the top positioner 5540.

[00617] In one embodiment, the weld head assembly 5500 includes a welding torch frame 5564 configured to receive a welding torch 5502. and a vertically extending hole 5572 provided therein. In one embodiment of the invention, horizontal guide rods 5556 and 5558 are configured to pass through holes 5566 and 5570 of the welding torch frame 5564, respectively. 5564. In one embodiment, the welding torch 5502 is configured to pass through the opening 5572 of the welding torch body 5564. the torch 5502 is placed in the opening 5572 of the frame of the welding torch 5564.

[00618] In one embodiment, welding torch body portion 5584 5564 is configured to engage with welding torch portion 5586 5502 so as to prevent welding torch 5502 from rotating when welding torch 5502 is positioned in welding torch body opening 5572.

[00619] In one embodiment, the motor 5550 is configured to (e.g., mechanically coupled to) rotate the lead screw 5552. In one embodiment, the motor 5512 is configured to rotate both clockwise and counterclockwise, resulting in left or right movement of the welding torch 5502 is substantially parallel to the A-A axis (as illustrated in FIG. 8) of the tubes 1022a, 1022b . Embodiments of the invention, the motor 5550 is configured to be indirectly connected, for example, through a series of transmission mechanisms 5576, 5578 and 5580 to rotate the lead screw 5552. gear 5576, 5578, and 5558 engaged with output shaft 5582 of motor 5550. In one embodiment, gear 5576 is coupled to output shaft 5582 of motor 5550, gear 5580 is coupled to or secured to lead screw 5552, and gear 5576 and 5580 are connected to each other through a transmission mechanism 5578. By connecting the motor 5550 to the lead screw 5552 through the transmission mechanism 5576, 5578 and 5580, the lead screw 5552 is driven when the motor 5550 is operating. In another embodiment of the invention, the motor 5550 is configured with possibility of direct connection t. e. without gears) to rotate the 5552 lead screw.

[00620] In the bottom embodiment, the helical nut 5554 is interlocked with the welding torch frame portion 5564 such that the rotation of the helical nut 5554 along the lead screw 5552 is blocked. In other words, the helical nut 5554 is prevented from rotating along the lead screw 5552, therefore, the screw drive nut 5554 is lateral/movable (i.e., substantially parallel to the YY axial direction, as illustrated in FIG. 53) together with the lead screw 5552. In one embodiment, the nut The screw assembly 5554 is locked and housed in the opening 5568 of the welding torch frame 5564. In one embodiment, the lead screw 5552 is configured to pass through the opening of the locked screw assembly nut 5554.

[00621] In one embodiment of the invention, the tilt positioning system 5510 is configured to cause the welding torch 5502 to change its angle of inclination in the plane of travel to account for changes in the direction of welding relative to the direction of gravity. In one embodiment of the invention, the angle of the welding torch 5502 can be changed to compensate for the force of gravity. In one embodiment of the invention, the angle of the welding torch 5502 can be adjusted to compensate for orientation due to gravity. In one embodiment of the invention, the angular orientation of the welding torch 5502 is controlled based on the profile of the area of the contact surface. In one embodiment of the invention, the angle of the welding torch 5502 can be adjusted on the fly based on profile data. In one embodiment of the invention, the angle of the welding torch 5502 may be adjusted based on profile data on the fly to compensate for and/or correct for other welding conditions (i.e., not just gravity).

[00622] Since the welding torch may oscillate during the welding operation, the gravitational forces acting on the weld pool as the welding torch rotates around the stationary pipe can be taken into account. In a particular case, the angle of the welding torch may be changed by driving at least one welding torch motor (i.e., welding torch tilt motor 5588), depending on whether the welding torch is moving upward relative to gravity or downward relative to gravity. gravity. One or more motors (eg, welding torch tilt motor 5588) can also change the welding angle within the plane of rotation based on a specific location within the up or down movement of the welding torch. It should be understood that since the welding torch can oscillate in some embodiments of the invention, it is better that it be tilted to compensate for the force of gravity, and it is also necessary that it is not fixed, assuming that, for example, that it will only move downward in relation to the force of gravity. In some embodiments of the invention, as noted above, the present patent application suggests that welding can be performed by moving the welding torch up (against gravity) or down (against gravity). Additionally, the welding torch may oscillate depending on various positions when turning (for example, welding at 10 degrees from top dead center may theoretically differ slightly from the requirements when the weld is made at 90 degrees from top dead center due to (for example) gravitational forces acting on the weld pool, as well as the tendency of the weld pool to hold differently on the inner surface of the pipe at different positions on the pipe being welded).

[00623] In one embodiment, the motors 5030 and 5074 guiding the sensor 5056 also rotate the welding torch 5002 in a circumferential direction on the plane of rotation to create a weld along the contact surface area 5136. In one embodiment, the tilt position motor 5588 controls angular oscillation of the welding torch 5502, usually within the plane of rotation. In one embodiment of the invention, the angular orientation of the welding torch 5502 is controlled based on the position of the torch. In one embodiment of the invention, the welding torch 5502 is articulated along the weld along the plane of rotation.

[00624] In one embodiment, the welding torch 5502 is configured such that the welding torch 5502 can have a different angle of inclination for each 90° rotation. For example, in one embodiment of the invention, the welding torch 5502 may have an angle of 1 when performing a welding procedure within 1 sector from 2 hours to 5 hours, the welding torch 5502 may have an angle of 2 when performing a welding procedure within 2 sectors from 5 hours up to 8 hours, the 5502 welding torch can be tilted at 3 for welding procedure within 3 sectors from 8 o'clock to 11 o'clock, and the 5502 welding torch can be tilted at 4 when welding procedure is performed within 4 sectors from 11 o'clock to 2 o'clock . In one embodiment of the invention, the welding torch 5502 is configured such that the welding torch 5502 can have a different angle of inclination for each 30° rotation. In one embodiment of the invention, the welding torch 5502 is configured such that the welding torch 5502 can have a different angle of inclination for each 60° rotation. In one embodiment of the invention, the welding torch 5502 is configured such that the welding torch 5502 can have a different angle of inclination for each 120° rotation. In one embodiment of the invention, the welding torch 5502 is configured such that the welding torch 5502 can be tilted at any desired angle.

[00625] In one embodiment of the invention, the welding torch 5502 can be configured to have a constantly changing angle of inclination to compensate for or correct for a continuous change in the orientation of the welding torch relative to the direction of gravity. In one embodiment of the invention, the welding torch 5502 can be configured to translate the angle of the torch based on the position in which the welding torch is located (ie, the position of the welding torch along the circumferential seam).

[00626] FIG. 54 illustrates the welding heater 5502 in a normal, non-tilted position. In one embodiment of the invention, the tilt positioning system 5510 is configured to tilt the welding torch 5502 in the range of +/- 5°. For example, as shown in FIG. 55 and 56, the welding torch 5502 is moved by the tilt positioning system 5510 with an angular inclination in the range of +5° so that the welding torch 5502 is positioned at the correct/desired/preset distance from the pipe to be welded. As illustrated in FIG. 57 and 58, the welding torch 5502 is moved by the tilt positioning system 5510 at an angular inclination of -5°, respectively, so that the welding torch 5502 is positioned at the correct/desired/predetermined distance from the pipe being welded. In one embodiment of the invention, the tilt positioning system 5510 is configured to tilt the welding torch 5502 in the range of +/- 7°. In one embodiment of the invention, the tilt positioning system 5510 is configured to tilt the welding torch 5502 in a range of less than +/- 5°.

[00627] In one embodiment of the invention, the annular arc between the axial point P and the particle collision point PI (as illustrated in Figs. 56 and 58) of the research radiation with the area of the contact surface remains generally constant during the welding procedure. In one embodiment of the invention, one or more processors 5140 are aware of a constant arc distance between the center point P (e.g., of a welding tip) and the probe point PI, thus one or more processors 5140 are configured to control the oscillation and rotation of the welding torch 5502 by based on pre-weld profile inspection data.

[00628] This configuration of the welding torch 5502, which allows the welding torch 5502 to rotate about the axis of rotation P, allows the angle of the welding torch 5502 to change during welding without affecting the speed at which the welding torch 5502 moves. For example, this is especially useful for welding systems with multiple welding torches. In one embodiment of the invention, the change in the angles of the welding torches will not be performed at the same time, in which case it would be desirable that the change in the angle of the torch occurs without any negative effect on the welding torches.

[00629] In one embodiment, the tilt positioning system 5510 includes a welding torch tilt motor 5588, guide rails 5544, guide rollers 5546. welding torch 5502. In the illustrated embodiment of the invention, the guide rollers 5546 may include two upper and two lower guide rollers. In one embodiment, the tilt positioning system 5510 includes one guide rail 5544 and four guide rollers 5546 located at opposite ends of the welding torch assembly 5500.

[00630] In one embodiment, the track rollers 5546 are built and mounted to couple to their respective vertical alignment members 5538. In one embodiment, each vertical alignment member 5526 is configured to couple to a respective guide rail 5544 using any suitable fastening mechanism (for example, fasteners 5548). This configuration allows each vertical positioning element 5526 to be connected to the corresponding vertical positioning element 5538 by engagement with the corresponding guide rail 5544 and guide rollers 5546.

[00631]In one embodiment, the motor 5588 is configured to (e.g., mechanically coupled to) rotate the transmission mechanism 5590. In one embodiment, the motor 5588 is configured to rotate both clockwise and counterclockwise, so as to cause tilt welding torch 5502 forward or backward.. In one embodiment of the invention, the motor 5588 is configured to be connected, for example, through a transmission mechanism 5590, with a guide rod 5544. In other words, the motor 5588 includes an output shaft 5592, and the transmission mechanism 5590 is connected to the output shaft 5592 of the motor 5588. Due to the connection motor 5588 with guide rail 5544 through the transmission mechanism 5590, the guide rail 5544 moves when the motor 5588 is running.

[00632] In one embodiment, the guide rail 5544 is configured to guide the top and bottom track rollers 5546. the ability to cause movement of the vertical positioning elements 5538 (connected to them), thus allowing the welding torch 5502 to change its angle of inclination in the plane of movement.

[00633] In one embodiment, two opposing vertical positioners 5538 are connected to each other by an upper positioner 5540 such that movement of one of the vertical positioners 5538 (i.e., caused by motor 5588) results in similar movement of the other element vertical positioning element 5538. The configuration of two horizontal guide rods 5556 and 5558, connected to the upper positioning element 5540 at their two ends, also helps to convert movement from one vertical positioning element 5538 to another.

[00634] The operation of the radial positioning system 5506 is described in more detail below. When the lead screw 5514 is turned by the motor 5512, the screw drive nut 5516 runs along the thread. In one embodiment of the invention, the direction of movement of the screw drive nut 5516 depends on the direction of rotation of the lead screw 5514 by the motor 5512.

[00635] Since the screw drive nut 5516 is locked in the hole 5536 of the radial positioning transverse member 5524, the radial positioning transverse member 5524 is configured to move/move the lead screw 5514 along the screw drive nut 5516. The movable engagement between the radial positioning transverse member 5524 and the front vertical guide rods 5518 and 5520 also contribute to such (up and down) movement/movement of the transverse radial positioning member 5524.

[00636] In addition, since the lateral positioning element 5524 is connected to the two vertical positioning elements 5526, moving (up or down) the lateral positioning element 5524 causes the two vertical positioning elements 5526 to move (up or down).

[00637] The two vertical positioning elements 5526 are also connected to the two rear radial positioning elements 5604 and 5606. Movement (up or down) of the two vertical positioning elements 5526 causes the two rear radial positioning elements 5604 and 5606 to move (up or down) by rear vertical guide rods 5600 and 5602. The movable engagement between the rear radial positioning elements 5604 and 5606 and the rear vertical guide rods 5600 and 5602 also facilitates such movement/movement (up and down) of the two vertical radial positioning elements 5526.

[00638] As mentioned above, each vertical positioning element 5526 is connected to the corresponding vertical positioning element 5538 by engagement with the corresponding guide rail 5544 and guide rollers 5546. Thus, movement (up or down) of each vertical positioning element 5526 also results in movement (up or down) of its respective vertical positioner 5538. Since the two vertical positioners 5538 are rigidly connected to the upper positioner 5540, movement (up or down) of the two vertical positioners 5538 results in movement (up or down) of the upper positioner 5540.

[00639] Since the welding torch 5502 is connected to the upper positioning element 5540 via the horizontal lead screw 5552, the two horizontal guide rods 5556 and 5558, and the welding torch frame 5564, movement (up or down) of the upper positioning element 5540 results in movement (up or down ) of the welding torch 5502. Thus, the welding torch 5502 is set to be moved by the radial positioning system 5506 such that the welding tip 5503 is movable towards and away from the welding surface of the pipes 1022a, 1022b.

[00640] The operation of the axis positioning system 5508 is described in more detail below. When the lead screw 5552 is turned by the motor 5550 through the transmission mechanism 5576, 5578 and 5580, the screw drive nut 5554 runs along the threads. In one embodiment of the invention, the direction of movement of the screw drive nut 5554 depends on the direction of rotation of the lead screw 5552 by the motor 5550.

[00641] Because the screw drive nut 5554 is locked in the bore 5568 of the welding gun body 5564, the welding gun body 5564 is movable/movable (transversely) along the screw drive nut 5554. Movable engagement between the welding gun body 5564 and the horizontal guide bars 5556 and 5558 also facilitates such movement/movement (up or down) of the welding torch frame 5564. The movable engagement between the two horizontal guide rods 5556 and 5558 and the welding torch frame 5564 also facilitates such movement/movement (up or down) of the welding torch frame 5564 ( and welding torch 5502). In one embodiment of the invention, the amount of axial movement of the welding torch frame 5564 is limited by an elongated hole 5594 in the upper positioning element 5540.

[00642] The operation of the tilt positioning system 5510 is described in more detail below. When the transmission mechanism 5590 is rotated by the motor 5588, the guide rail 5544 moves along the teeth. In one embodiment of the invention, the direction of movement of the guide rail 5544 depends on the direction of rotation of the transmission mechanism 5590 by the motor 5588.

[00643] In one embodiment, the top and bottom guide rollers 5546 urged by the guide rail 5544 are configured to drive/tilt respective vertical positioning members 5538 (connected to the guide rollers 5546).

[00644] In one embodiment of the invention, the configuration of two opposite vertical positioning elements 5538, connected to each other through the upper positioning element 5540, thus allows one of the vertical positioning elements 5538 to move (i.e., caused by the motor 5588), such that results in similar movement of the other vertical positioner 5538. The configuration of two horizontal guide rods 5556 and 5558 connected to the upper positioner 5540 at their two ends also facilitates translation of movement from one vertical positioner 5538 to the other.

[00645] When the vertical positioning elements 5538 and the upper positioning element 5540 move/tilt (along the two horizontal guide bars 5556 and 5558), this movement allows the welding torch 5502 (connected to the two horizontal guide bars 5556 and 5558 via the welding torch frame 5564) change the angle of inclination of the welding torch 5502 in the plane of movement.

[00646] As mentioned above, the welding torch is set to move such that when it is moved by the welding torch tilt motor 5588, it rotates around a point that is at or slightly in front of the welding torch tip. For example, the tip of a welding torch may oscillate around sitting in the weld pool created during welding. As a result, the position of the weld pool does not change with respect to the radius drawn to the weld pool, despite the fact that the welding torch may oscillate due to the welding torch tilt motor. Thus, the length of the arc between the weld pool and the point at which the emitted research beam from the test laser hits the inner surface of the pipes to be welded (for example, the area of the contact surface) remains constant, since the orientation motors rotate the welding torch and the test laser, despite to the oscillation of the welding torch by the welding torch tilt motor. And since the speed and orientation control motors are controlled and known to one or more processors, one or more processors can control the welding parameters in a certain area of the contact surface area, knowing the fixed arc length and based on the processor's calculation of the detected weld profile in the approaching area in front of the welding tip. . In one embodiment of the invention, attitude motors are provided with angle encoders operatively coupled to one or more processors, allowing one or more processors to determine the angular position of the motors and thus the positions of the clamps and tubes. In another embodiment of the invention, signals from a measuring sensor (for example, a test laser) used to determine the movement of pipes to be welded, taking into account the use of signals by one or more processors and knowing a fixed arc length, are used to control the torch at the desired location corresponding to a certain position of the welding burners. In another embodiment of the invention, the point for oscillation of the welding torch does not have to be in a position in front of or at the welding tip, and the length of the arc between the weld pool and the point where the laser radiation hits the area of the contact surface does not have to remain constant. Instead, one or more processors, having received information about the positioning of the welding torch tip from one or more welding torch motors and / or a measuring sensor, uses it to calculate the current position of the welding tip in relation to the pipe in real time ("on the fly") for controlling one or more welding torch motors; and setting the welding torch tip to a predetermined position based on the profile data received from the measurement sensor.

[00647] As mentioned above, the welding torch is movable or driven by one or more motors, typically in a radial direction, along the longitudinal axis of the welding torch tip, both towards and away from the inner surface of the pipe to be welded. It should be understood that since the longitudinal axis of the welding torch (for example, through the tip of the welding torch) may not coincide with the radius of the pipe to be welded (taken along the central axis) or the radius of the rotary center hub, given the fact that the welding torch is usually directed at an angle to the forward direction of the weld (and rotated by the tilt motor of the 5588 welding torch, when it comes to “radial” movement of the welding torch and its tip towards and away from the inner surface of the pipe (for example, the area of the contact surface), such a radial movement is used in the context described above). For example, such radial movement of the welding torch can be considered with reference to the longitudinal movement of the welding torch along the axis of the welding torch tip. Since the welding torch is set to be moved by at least one welding torch motor, and in particular the 5512 radial welding torch motor, allowing the torch tip to move towards and away from the weld face, the welding tip can also be moved away from the contact surface area after each weld pass for deposition of welded material. After the first second pipe engagement device is fixed to the pipes, the welding torch can be used to make a full pass in welding the root of the weld, the "root" of the weld being the first weld to be applied between the ends of the pipe (e.g. one 360 degree weld ). After making a root pass, the welding tip can be slightly moved (retracted) away from the inner surface of the pipes (and in particular from the weld material applied by the root weld) so that the second weld pass is also called "hot" weld pass can be performed with a welding tip at a certain distance from the pass material when welding the root of the weld.

[00648] In one embodiment, one or more processors 5140 control motors 5030 and 5074 and one or more welding torches 5502 to generate a completed circumferential weld along the contact surface region 5136 by rotating one or more welding torches 5502 along the contact surface region 5502 in one direction of rotation until a complete girth weld is made.

[00649] In one embodiment, one or more welding torches 5502 comprise a plurality of welding torches. In one embodiment of the invention, at least one of the plurality of welding torches performs a weld in an upward direction of rotation, while at least one of the plurality of welding torches performs a weld in a downward direction of rotation.

[00650] In one embodiment, the welding tip is configured to be a weld direction indicator. In one embodiment of the invention, the welding torch always points in the direction of travel. In other words, the welding tip generally points in the direction of travel. In one embodiment of the invention, the welding torch angle is slightly larger when the welding torch 5502 is performing a procedure while ascending (when the welding torch 5502 is welding in an upward direction of rotation), and the welding torch is slightly less inclined when a welding procedure is being performed on a downhill (when the welding torch 5502 welds with downward rotation).

[00651] In one embodiment of the invention, the internal welding system is configured to perform a downhill welding procedure (i.e., weld in a downward direction of rotation) using a short arc welding procedure.

[00652] In one embodiment of the invention, when the internal welding system is configured to perform the welding procedure in an upward direction (i.e., to weld in an upward direction of rotation), the productivity and quality of the weld can be improved. In one embodiment of the invention, the uphill welding procedure is configured to provide the option to weld both sides of the pipe at the same time, instead of the downhill welding procedure being performed on each side in sequence. For example, this can be done with multiple welding torches and have multiple overlap welds. Alternatively, welding 360° in one continuous pass can be an option to produce a weld with only one overlap. In one embodiment of the invention, customer requirements and pipe size may dictate which approach will be used.

[00653] In one embodiment of the invention, in the case where quality requirements do not dictate the presence of only one overlap of the weld, the weld can be performed by multiple welding torches installed inside the pipe. In one embodiment, the internal welding system 5004 may comprise four welding torches, six welding torches, or eight welding torches, with half of these welding torches welding down and the other half of those welding torches welding up. In one embodiment of the invention, half of these welding torches are configured to perform a clockwise welding procedure and the other half of these welding torches are configured to perform a counterclockwise welding procedure. In one embodiment of the invention, the four welding torches of the internal welding system 5004 may be spaced 90° apart and configured to rotate each torch 90°. In one embodiment, the six welding torches of the internal welding system 5004 may be spaced 60° apart and configured to rotate each torch 60°. In one embodiment of the invention, the eight welding torches of the internal welding system 5004 may be spaced 45° apart and each rotatable by 45°. In one embodiment of the invention, the internal welding system 5004 may include two welding torches spaced 180° apart and configured to rotate each torch 180°. In one embodiment of the invention, the internal welding system 5004 may include a single welding torch that is rotatable through 360°.

[00654] The ability to weld in an upward direction as well as in a downward direction can increase the speed of the welding operation (time to complete the weld) as well as improve the quality of the weld (taking into account the influence of gravity forces at different positions). In addition, if a plurality of welding torches are represented, welding is performed in both up and down directions at the same time (for example, a plurality of circumferentially distributed welding torches moving in the same direction while depositing weld metal), wherein at least one welding torch moves up while at least one more moves down. This is faster, for example, compared to sequential down welding on each side of the pipe. Alternatively, in one embodiment of the invention, a separate welding torch is used to make a 360 degree weld providing a continuous weld without overlapping weld areas. This overlap occurs when more than one welding torch is used and the end of each piece of weld from the lag welding torch must join and slightly overlap the start of the next piece of weld deposited by the welding torch in front of the lag welding torch. As a result, for some applications where it may be desirable to avoid weld overlap (which makes the weld pass less uniform at the overlap points), it is effective to use a continuous 360 degree internal weld.

[00655] In one embodiment of the invention, all welding torches indicate the direction of the weld forward. In other words, they point slightly in the direction of the weld, so that the tip of the welding torch is "pushing" the weld rather than pulling it along. This is true whether the welding torch is placed inside, as in some embodiments of the invention, or outside, as in other embodiments of the invention described herein. This is illustrated with respect to the internal welder as illustrated in FIG. 56A. In one embodiment of the invention, the tip of the welding torch is directed at an angle Ѳ (for example, "lead") in the range from 3 degrees to 7 degrees. The lead Ѳ is defined as the angle measured between the line (radius) R from the axial center of the pipes to be welded to the tip of the welding torch (or weld pool) as illustrated in FIG. 56A (line R can also be considered as a radius taken from the axial center of the pivot hub 5078 to the torch tip or weld pool), and a line through longitudinal axis A of the welding torch tip. As illustrated in FIG. 56A, the welding torch moves in a counter-clockwise direction as illustrated by arrow D. The lead t can be changed by operating the welding torch tilt motor 5588 as the welding torch is moved by the motor to orient in a circle around the inner surface of the pipes. The angle Ѳ is expected to be slightly larger (eg 6 degrees) when the welding torch moves up and slightly smaller (eg 4 degrees) when it moves down. Additionally, in one embodiment of the invention, the lead Ѳ can change continuously throughout the entire path of a certain welding torch. In another embodiment of the invention, the pipe can be divided into sectors, while the welding angle t varies depending on the sector. For example, when considering a full 360-degree movement or movement corresponding to the hour hand on a clock, the pipe can be divided into sectors: 2-5, 5-8, 8-11, 11-2. One or more engines may be controlled by one or more processors to change sector boundaries.

[00656] As will be understood from FIG. 56A, welding is performed in the counterclockwise direction in the illustrated image. For welding in the clockwise direction, one or more 5140 processors send a signal to one or more torch motors so that the 5590 gear mechanism rotates and the 5502 welding torch rotates (for example, around point P) so that the axis through the torch (line A) moves in the opposite direction from the radial line R. For this reason, the angle θ will be negative when welding clockwise. This allows the welding torch to point forward ("push" the weld pool), when welding in the clockwise direction.

[00657] In one embodiment of the invention, as illustrated in FIG. 60A-63, internal welding system 5004 may include a welding torch WT, chamber C, and two measurement sensors L ₁ and L ₂ . In one embodiment of the invention, the welding torch WT and chamber C are separated by 180°. In one embodiment of the invention, the angle between the chamber and the welding torch WT may vary.

[00658] In one embodiment of the invention, one or two measurement sensors L ₁ and L ₂ may be guiding measurement sensors that are configured to guide the welding torch WT during a welding procedure, as well as provide data prior to welding. In one embodiment of the invention, one or two measurement sensors L ₁ and L ₂ may be towing measurement sensors, which are configured to tow the welding torch WT during the welding procedure, as well as provide data after welding.

[00659] In one embodiment of the invention, the measurement sensor L ₁ and the welding torch WT are separated by an angle of 20°. In one embodiment of the invention, the measuring sensor L ₂ and the welding torch WT are separated by an angle of 20°. In one embodiment of the invention, the angle between the measurement sensor L ₂ and the welding torch WT, and the angle between the measurement sensor L ₁ and the welding torch WT may vary.

[00660] In one embodiment of the invention, the angle between the measurement sensor L ₂ and the welding torch WT, and the angle between the measurement sensor L ₁ and the welding torch WT can be adjusted. For example, in one embodiment of the invention, when L ₁ is a directional measurement probe, then the angle between the measurement probe L ₁ and the welding torch WT is 20° or less, and the angle between the towing measurement probe L ₂ and the welding torch WT is greater than 20°. In one embodiment of the invention, when L ₂ is a directional gauge, then the angle between the L ₂ gauge and the welding torch WT is 20° or less, and the angle between the towing gauge L ₁ and the welding torch WT is greater than 20°.

[00661] In one embodiment of the invention, as illustrated in FIG. 60A, the measuring sensor L ₁ is located in the initial position. In one embodiment of the invention, as illustrated in FIG. 60B, the welding torch WT starts the welding procedure when the welding torch WT is positioned at the Start point _WT. In one embodiment of the invention, the welding torch WT is movable in a clockwise direction (as indicated by arrow T ₁ ) during a welding procedure. In one embodiment of the invention, as illustrated in FIG. 61, the WT welding torch ends the welding procedure when the WT welding torch reaches the Stop _{WT point.} In one embodiment of the invention, the weld bead WB ₁ is formed by the welding torch WT as it moves from the Start point _WT to the Stop point _WT in the clockwise direction indicated by the arrow T ₁ . In one embodiment of the invention, as illustrated in FIG. 60B and 61, the burner WT follows the sensor L ₁ while moving from the Start point _WT to the Stop point _WT in the clockwise direction indicated by the arrow T ₁ . After the welding procedure, the welding torch WT is moved in a counter-clockwise direction (that is, in the opposite direction of the arrow T ₁ ) so that the measuring probe L ₂ is positioned back to its initial position, the Start point _WT .

[00662] In one embodiment of the invention, as illustrated in FIG. 62, the welding torch WT starts the welding procedure when the welding torch WT is positioned at the Start point _WT. In one embodiment of the invention, the welding torch WT is movable in a counter-clockwise direction (as indicated by arrow T ₂ ) during a welding procedure. In one embodiment of the invention, as illustrated in FIG. 63, the WT welding torch ends the welding procedure when the WT welding torch reaches the Stop _{WT point.} In one embodiment of the invention, the weld bead WB ₂ is formed by the welding torch WT as it moves from the Start _WT to the Stop _WT in the counterclockwise direction indicated by arrow T2. In one embodiment of the invention, as illustrated in FIG. 62-63, the burner WT follows the sensor L ₂ while moving from the Start _WT to the Stop _WT in the counterclockwise direction indicated by the arrow T ₂ . After the welding procedure, the welding torch WT is moved in a clockwise direction (that is, in the opposite direction of the arrow T ₂ ) so that the laser L ₁ is positioned back to its initial position, the Start point _WT .

[00663] In one embodiment of the invention, as illustrated in FIG. 64-69, internal welding system 5004 may include a welding torch WT ₁ and WT ₂ , a chamber C, and one measurement sensor L. In one embodiment, the measurement sensor L and welding torch WT ₁ are separated by a 20° angle. In one embodiment of the invention, the measuring sensor L and the welding torch WT ₂ are separated by an angle of 20°. In one embodiment of the invention, the measurement sensor L and chamber C are separated by 180°.

[00664] In one embodiment of the invention, as illustrated in FIG. 64, the measurement sensor L is located at the home position. In one embodiment of the invention, as illustrated in FIG. 65, the welding torch WT ₁ starts the welding procedure when the welding torch WT ₁ is positioned at the Start point _WT1. In one embodiment of the invention, the welding torch WT ₁ is movable in a counterclockwise direction (as indicated by the arrow T ₁ ) during the welding procedure. In one embodiment of the invention, as illustrated in FIG. 66, the welding torch WT ₁ ends the welding procedure when the welding torch WT ₁ reaches the stop point _WT1 . In one embodiment of the invention, as illustrated in FIG. 66, the weld bead WB _WT1 is formed by the welding torch WT ₁ when moving from the Start point _WT1 to the Stop point _WT1 in the counterclockwise direction indicated by the arrow T ₁ . In one embodiment of the invention, as illustrated in FIG. 64-66, the burner WT ₁ follows the measuring probe L during its movement from the Start point _WT1 to the Stop point _WT1 in the counterclockwise direction indicated by the arrow T ₁ . After the welding procedure, the welding torch WT ₁ is moved in a counterclockwise direction (i.e., opposite to the direction of the arrow T ₁ ) so that the measuring sensor L is positioned back to the initial position illustrated in FIG. 67.

[00665] In one embodiment of the invention, as illustrated in FIG. 68, the welding torch WT ₂ starts the welding procedure when the welding torch WT ₂ is positioned at the Start point _WT2 . In one embodiment of the invention, the welding torch WT ₂ is movable in a counter-clockwise direction (as indicated by the arrow T ₂ ) during the welding procedure. In one embodiment of the invention, as illustrated in FIG. 69, the welding torch WT ₂ ends the welding procedure when the welding torch WT ₂ reaches the stop point _WT2 . In one embodiment of the invention, the weld bead WB _WT2 is formed by the welding torch WT ₂ when moving from the Start point _WT2 to the Stop point _WT2 in the counterclockwise direction indicated by the arrow T2, as illustrated in FIG. 69. In one embodiment of the invention, as illustrated in FIG. 68-69, the burner WT ₂ follows the measuring sensor L during its movement from the Start point _WT2 to the Stop point _WT2 in the counter-clockwise direction indicated by the arrow T ₂ . After the welding procedure, the welding torch WT ₂ is moved in a counterclockwise direction (i.e., opposite to the direction of the arrow T ₂ ) so that the measuring sensor L is positioned back to the initial position illustrated in FIG. 64 and 67.

[00666] In one embodiment, the internal welding system 5004 may include one welding torch and one measurement sensor. In one embodiment of the invention, the angle between the measuring sensor and the welding torch may be 20° or less. In one embodiment of the invention, the sensor and the welding torch are separated by an arc length AL (as illustrated in FIG. 64) of 3 inches. In one embodiment of the invention, the measuring probe and the welding torch are separated by an arc length AL of 4 inches. In one embodiment of the invention, the angle between the measuring sensor and the welding torch may be 19°. In one embodiment of the invention, the angle between the measuring sensor and the welding torch may be 16°. In one embodiment of the invention, the angle between the measuring sensor and the welding torch may be 14°. In one embodiment of the invention, the angle between the measuring sensor and the welding torch may be 12°.

[00667] FIG. 70 illustrates a schematic diagram depicting the flow of compressed air through the internal welding system 5004, with some components of the internal welding system 5004 not illustrated for clarity, and to better illustrate other components and/or characteristic properties of the internal welding system 5004.

[00668] As illustrated in FIG. 70, air bottle 5128, brake cylinder 5133, drive wheel cylinder 5137, brake valve 5190, and drive wheel valve 5192 are illustrated in the drive section 5010 of the 5004 internal welding system. the front clamp 5142 is illustrated in the center section 5008 of the internal welding system 5004. The front rotating sleeve 5032 and the front clamp control valve 5018 are illustrated in the frontmost section 5006 of the internal welding system 5004.

[00669] In one embodiment of the invention, the compressed air cylinder 5128 has two separate communication channels connected through a valve 5113. 5133 Brake Cylinder), 5192 Drive Wheel Valve (and 5137 Drive Belt Cylinder), 5062 Rear Clutch Control Valve (and 5144 Rear Clutch), 5072 Rear Rotary Clutch, 5032 Front Rotary Clutch, 5018 Front Clutch Control Valve (and 5142 Front Clutch) , and compressor 5029.

[00670] Compressed air stored in compressed air cylinder 5128 is directed through the fluid passage to valve 5194. Some of the compressed air received by valve 5194 is directed to brake valve 5190, and the remainder of compressed air received by valve 5194 is directed to valve 5196. Valve brake cylinder 5190 is fluidly connected via channels 5198 and 5199 to brake cylinder 5133. In one embodiment, brake valve 5190 is configured to supply compressed air to activate brake cylinder 5133 when it receives a signal from drive section electronics module 5118. Compressed air actuates the brake cylinder 5133, which through its operation applies a braking force to the drive rollers 5122. In one embodiment of the invention, the brake cylinder 5133 and the brake valve 5190 can be called a brake system, configured to fix the frame of the internal welding system 5004 in a given position inside the tru b 1022a, 1022b from moving. In one embodiment of the invention, a brake system configured to lock the frame of the internal welding system 5004 in a predetermined position within the pipes 1022a, 1022b from movement may include a wheel/roller lock. In one embodiment, the wheel/roller lock is configured to prevent one or more rollers 5122 from moving to secure the frame of the internal welding system 5004. In one embodiment, the brake system also includes a motor lock. In one embodiment, the motor lock is configured to prevent rotation of the drive motors 5124 that drive the rollers 5122 to move the frame of the internal welding system 5004.

[00671] A portion of the compressed air received by valve 5196 is directed to drive wheel valve 5192, and the remainder of compressed air received by valve 5196 is directed to valve 5198. Drive wheel valve 5192 is fluidly connected via channels 5200 and 5201 to the drive wheel cylinder 5137. In one embodiment, the drive wheel valve 5192 is configured to supply compressed air to activate the brake cylinder 5137 when it receives a signal from the drive section electronics module 5118. The compressed air actuates the drive wheel cylinder 5137, which through its operation applies braking force to the drive rollers 5122. In one embodiment, the drive wheel cylinder 5137 may be operatively coupled to a shaft containing the drive rollers 5122. In one embodiment, the drive wheel cylinder 5137 may be operatively coupled to the shaft by one or more transmission mechanism.

[00672] In one embodiment, both the drive wheel cylinder 5137 and the brake cylinder 5133 are compressed during installation of the internal welding system 5004 into the pipes. In one embodiment of the invention, the drive wheel cylinder 5137 is compressed only when the internal welding system 5004 is removed from the pipes. In one embodiment of the invention, the drive wheel cylinder 5137 is expanded to accelerate or decelerate (move) the internal welding system 5004 in pipes.

[00673] A portion of the compressed air received by valve 5198 is directed to the rear rotating sleeve 5072, and the remainder of the compressed air received by valve 5198 is directed to the rear clamp control valve 5062. The rear clamp control valve 5062 is connected by a fluid transmission channel through channels 5202 and 5203 with rear jaw 5144. In one embodiment, fluid passage 5202 is used to expand clamps 5144 and fluid passage 5203 is used to retract clamps 5144. In one embodiment, back clamp control valve 5062 is configured to supply compressed air to actuate and operate the 5144 rear clamp when it receives signals from the 5064 center section electronics module.

[00674] The compressed air output through the rear rotary sleeve 5072 is directed to the front rotary sleeve 5032. The compressed air output through the front rotary sleeve 5032 is directed to the valve 5204. A portion of the compressed air received by valve 5204 is directed to the front clamp control valve 5018 , and the remainder of the compressed air received by the valve 5204 is directed to the compressor 5029. In one embodiment of the invention, the compressor 5029 is configured to replenish the system (for example, filling a cylinder with compressed air) using the received compressed air.

[00675] The front jaw control valve 5018 is fluidly connected via ports 5206 and 5207 to the front jaw 5142. back of the front jaw 5142. In one embodiment, the front jaw control valve 5018 is configured to supply compressed air to actuate and operate the front jaw 5142 when it receives signals from the forwardmost electronics module 5014.

[00676] FIG. 71 illustrates a schematic diagram showing the flow of electrical power supply, including welding power, communication data, and control data through the internal welding system 5004, with some components of the internal welding system 5004 not illustrated for clarity and to better illustrate other components and/or characteristic properties of the internal welding system 5004.

[00677] As illustrated in FIG. 71, rearmost electronic module 5014, front rotation motor 5030, forward position sensor 5022, front clamp control valve 5018, front slip ring 5016, wire feed electronic module 5046 of the wire feed unit 5020, wire feed system 5044 and shield gas control valve 5042 are illustrated in the rearmost section 5006 of the internal welding system 5004. Swivel hub 5078, welding torches 5502, measurement sensors 5056, control chamber 5112, front clamp 5142 and rear clamp 5144, rear slip ring 5080, center section electronic module 5064, rear position sensor 5076, 5062 rear clamp control valve and 5074 rear rotation motor are illustrated in center section 5008 of 5004 internal welding system. .

[00678] In one embodiment, welding power is supplied to the internal welding system 5004 via a tether 5034. In one embodiment, welding power is supplied via a tether 5034 to the welding torches 5502 via a front slip ring 5016.

[00679] In one embodiment, the batteries 5116 of the drive section 5010 are configured to supply power to all electronic modules of the internal welding system 5004, including the rearmost electronic module 5014, the wire feed electronic module 5046, the center section electronic module 5064, and the drive section electronic module 5118. In one embodiment, the batteries 5116 of the drive section 5010 are configured to supply power to all electric drive motors of the internal welding system 5004, including the forward rotation motor 5030, the wire feed systems motors 5044, the rear rotation motor 5074, the drive motors 5124, the axial motor 5550 welding torch motor, 5512 radial welding torch motor and 5588 welding torch tilt motor.

[00680] In one embodiment, battery power 5116 is directly supplied to rear slip ring 5080, center section electronics 5064, and drive section electronics 5118. In one embodiment, battery power 5116 is supplied to front slip ring 5016 via rear slip ring 5080. In other words, battery power 5116 is transmitted from rear slip ring 5080 to front slip ring 5016. wire 5046.

[00681] In one embodiment, battery power 5116 is provided from the rearmost electronics module 5014 to the forward rotation motor 5030, and from the wire feed electronics 5046 to the motors of the wire feed systems 5044. In one embodiment, battery power 5116 is supplied from the center section electronics module 5064 to the rear rotation motor 5074. In one embodiment, battery power 5116 is supplied from the drive section electronics module 5118 to the drive motors 5124. In one embodiment, battery power 5116 is supplied from the electronic supply module wire 5046 to the 5550 axial gun motor, 5512 radial gun motor and 5588 gun tilt motor.

[00682] In one embodiment of the invention, the batteries 5116 are also configured to supply power to the control chamber 5112 and measurement sensor 5056. For example, battery power 5116 is supplied from the electronic wire feed module 5046 to the control chamber 5112 and measurement sensor 5056.

[00683] In one embodiment, the batteries 5116 are also configured to supply power to the forward position sensor 5022 and the rear position sensor 5076. section 5064 to rear position sensor 5076.

[00684] In one embodiment, the batteries 5116 are also configured to power the front clamp control valve 5018, the shield gas control valve 5042, the rear clamp control valve 5062, the brake valve 5190, and the drive wheel valve 5192. For example, power from the batteries 5116 from the 5014 rearmost electronics to the 5018 front clamp control valve, from the 5046 wire feed electronics to the 5042 shield gas control valve, from the 5064 center section electronics to the 5062 rear clamp control valve, and from the 5118 electronics to the 5190 brake valve, and drive wheel valve 5192.

[00685] In one embodiment, the internal welding system 5004 is configured to receive and transmit communication signals via a tether 5034 to an external computer system (eg, having one or more processors). In one embodiment of the invention, received communication signals may travel from the halyard 5034 to the rearmost electronics module 5014, then to the wire feed electronics module 5046 via the front slip ring 5016, then to the center section electronics module 5064 via the rear slip ring 5080, and then to drive section electronics module 5118.

[00686] In one embodiment of the invention, the communication signal may travel (in the opposite direction of the received signal) from the drive section electronics module 5118, then to the center section electronics module 5064, then to the wire feed electronics module 5046 via the rear slip ring 5080, then, to the rearmost electronics module 5014 via the front slip ring 5016, and to the file (and an external computer system having one or more processors).

[00687] In one or more embodiments of the invention described herein, and as is clear from FIG. 71, one or more processors 5140 operatively coupled to a measurement sensor 5056, such as a measurement laser (or optionally a plurality of measurement sensors 5056 if more than one sensor is provided) via a wired communication channel or channels 5056a that transmit signals from the measurement laser. 5056 to one or more processors 5140. The wired communication path has (i) a movable portion 5056b that moves with the measurement probe 5056 when the measurement laser directs the probe beam along the contact surface region, and (ii) a stationary portion 5056c that remains stationary. during the movement of the moving part 5056b. The system further comprises the previously described front slip ring 5016 (which, on the one hand, is considered part of the wired communication channel), which provides an interface between the moving part section 5056b and the fixed part section 5056c of the communication channel, allowing signals to pass from the moving part 5056b to the fixed part 5056c .

[00688] It should be understood that the wired communication channel or channels 5056a (including its movable and fixed parts) are also capable of (or, alternatively, configured if a wireless communication channel for measurement sensors 5056 is provided, designed to to communicate with one or more processors) transmit power to the 5056 measurement sensors via the 5016 slip ring.

[00689] 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 bearings 5016k between them. The stator 5016a is rigidly attached to the central frame 5068 (see FIGS. 23 and 24), while the rotor 5016b is connected to the pivot hub 5078 on its central axis (eg, see FIG. 24). The rotor 5016b rotates with the pivot hub 5078 when the hub is rotated. The stator 5016a is connected to the fixed wireline portion 5056c, and the rotor 5016b is connected to the movable wireline portion 5056b, as illustrated in FIG. 26. As seen in FIG. 26, the rotor 5016b of the front slip ring 5016 has a hollow cylindrical configuration with a central passage 5016d through it. Passage 5016d allows other ducts or lines to pass through, such as, for example, pneumatic ducts from the front rotating sleeve (eg, an external compressed air duct that will be connected to compressed air bottle 5128).

[00690] It is understood that the wired connection between the measurement sensor 5056 and one or more processors 5140, in some embodiments of the invention, may pass through other components. For example, as shown in FIG. 71, the communication path from the 5056 gauge may pass through the 5046 wire feed electronics before entering the 5016 slip ring.

[00691] The slip ring 5016 allows the movable communication path portion 5056b to move with the pivot hub 5078 as the hub 5078 rotates during the scanning operation of the sensing probe 5056, during the pre-weld scan of the area of the contact surface between pipes before welding, and also during scanning "on the fly" of the area of the contact surface between the pipes during the welding operation.

[00692] It should also be understood that the slip ring 5016 is further configured to connect a communication connection between one or more processors 5140 and the control camera 5112, as well as provide power to the control camera 5112. This is done through the same communication channel or channels 5056a . One or more processors 5140 are configured to receive control camera data from control camera 5112 before, after, or during a welding operation. The moving part 5056b moves with the camera (and the pivot hub 5078) when the camera scans the area of the contact surface, and the fixed part 5056c remains fixed during the movement of the moving part 5056b, which is connected to the camera 5112.

[00693] Additionally, it should be understood that the same slip ring 5016 (and/or slip ring 5080) is configured to transmit electrical power to other components that rotate with the rotary sleeve 5078. For example, as illustrated in FIG. 35B, welding power channels 5502k for supplying welding power to welding torches 5502, power and command channels 5550k for controlling and supplying power to one or more welding torch motors 5550, 5512, 5588 that control the operation of the welding torch - all of these channels are configured to pass through through slip ring 5016. For example, for illustrative purposes, in FIG. 26 and 35B, the fixed portion of the hardware power path for the welding power path 5502k is designated 5112c, and the movable portion of the power path for welding is designated 5112b. It should be understood that, alternatively, they may be represented by illustrating additional channels in the same slip ring 5016, or illustrated with respect to a separate slip ring.

[00694] Similarly, a 5550k hardware data link can be provided via a slip ring 5016 to transmit commands (and control) as well as power to the 5550, 5512, 5588 welding torch motors. channel 5550k is illustrated in FIG. 35B but not illustrated in FIG. 26. It should be understood that this FIG. 26 and also Fig. 71 are used to illustrate how the 5016 slip ring (or other slip ring) can be used to transfer power and communication data to the 5502 welding torches, as the welding torches rotate with the 5078 rotary hub, effectively receiving power and control commands to create weld during the welding operation.

[00695] As illustrated in FIG. 35B (and several other figures), the pivot hub 5078 typically has a hollow cylindrical portion 5078a. The middle of the cylindrical portion, in a region that is generally axially aligned with the welding torch, lasers, and camera, has a plurality of holes or slots 5078b extending through it. Openings 5078b allow movable power and data paths from slip ring 5016 (and optionally from slip ring 5080) to extend radially outward from inside 5078c of pivot hub 5078 to outside of hub 5078 for connection between welding torches, lasers, and camera .

[00696] It should be understood that although the pivot hub 5078 is illustrated and described herein as having a cylindrical configuration, the hub may have a variety of shapes. The swivel hub can be of any tubular shape (just for example, with a rectangular or triangular section). Additionally, the swivel hub may also be referred to interchangeably as a 'swivel frame'.

[00697] As illustrated and described above, the measurement sensor 5056 is mounted on the outer part of the cylindrical hub, while the cylindrical hub has opposite ends and radial holes 5078b between the ends. The movable portion 5056b of the power and communication channels extends from the front slip ring 5016 and the electronic wire feed module 5046, passes through the interior 5078c of the cylindrical hub 5078, through the radial holes 5078b, and connects to one or more measurement sensors 5056.

[00698] As will also be clear from FIG. 24 and 35B, the pneumatic line 5032a transporting the shielding gas (inert gas) passes through the rear rotating sleeve 5072, through the holes 5080d in the slip ring, and continues through the hollow interior 5078c of the rotary hub 5078 to one or more shielding gas valves 5042 ( see Fig. 72), while the valves are installed in the electronic wire feed module 5046 (see Fig. 71), which is mounted on the rotary hub 5078 to rotate with it. Hydraulic conduit 5032a, which is a movable conduit that moves with the rotation of the rotary hub 5078, after being connected to the shielding gas valves 5042, returns back again and again passes through the hollow inner part 5078c of the rotary hub 5078 (for this reason, two channels 5032a in Fig. .24). The pneumatic conduit 5032a extends through one or more apertures 5078b, thus passing in close proximity to the welding torch tip 5502. The pneumatic conduit 5032a illustrated in FIG. 35B contains the movable part of the pneumatic passage, which rotates when the pivot hub 5078 rotates.

[00699] FIG. 25 is a partial sectional view of the front rotary coupling 5032, which is, in fact, the same design as the rear rotary coupling 5072. The front rotary coupling 5032 is used to transfer compressed air from an external source 5029 to the built-in compressed air tank 5128. Front the rotating sleeve includes a stator 5032d and a rotor 5032e. Rotor 5032e is mounted on stator 5032d by means of ball bearings 5032f. The stator 5032d is fixed with respect to the central frame 5068 and the rotor 5032e is connected to the movable part 5072d of the pneumatic channel, the opposite ends of the movable part 5072d are connected to the rotor or rear rotating sleeve 5072. The movable part of the pneumatic channel 5072d passes through the central passage 5016d of the slip ring 5016, is inserted into the inner part 5078c of the swing hub 5078, and then to the rotor of the rear rotating coupling 5072.

[00700] It should be understood that although the front slip ring 5016 is illustrated in FIG. 26 and the front rotating sleeve 5032 is illustrated in FIG. 25, the same configuration for each applies to both the 5072 Rear Rotary Sleeve and the 5080 Rear Slip Ring.

[00701] The manner in which the movable portion of the pneumatic conduit passes through the central passage 5016d of the slip ring 5016 will be better understood by looking at the cross section of FIG. 24, which illustrates this feature as applied to the rear slip ring 5080 and the rear rotary sleeve 5072. In particular, the rear rotary sleeve 5072 has an outer stator 5072a and an inner rotor 5072b. Rotor 5072b receives pressurized air from a rotating pneumatic supply duct 5072d (see FIGS. 24 and 70; it should be understood that FIG. 70 is a schematic representation, and duct 5072d is schematically shown in FIG. 70, but passes through the inside of the rotary hub 5078c , as illustrated in Fig. 24). The rotary supply port 5072d is connected at its opposite end to the rotor of the front rotary coupling 5032. In particular, the external supply bottle 5029 first passes compressed air through the stator of the front rotary coupling 5032, and then outputs through the rotor of the front rotary coupling 5032. The front rotary coupling 5032 has a rotor , operatively connected to the pivot hub 5078 so as to rotate together. A rotary supply duct 5072d extends from the front rotary sleeve rotor 5032 to the rear rotary sleeve rotor 5072b 5072. Compressed air passes through the rear rotary sleeve stator 5072a to a stationary pneumatic supply path 5072f passing through it. The fixed pneumatic supply port 5072f is connected through valves to a compressed air bottle 5128, which periodically receives compressed air from an external supply bottle 5029 when the bottle 5128 is used up. As seen in FIG. 24, a rotary feed passage 5072d extends from the rotor 5072b through a central hole 5080d in the rear slip ring 5080. Then, a movable pneumatic feed passage 5072d passes through a passage 5078c within the pivot hub 5078 to connect to the front rotating sleeve 5032.

[00702] As seen in FIG. 24, the 5080 rear slip ring has a 5080r inner rotor, a 5080s outer stator, and a 5080m bearing in between.

[00703] As will also be clear from FIG. 24, 72, the rear rotating sleeve 5072 also has another fixed port 5072g that receives shielding gas and shielding gas bottle 5262, described in more detail below. Shielding gas flows from the stator 5072a to the rotor 5072b and then out of the rotor through the movable pneumatic passage 5032a. The movable pneumatic passage 5032a extends through the slip ring opening 5080d and in the passage 5078c. The pneumatic conduit 5032a moves with the rotation of the pivot hub 5078. The opposite end of the pneumatic conduit 5032a connects to the shielding gas valves 5042 and then returns (in this regard, two conduits 5032a are illustrated in Fig. 24) and passes to the welding torches 5502. Along the way to the welding torches 5502, the movable pneumatic passage 5032a passes through holes 5078b in the pivot hub 5078, as will be understood from FIG. 72.

[00704] Although not described in detail herein, it should be understood that the supply of shielding gas through the rear rotary sleeve 5072 also applies to the passage of purge gas from the purge gas cylinder 7070 through the rear rotary sleeve 7072, as illustrated in FIG. . 94 described below.

[00705] FIG. 25, the front rotary coupling 5032 is illustrated as having two inlets and outlets. As illustrated, only one of the channels is used to transfer compressed air through the pneumatic channel (stationary part 5032c and movable part 5072d). The other channels are not used for the front rotary coupling, however, both channels are used for the rear rotary coupling 5072, as will be clear from the above description.

[00706] It should be understood that in some embodiments of the invention, a wireless connection to/from the measurement sensor, chamber and/or welding torch may be provided, in which case the use of a slip ring to provide certain functionality may be omitted.

[00707] In one embodiment of the invention, communication signals may not traverse the entire communication path between tether 5034 and drive section electronics module 5118, and may traverse between certain devices/modules of the communication path.

[00708] In one embodiment, all electronic modules in the internal welding system 5004, including the forwardmost electronic module 5014, the wire feed electronic module 5046, the center section electronic module 5064, and the drive section electronic module 5118 - each may have a memory, a secondary device storage, and one or more processors configured to control the system. In one embodiment of the invention, all electronic modules in the internal welding system 5004 may be configured to receive, process, store, retrieve, and transmit signals (sensors or controls) and data. In one embodiment of the invention, these electronic modules may contain other components. For example, various electronic circuits such as a power supply circuit, a signal conditioning circuit, a solenoid drive circuit, and/or other circuits known in the art may be integrated into the electronic modules. In one embodiment of the invention, all electronic modules in the internal welding system 5004 can be configured to transmit control signals used to control the operation of devices operatively associated with them, and receive data or other signals (sensors) from devices operatively associated with them. .

[00709] For example, the forwardmost electronic module 5014 is operatively coupled to the front rotation motor 5030, forward position sensor 5022, and front clamp valve 5018. In one embodiment, the forwardmost electronic module 5014 is configured to transmit control signals to control the operation of the front motor rotation 5030 and front clamp control valve 5018, and receive control signals from the forward position sensor 5022.

[00710] In one embodiment, the electronic wire feed module 5046 is operatively coupled to the shield gas control valve 5042, the wire feed systems motors 5044, the axial welding torch motor 5550, the radial welding torch motor 5512, and the welding torch tilt motor 5588. In one embodiment, In carrying out the invention, the electronic wire feed module 5046 is configured to transmit control signals for the operation of the shielding gas control valve 5042, the wire feed systems motors 5044, the welding torch axial motor 5550, the welding torch radial motor 5512, and the welding torch tilt motor 5588.

[00711] In one embodiment, center section electronics module 5064 is operatively coupled to rear rotation motor 5074, rear position sensor 5076, and rear clamp control valve 5062. In one embodiment, center section electronics module 5064 is configured to transmit control signals to control the operation of the 5074 rear rotation motor and 5062 rear clamp control valve, and receive control signals from the 5076 rear position sensor.

[00712] In one embodiment, drive section electronics module 5118 is operatively coupled to drive motors 5124, brake valve 5190, and drive wheel valve 5192. In one embodiment, drive section electronics module 5118 is configured to transmit control signals to control operation. drive motors 5124, brake valve 5190 and drive wheel valve 5192.

[00713] FIG. 72 illustrates a schematic diagram depicting the flow of shielding gas through the internal welding system 5004, with some components of the internal welding system 5004 not illustrated for clarity, and to better illustrate other components and/or characteristic properties of the internal welding system 5004.

[00714] In one embodiment of the invention, the inert/shielding gas supply channel is configured to control the supply of inert/shielding gas from the inert/shielding gas source 5262 to the area between the first and second clamps 5142, 5144, and towards the area in the immediate vicinity from the welding tip 5503 of the welding torch 5502 to reduce the amount of oxygen in the vicinity of the welding tip 5503 during the welding operation.

[00715] As illustrated in FIG. 72, shielding gas cylinders 5262 are illustrated in the actuator section 5010 of the internal welding system 5004. In one embodiment, the high pressure regulator 5264 may be located in the actuator section 5010 of the internal welding system 5004. In one embodiment, the high pressure regulator 5264 may be located in the center section 5008 of the internal welding system 5004. In one embodiment, the rear rotating sleeve 5072, welding torches 5502, pivot hub 5078, rear and front clamps 5142, 5144 are illustrated in the central section 5008 of the internal welding system 5004. In one embodiment of the invention , front and rear seals 5146 and 5148 can be placed in the center section 5008 of the internal welding system 5004. Shielding gas valves 5042 are illustrated in the frontmost section 5006 of the internal welding system 5004.

[00716] In one embodiment, the shield gas cylinders 5262 are configured to maintain a pressure of 500-2400 psi. inch. Shield gas cylinders 5262 are fluidly connected via fluid channels to the rear rotary sleeve 5072. In one embodiment, shield gas cylinders 5262 are fluidly connected to the rear rotary sleeve 5072 via valve 5266 and high pressure regulator 5264 In one embodiment, the 5264 high pressure regulator is configured to automatically shut off the purge gas flow at 75 psi. inch. In other words, the 5264 high pressure regulator is typically set to depressurize the 5262 shield gas cylinder to 75 psi. inch in the fluid path after the 5264 high pressure regulator, and from the 5072 rear rotary coupling to the 5042 shielding gas valves.

[00717] In one embodiment, the rear rotating sleeve 5072 is fluidly connected via the fluid transmission path to the shielding gas valves 5042. to the rear rotating sleeve 5072 and then through the fluid transfer path from the rear rotating sleeve 5072 to the shielding gas valves 5042. In one embodiment, each shielding gas control valve 5042 is configured to control the flow rate of the shielding gas supply to the respective welding torch 5502 through the shielding gas supply line 5268. In one embodiment of the invention, each welding torch 5502 has a corresponding shielding gas valve 5042 connected to it. In one embodiment, the shield gas valve 5042 is operatively coupled to receive control signals from the electronic wire feed module 5046. electronic wire feed module 5046.

[00718] In one embodiment, the drive section 5010 of the internal welding system 5004 may include purge gas bottles, shield gas bottles 5262, and compressed air gas bottles. In one embodiment, shield gas bottles 5262 are only used to supply shield gas to welding torches 5502. In one embodiment, separate purge gas bottles can be configured to fill and store purge gas in the purge gas chamber. In one embodiment, compressed air is used to inflate seals 5146 and 5148 and expand clamps 5142 and 5144.

[00719] In one embodiment, the drive section 5010 of the internal welding system 5004 may include compressed air gas bottles and purge/shield gas bottles. That is, the purge and shield gas cylinders are the same. In one embodiment, compressed air from compressed air gas cylinders is used to inflate seals 5146 and 5148 and expand clamps 5142 and 5144. In one embodiment, seals 5146 and 5148 are optional in the internal welding system 5004. In one embodiment, the shield gas supplied to the 5502 welding torches and the purge gas supplied to the purge gas chamber are supplied by the same purge/shield gas cylinder. In one embodiment of the invention, the supply of purge gas to the purge gas chamber is optional.

[00720] In one embodiment, the drive section 5010 of the internal welding system 5004 may only contain purge/shield gas cylinders (i.e., no compressed air gas cylinders). This may be the case for small internal welding systems. In one embodiment, the purge/shield gas cylinders are configured to supply purge/shield gas to the 5502 welding torches, purge/shield gas to the purge gas chamber, and purge/shield gas to fill seals 5146 and 5148 and to expand clamps 5142 and 5144 In one embodiment, the seals 5146 and 5148 in the internal welding system 5004 are optional. In one embodiment of the invention, the supply of purge gas to the purge gas chamber is optional.

[00721] In FIG. 72A, 72B, and 72C illustrate close-up views of the internal welding torch used in the prior art system and internal welding system 5004, respectively, with pipes having a wide range of gap alignment and radial offset. For example, as illustrated in FIG. 72A, pipes 1022a, 1022b have a gap and radial offset of 1 mm.

[00722] As illustrated in FIG. 72B, in the prior art system, the raised pipe edge protects the left side of the weld edge, resulting in a reduced penetration depth. As illustrated in FIG. 72C, one or more processors 5140 associated with the internal welding system 5004 are configured to obtain welding profile data (for example, before, during and after the welding procedure), and also configured to move the internal welding torch 5502 and / or tilt the external 5502 welding torch to achieve full penetration based on the obtained weld profile data. Thus, weld profile data from the internal welding system 5004 can be used to improve the quality of the weld.

[00723] In one embodiment of the invention, one or more processors 5140 are configured to receive from the field system 5000 profile data associated with welding of the area of the contact surface 5136 between the first pipe 1022a and the second pipe 1022b. In one embodiment of the invention, the relevant profile data is based on a scan of the contact surface area 5136 between pipes 1022a, 1022b. In one embodiment, one or more processors 5140 are configured to compare one or more characteristics of the corresponding profile data with one or more predefined profile characteristics to generate a response to the field system 5000. In one embodiment, one or more processors 5140 are configured to sending a 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 of the invention, one or more processors 5140 are configured to send a signal to the field system 5000 to terminate a welding procedure, modify or improve a welding protocol, save or further analyze the profile data of the 5136 contact surface area, store or further analyze the profile data before welding, saving or analyzing profile data after welding, confirming or modifying their version, etc.

[00724] In one embodiment of the invention, one or more processors 5140 are operatively coupled to the measurement sensor 5056 to determine the profile of the contact surface area 5136 between two pipes 1022a, 1022b. In one embodiment of the invention, the welding torch 5502 is configured to create a weld in the area of the contact surface 5136 between the pipes 1022a, 1022b based on the profile data of the contact surface 5136 between the pipes 1022a, 1022b. In one embodiment of the invention, the welding torch (for example, external welding system 7500) is configured to create a weld between pipes 1022a, 1022b based on profile data of the contact surface area 5136 between pipes 1022a, 1022b.

[00725] In one embodiment of the invention, one or more processors 5140 are configured to receive control data from the measurement sensor 5056 before, after, or during a welding operation. In one embodiment of the invention, one or more processors 5140 are configured to receive inspection data from inspection chamber 5112 before, after, or during a welding operation. In one embodiment of the invention, one or more processors 5140 are configured to receive control data from the measurement sensor 5056 and control camera 5112 before, after, or during a welding operation.

[00726] In one embodiment of the invention, the inspection camera 5112 is configured to scan the region of the weld contact surface 5136 after the welding operation has been performed. In one embodiment of the invention, the monitoring camera 5112 is configured to send signals to one or more processors 5140 based on the scan. In one embodiment of the invention, one or more processors 5140 are configured to characterize the area of the weldable contact surface 5136 based on signals from the control camera 5112.

[00727] In one embodiment of the invention, one or more processors 5140 are configured to analyze data to automatically detect undercuts or other form deviations.

[00728] In one embodiment, when the value of the contact surface region characteristic 5136 is greater than a predetermined threshold value, it may be referred to as an undesirable contact surface region characteristic 5136. In one embodiment, when the value of the contact surface region characteristic 5136 is greater than threshold value and the difference between the characteristic value and the predetermined threshold value is within the predetermined allowable/acceptable range, it is determined that there is no need to correct the undesirable characteristic of the contact surface area 5136. In one embodiment of the invention, in the case where the characteristic value of the area contact surface 5136 is greater than the preset threshold value and the difference between the characteristic value and the preset threshold value is not within the limit variant of the given allowable/acceptable range, it is determined that it is necessary to correct the undesirable characteristic of the area of the contact surface 5136.

[00729] In one embodiment, when the value of the contact surface region characteristic 5136 is less than a predetermined threshold value, it may be referred to as an undesirable contact surface region characteristic 5136. In one embodiment, when the value of the contact surface region characteristic 5136 is less than threshold value and the difference between the characteristic value and the predetermined threshold value is within the predetermined allowable/acceptable range, it is determined that there is no need to correct the undesirable characteristic of the contact surface area 5136. In one embodiment of the invention, in the case where the characteristic value of the area contact surface 5136 is less than the preset threshold value and the difference between the characteristic value and the preset threshold value is not within the limit variant of the given allowable/acceptable range, it is determined that it is necessary to correct the undesirable characteristic of the area of the contact surface 5136.

[00730] In one embodiment, when the value of the contact surface region characteristic 5136 is not within a predetermined range, it may be referred to as an undesirable contact surface region characteristic 5136. In one embodiment, in the case where the value of the contact surface region characteristic 5136 is not within the predetermined range, but is within the predetermined allowable/acceptable range, it is determined that there is no need to correct the undesired characteristic of the contact surface area 5136. In one embodiment of the invention, in the case where the value of the characteristic of the contact surface area 5136 is not is within a predetermined range and is not within a predetermined allowable/acceptable range, it is determined that there is no need to correct the undesirable characteristic of the contact area. th surface 5136.

[00731] In one embodiment of the invention, one or more processors 5140 are configured to receive electronic signals (for example, generated by a measurement sensor receiver 5136) to determine whether correction is required for an undesired characteristic of the contact surface area 5136. In one embodiment of the invention, one or more processors 5140 are configured to send commands to the motors 5030, 5074, which control the angular position relative to the axis of one of the tubes, in response to the detection of one or more undesirable characteristics of the area of the contact surface 5136, so that through the motors 5030, 5074 to cause rotation of one of the tubes 1022a, 1022b relative to the other from tubes 1022a, 1022b to correct the unwanted characteristic. In one embodiment, the motors 5030, 5074 are configured to move the radial clamps 5142, 5144.

[00732] In one embodiment, a welding torch 5502 operatively associated with one or more processors 5140 is configured to perform a welding operation to weld pipes 1022a, 1022b together in response to one or more processors 5140 detecting the absence of undesirable characteristics.

[00733] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to determine the profile of the area of the contact surface 5136 between the pipes 1022a, 1022b before the welding operation and generate based on profile data before welding. In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the entire area of the contact surface 5136 between pipes 1022a, 1022b to generate pre-weld profile data prior to deposition of weld metal to weld two pipes 1022a, 1022b together. In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 to obtain pre-weld profile data after the first clamp 5142 and second clamp 5144 engaged with the first pipe and second pipe 1022a, 1022b, respectively.

[00734] Additionally or alternatively, one or more processors 5140 are configured to interface with a 5112 inspection chamber, x-ray inspection device, gamma ray inspection device, ultrasonic inspection device, magnetic particle inspection device, vortex inspection device. currents or other control devices to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to determine the profile of the area of the contact surface 5136 before the welding operation.

[00735] The pre-weld scan/inspection procedure is the same for the internal welding system 3001 and the purge and inspection system 7001, and therefore will not be described again with reference to the butt internal welding system 3001 and the purge and inspection system 7001.

[00736] In various embodiments of the invention described in this application, the profile data "before welding" refers to data obtained from a measuring sensor (for example, using a verification laser) that scanned the area of the contact surface between the two pipes to be welded, before actuating the welding burners to start connecting the pipes to each other. This pre-weld profile data is communicated to one or more processors to determine if the pipes are sufficiently aligned before applying any weld metal to the contact surface area. In one embodiment of the invention, when misalignment is detected, for example by determining by one or more processors that the misalignment is out of alignment, the one or more processors are configured to send signals to platforms interacting with the outer surfaces of the pipes. One or both of the platforms can be adjusted based on the output signals obtained from the pre-weld profile data to adjust the relative positioning between the pipes to provide an acceptable level of interface area alignment misalignment.

[00737] It should be understood that, given the small inconsistencies in the structures of the pipes, it is often (and usually) not possible to achieve absolutely perfect alignment. However, there is no need for such an ideal alignment in the case where the alignment is within the tolerance range suitable for a quality weld.

[00738] In one embodiment, the pre-weld profile data may include pipe roundness data. In one embodiment, pipe roundness data may include the location and magnitude of the minimum internal diameter, the location and magnitude of the maximum internal diameter, the average pipe diameter, the pipe wall thickness, the location and magnitude of the minimum wall thickness, and/or the location and magnitude of the maximum wall thickness. In one embodiment, the tube roundness data may include a comparison between each location and value of the minimum inside diameter, location and value of the maximum inside diameter, location and value of the minimum wall thickness, and location and value of the maximum wall thickness, and their respective predetermined values. In one embodiment of the invention, the pipe roundness data may include data obtained from a comparison between each average pipe inner diameter and the average pipe wall thickness, and their respective predetermined values. In one embodiment of the invention, the pipe roundness data may include deviations in the inner diameter of the pipe at all locations around the circumference of the pipe, obtained from a comparison.

[00739] In one embodiment, the pre-weld profile data may include pipe groove profile data. In one embodiment of the invention, the pipe groove profile data may include the pipe groove geometry. In one embodiment of the invention, the pipe groove profile data may include data obtained from a comparison between each groove size and shape, pipe groove flare thickness, pipe groove chamfer angle, pipe groove offset, and taper angle. pipe grooves, and their respective preset values. In one embodiment of the invention, the pipe groove profile data may include pipe groove deviations at all locations around the pipe circumference based on comparison.

[00740] In one embodiment, the pre-weld profile data may include weld fit and alignment data. In one embodiment of the invention, the weld fit and alignment data may include gap data between inner adjacent ends (after pipe alignment). In one embodiment of the invention, the weld fitting and alignment data may include pipe groove gap data (after pipe alignment). In one embodiment, the weld fit and alignment data may include the location and amount of the minimum gap, the location and amount of the maximum gap, and/or the average gap. In one embodiment, the weld fitting and alignment data may include a comparison of each minimum gap location and amount and maximum gap location and amount, and their respective predetermined values. In one embodiment, the weld fitting and alignment data may include data obtained from a comparison between an average gap value and its corresponding predetermined value. In one embodiment of the invention, the weld fitting and alignment data may include pipe clearance deviations at all locations around the pipe circumference, based on comparison. In one embodiment of the invention, weld fit and alignment data may include minimum differences in height between pipes (eg, allowable alignment), and so on.

[00741] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 after the first clamp 5142 and the second clamp 5144 engaged with the first tube and the second tube 1022a, 1022b, respectively . In one embodiment, one or more processors 5140 are operatively coupled to a first pipe engagement device 5052 and a second pipe engagement device 5054. In one embodiment, one or more processors 5140 are configured to control the first pipe engagement device 5052 and/ or a second pipe engagement device 5054 based on pre-weld profile data to change the contact surface area 5136 between pipes 1022a, 1022b before the welding operation.

[00742] In one embodiment of the invention, one or more processors 5140 are configured to change the contact surface area 5136 between pipes 1022a, 1022b before the welding operation by actuating the first pipe engagement device 5052 and/or the second pipe engagement device 5054 to change the roundness of the first pipe 1022a and/or second pipe 1022b based on pre-weld profile data. For example, in one embodiment of the invention, one or more processors 5140 are configured to change the contact surface area 5136 between pipes 1022a, 1022b prior to a welding operation by selectively actuating one or more clamp shoes 5157 of clamps 5142 and/or 5144 to change the roundness of the first pipe. 1022a and/or second pipe 1022b based on pre-weld profile data.

[00743] In one embodiment, one or more processors 5140 are configured to change the contact surface area 5136 between pipes 1022a, 1022b prior to a welding operation by actuating the first pipe engagement device 5052 and/or the second pipe engagement device 5054 to rotate and/ or longitudinal movement of the first pipe 1022a and/or the second pipe 1022b based on profile data before welding. In one embodiment of the invention, one or more processors 5140 are configured to change the contact surface area 5136 between pipes 1022a, 1022b prior to a welding operation by rotating one pipe 1022a or 1022b relative to another pipe 1022a or 1022b.

[00744] In one embodiment, the one or more processors 5140 are configured to improve the welding protocol based on pre-weld profile data. In one embodiment, the welding protocol includes a welding speed protocol and a welding torch position protocol.

[00745] In one embodiment of the invention, one or more processors 5140 are configured to control platforms 5330 (as illustrated in Figs. 10A and 10B) or 6010A and 6010B (as illustrated in Fig. 73) to supply incoming pipe 1022a at the second end of the pipe 1022b (after positioning the frame assembly of the internal welding system 5004 at the second end of the pipe 1022b) based on the pre-weld profile data to change the contact surface area 5136 between the pipes 1022a, 1022b before the welding operation. In one embodiment of the invention, one or more processors 5140 are configured to control the externally placed rollers 5332 of the platforms 5330 to feed the incoming pipe 1022a at the second end of the pipe 1022b (after positioning the frame assembly of the internal welding system 5004 at the second end of the first pipe 1022b) based on profile data before welding.

[00746] In one embodiment of the invention, one or more processors 5140 are configured to control platforms 5330 (as illustrated in Fig. 10A and 10B) or 6010A and 6010B (as illustrated in Fig. 73), to create a relative movement between the first pipe 1022a and a second pipe 1022b based on the pre-weld profile data to change the contact surface area 5136 between the pipes 1022a, 1022b before the welding operation. In one embodiment of the invention, if it is determined from pre-weld profile data that adjustment is required, the outer surface 5346 and/or 5348 (as illustrated in FIG. 2G) of the first pipe 1022a and/or the second pipe 1022b engages to adjust the relative positioning pipes 1022a, 1022b. In one embodiment of the invention, when it is determined from pre-weld profile data that adjustment is required, platforms 5330 (as illustrated in FIGS. 10A and 10B) and 6010A and 6010B (as illustrated in FIG. 73) are controlled by one or more processors 5140 (or otherwise controlled) to engage with outer surfaces 5346 and/or 5348 (as illustrated in FIG. 2G) of first tube 1022a and/or second tube 1022b to adjust the relative positioning of tubes 1022a, 1022b.

[00747] In one embodiment of the invention, in the event that refinement of the profile data is required before welding, the first clamp and/or the second clamp 5142, 5144 are opened to allow adjustment of the relative positioning of the pipes 1022a, 1022b. In one embodiment of the invention, in the case where refinement of the profile data is required before welding, the first clamp and/or the second clamp 5142, 5144 are opened to allow adjustment of the relative positioning of the pipes 1022a, 1022b. In one embodiment of the invention, in the case where refinement of the profile data is required before welding, the first and second clamps are located outside the clamps and are opened to allow the relative positioning of the pipes 1022a, 1022b to be adjusted. In one embodiment of the invention, the first and second clips include both internal clips and external clips. In one embodiment of the invention, in the event that refinement of profile data is required prior to welding, both the inwardly placed clamps and the outwardly placed clamps are opened to allow the relative positioning of the tubes 1022a, 1022b to be adjusted.

[00748] In one embodiment of the invention, adjustment of the relative positioning of pipes 1022a, 1022b (based on pre-weld profile data) can be performed either automatically by processors 5140 controlling externally placed rollers 5332 (as illustrated in FIGS. 10A and 10B) or performed by an operator with using a tap and (internal and/or external) clamps. In one embodiment of the invention, adjusting the relative positioning of pipes 1022a, 1022b (based on pre-weld profile data) may also be referred to as realigning pipes 1022a, 1022b.

[00749] In one embodiment, adjusting the relative positioning of pipes 1022a, 1022b (based on pre-weld profile data) may include adjusting along the longitudinal axis of pipes 1022a, 1022b and/or adjusting along the radial axis of pipes 1022a, 1022b. In one embodiment of the invention, adjusting the relative positioning of pipes 1022a, 1022b (based on pre-weld profile data) may include adjusting the position and adjusting the orientation of pipes 1022a, 1022b. In one embodiment of the invention, adjusting the relative positioning of pipes 1022a, 1022b (based on pre-weld profile data) may include up and down movement and longitudinal movement (along the longitudinal axis of pipes 1022a, 1022b).

[00750] In one embodiment, the inner and/or outer clamp(s) (holding tubes 1022a, 1022b in place during the pre-weld procedure) are released, and a crane placed outside can be used to manipulate the tube based on pre-weld profile data. rollers 5332 with electronic control or other similar devices. In one embodiment, the inner and/or outer clamp(s) (holding tubes 1022a, 1022b in place during the pre-weld procedure) are released prior to the realignment procedure. In one embodiment of the invention, after the pipes 1022a, 1022b are realigned, the pipes 1022a, 1022b are clamped with external and/or internal clamps.

[00751] In one embodiment of the invention, the new pipe 1022a to be welded can be rotated about its longitudinal axis relative to the previous pipe 1022b that was welded, based on the pre-weld profile data that was obtained from the measurement sensor (eg, inspection laser) 5056 In particular, pre-weld profile data can be used to determine that, in some cases, the relative rotation positions of pipes 1022a and 1022b can be changed to provide the best match for welding. For example, if each of the tubes 1022a, 1022b is slightly rounded, then matching the tubes so that the major axis of each of the two tubes is typically aligned and the minor axis of each of the two tubes is typically aligned can have an overall beneficial effect. . Thus, in one embodiment of the invention, the measurement sensor 5056 may generate signals that are processed by one or more processors 5140 to determine a more appropriate angular position for the incoming pipe 1022a to be welded. Such rotation may be performed by one or more processors 5140 that drive the forward rotation motor 5030 to rotate the pipe 1022a prior to the welding operation. In particular, for rotation of the incoming pipe 1022a, the central frame 5068 remains stationary in terms of rotation relative to the previously welded pipe. This rotationally fixed connection between the central frame 5068 and the tube 1022b is achieved by the fact that the back clamp 5144, actuated by one or more processors 5140, securely engages the inner surface of the tube 1022b to prevent mutual rotation between them. In addition to the rear clamp 5144 and the center frame 5068 being rotationally fixed relative to the pipe, the rear rotation motor 5074 is not driven by the processor 5140, thus blocking the rotation of the motor shaft. Because rotation of the rear rotation motor shaft is locked, the entire pivot hub 5078 remains stationary in terms of rotation relative to the center frame 5068 and tube 1022b. Then, the front rotation motor 5030 is activated. Its shaft rotates to drive the transmission mechanism, as illustrated in FIG. 19 and described above so that the teeth of the gear 23 are rotatably engaged by the teeth of the gear 5023 of the ring gear 5021. 5030 and the transmission mechanism 5023 operatively associated with it move circumferentially along the ring gear 5021. This rotational driving force generated on the front rotation motor 5030 rotatably moves the frontmost frame section 5026 to which the motor 5030 is coupled. rotation of the frontmost frame section 5026 rotatably drives the front clamp 5142. The clamp 5142 rotates around the pivot hub 5078 on bearings 5108, 5098, which are located between the clamp 5142 and the pivot hub 5078. As the clamp 5142 is extended and clamped on the inner surface of the pipe 1022a, resulting in pipe 1 022a is rotated to a position determined by one or more 5140 processors based on scanned information obtained from the 5056 measurement sensor before welding. pipes, rollers 5332 on the outer platform (5330, 6010A, 6010B) are commanded by one or more 5140 processors to additionally be in a freewheeling state in which they are passive, or additionally one or more motors operatively connected with rollers 5332 are commanded by one or more processors 5140 to cause the rollers 5332 to move at a rotational speed commensurate with (similar to or the same as) the speed at which the front rotation motor 5030 rotates within the tube 1022a. This latter approach creates rotational forces for the pipe 1022a both inside and outside the pipe, although in some embodiments of the invention only one driving force may be sufficient.

[00752] In the embodiment just described, clips 5142 and 5144 engage respective tubes 1022a and 1022b to prevent relative rotation between frame 5026 and tube 1022a and to prevent rotation between center frame 5068 and tube 1022b. However, in one or more embodiments of the invention, clamps 5142 and 5144 need not be configured to perform this function. Instead, wheels operatively associated with both frames may be configured to engage the associated tubes with sufficient friction and/or external force to prevent relative rotation between the tubes and the frames. In one embodiment of the invention, the wheels actuate or move between the frames and tubes, thereby generally only allowing longitudinal movement between the frames and tubes and preventing relative rotational movement between them. This may be true for wheels on one or more frames. The wheel engagement option can be used on only one of the carcasses, on both carcasses, and can optionally be used in combination with the clamping technique for one or both carcasses.

[00753] The tubing rotation methods described herein can also be used to return scaffolds to the desired "start" rotational position or "full stop" rotational position after a welding operation has been completed, with new pipe fed for the next pre-weld scan.

[00754] In one embodiment, the one or more processors 5140 are configured to send pre-weld profile data to a remote processor for further processing.

[00755] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to determine the profile of the area of the contact surface 5136 between the pipes 1022a and 1022b during the welding operation in area of the contact surface 5136 before applying the weld metal thereto and generating profile data on the fly.

[00756] The on-the-fly scan/test procedure is the same for the internal weld system 3001 and the purge and test system 7001, and therefore will not be described again with reference to the butt internal weld system 3001 and the purge and test system 7001.

[00757] In various embodiments, on-the-fly profile data refers to data received from a measurement sensor during a welding operation. For example, on-the-fly profile data is obtained from a position just ahead of the area to be welded (eg, 2.54 cm - 15.24 cm (1-6 inches) in front of the area to be welded). In particular, the measuring sensor scans the area of the contact surface within the area to be welded to provide data on the profile of the area of the contact surface just before the application of the weld metal. It should be appreciated that the profile of the contact surface area between the pipes may vary slightly as the welding process proceeds over the majority of the contact surface area. In other words, the sequential welding itself may slightly change the alignment/positioning of the pipes in the contact surface area in the portions of the contact surface area to be welded. The measuring sensor measures the profile of the area of the contact surface just before the welding torch applies the weld metal in the areas of the contact surface to be welded, and the signals from the measuring sensor are received and used by one or more processors to output signals/commands to the welding torch and/or its motors for control of various parameters of the welding torch in order to adapt the welded joint to the pipes as they are being welded. The welding torch parameters may include one or more of the following: wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas consumption, welding arc power levels, weld current, welding voltage, weld resistance, speed movement of the welding torch, the position of the welding tip of the welding torch along the axis of the pipe, the angular positioning of the welding tip of the welding torch relative to its plane of rotation and/or the distance from the welding tip of the welding torch to the inner surfaces of the pipes to be welded.

[00758] In one embodiment, the on-the-fly weld profile data may include stagger data. In one embodiment of the invention, the in-service weld profile data may include stagger data. In one embodiment of the invention, the step data may include a comparison between an average height difference and its corresponding predetermined value. In one embodiment of the invention, the stagger data may include pipe height difference deviations at all positions along the entire perimeter of the pipes based on a comparison.

[00759] In one embodiment of the invention, weld profile data acquired on the fly may include weld characteristics.

In one embodiment of the invention, the weld profile data obtained on the fly may include the width of the weld and the root gap of the weld.

[00760] In one embodiment of the invention, one or more processors 5140 are configured to generate welding signals for controlling the welding torch 5502 based on on-the-fly profile data. In one embodiment, the one or more processors 5140 are configured to control the position and speed of the welding torch 5502 based on on-the-fly profile data during a welding operation. In one embodiment, the torch motor 5588 is operatively coupled to one or more processors 5140 to control the angle of the weld torch 5502 during a welding operation.

[00761] In one embodiment, one or more processors 5140 are configured to instruct one or more torch motors 5512 to move the welding tip 5503 away from the contact surface area 5136 after each weld pass to accommodate the weld metal deposit. In one embodiment, one or more processors 5140 are configured to control the welding torch axial motor 5550 to control the axial movement of the welding torch 5502 (ie, move the welding tip 5503 away from the contact surface area 5136).

[00762] In one embodiment, the one or more processors 5140 are configured to generate an initial plotted weld profile based on pre-weld state profile data and modify/adjust the initial plotted weld profile based on the profile data obtained. "on the fly".

[00763] In one embodiment of the invention, the wire feed speed, oscillation width, arc power levels, and/or distance from the welding tip 5503 of the welding torch 5502 to the surfaces of the pipes to be welded can be controlled based on profile data obtained "on fly."

[00764] In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 between the pipes 1022a, 1022b to determine the profile of the area of the contact surface 5136 between the pipes 1022a and 1022b after the welding operation and generate on its based on profile data after welding. In one embodiment of the invention, post-weld profile data is obtained using a measurement sensor 5056 located inside the first pipe 1022a and/or the second pipe 1022b, without disengaging the first pipe engagement device 5052 or the second pipe engagement device 5054, respectively, with the inner surface 5130 the first pipe 1022a or the inner surface 5132 of the second pipe 1022b.

[00765] The post-weld scan/inspection procedure is the same for the pipe string welding system 3001 and the purge and inspection system 7001, and therefore will not be described again with reference to the pipe string welding system 3001 and the purge and inspection system 7001.

[00766] As an additional or alternative option, one or more 5140 processors are configured to interface with a 5112 inspection camera, X-ray inspection device, gamma radiation inspection device, ultrasonic inspection device, magnetic particle inspection device, eddy current inspection device, or other inspection devices. devices for scanning the area of the contact surface 5136 between the pipes 1022A, 1022b to determine the profile of the area of the contact surface 5136 after the welding operation.

[00767] In one embodiment, the post-weld profile data may include the profile(s) of weld beads formed. In one embodiment, the post-weld profile data may include root pass profile(s). In one embodiment, the post-weld profile data may include weld shape characteristics such as mismatch, weld bead slack, and lead angle.

[00768] In one embodiment of the invention, one or more processors 5140 are configured to prescribe, based on the post-weld profile data, another welding operation in the area of the contact surface 5136 between the pipes 1022a, 1022b.

[00769] Some weld variables/parameters are well known for their relationships. This means that a change in one welding variable/parameter entails a corresponding change in another welding variable/parameter. Welding variables/parameters such as welding current, welding voltage, welding torch speed and heat input are interconnected. For example, if the welding current is increased while all other welding variables/parameters remain unchanged, then the voltage decreases. Also, if the welding torch travel speed is increased while all other welding variables/parameters remain unchanged, then the heat input decreases. In one embodiment of the invention, one or more processors 5140 are configured to analyze the collected data (eg, before, after, or during a welding operation) to detect problems and change the process/parameters. In one embodiment of the invention, based on the analysis and detection, one or more processors 5140 are configured to receive the internal welding system 5004 offline for service as needed to prevent a recurrence of the situation.

[00770] In one embodiment, each data point collected/received by one or more processors 5140 before, after, or during a welding operation is compared to its corresponding (gold standard) ideal welding value. If any process variables differ by more than a set/preset limit, these differences can be noted. If the differences exceed the maximum allowable defect volume, the welding process can be stopped so that the weld can be repaired. Over time, ideal welding values and tolerance limits can be improved as more welding data is collected.

[00771] In one embodiment of the invention, one or more processors can be configured to see what happened just before the deviation occurred and determine if there is a defect in the control loop programming that allowed the deviation to occur. In such a case, one or more processors may send the updated control cycle program to the internal welding system 5004 and see if the change improves the performance of the internal welding system 5004.

[00772] In one embodiment of the invention, one or more processors may also be configured to monitor commands given locally by an operator to the internal welding system 5004. If these commands are defined to prescribe welding defects, one or more processors are configured to sending a message to the operator to stop providing commands to the internal welding system 5004. If the commands are defined to prevent welding defects, one or more processors are configured to send a message to all operators, instructing them to start using the specified commands.

[00773] In one embodiment of the invention, one or more processors are configured to collect and analyze non-destructive testing (NDT) data. In one embodiment of the invention, the locations where welding defects are found can be compared with the welding parameters that were recorded at the same location, even if the defect is small enough not to require repair. In one embodiment of the invention, one or more processors will be able to receive information about welding defects that would not be included in a normal inspection report. This provides one or more processors with a very good statistical sample for each weld parameter and the quality of the weld produced. This statistical model can be used to determine the best settings for each welding parameter as well as the allowable deviation from the settings. These new parameters can be transferred directly to the 5004's internal welding system as each new NDT scan improves the statistical model.

[00774] In one embodiment, as described herein, computer system 5138 (comprising one or more processors 5140) may be a computer system that is local to field system 5000. In another embodiment, as described in herein, computer system 5138 may be a computer system located remotely from field system 5000 (e.g., remote computer system 13704 or another remote computer system) and may be communicatively connected to field system 5000 or its local computer system.

[00775] In one embodiment of the invention, one or more processors 5140 may receive (via a receiver) test data related to test area of contact surface 5136 between conduits 1022a, 1022b from field system 5000 (e.g., raw data from test devices, data from 2D or 3D images, or other verification data). The one or more test devices used for the test may include one or any combination of a test laser, a test camera, an X-ray tester, a gamma ray tester, an ultrasonic tester, a magnetic particle tester, an eddy current tester, a temperature control device, or other checking device. The inspection data may respectively include one or any combination of laser inspection data, inspection chamber 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. .

[00776] In one embodiment of the invention, one or more processors 5140 can automatically generate a response containing profile data for the area of the contact surface 5136 (for example, pre-weld condition profile data, on-the-fly profile data, post-weld condition profile data, or other data ) based on the received verification data, and transmit (via the transmitter) the profile data to the field system 5000. For example, in one embodiment, when the received verification data is based on scanning the area of the contact surface prior to the welding operation, one or more processors 5140 may use received verification data to generate a response containing the pre-weld profile data for the area of the contact surface 5136, and transmit (through the transmitter) the pre-weld profile data to the field system 5000. In one embodiment of the invention, in which the received verification data is based on a scan of the area contact surface during a welding operation, one or more 5140 processors can use the received test data to generate a response containing on-the-fly welding profile data for the 5136 contact surface area and transmit (via a transmitter) the on-the-fly profile data to the field system 5000. In one embodiment in which the received verification data is based on a scan of the contact surface area after the welding operation, one or more processors 5140 may use the received verification data to generate a response containing the post-weld profile data for the contact surface region 5136 and transmit (via transmitter) post-weld profile data to Field System 5000.

[00777] In one embodiment of the invention, one or more processors 5140 can automatically generate a response containing one or more welding protocols or other operation protocols based on the received verification data, and transmit (via the transmitter) operation protocols as data on the operation of the control system in field system 5000. As an example, upon receipt of operation protocols, field system 5000 may perform one or more operations based on the received operation protocols. In another embodiment, one or more processors 5140 may generate profile data based on the received verification data to obtain profile data for the contact surface area 5136 (e.g., pre-weld profile data, on-the-fly profile data, post-weld profile data, or other profile data). In yet another embodiment, one or more processors 5140 may use the profile data to obtain welding protocols or other operation protocols and transmit (via a transmitter) the operation protocols to the field system 5000.

[00778] In one embodiment of the invention, one or more processors 5140 can generate a weld protocol or other operation protocol based on test data associated with one or more other pipes (other than pipes 1022a, 1022b), data associated with input parameters (for example, , welding or other parameters) used to perform one or more operations (for example, welding or other operations) on other pipes, data related to operation observations, or other data. As an example, one or more processors 5140 may receive test data from one or more field systems and analyze the test data to determine if any pipe has defects and which pipe has defects. The processors may then compare one or more observation sets of an operation performed on one or more items that have defects (after the operation has been performed) with one or more other sets of observations of the same operation performed on one or more other items that have defects. no defects found to determine what circumstances likely led to the defect (as described in more detail elsewhere in this document). Based on this comparison, one or more of the 5140 processors can generate a welding protocol or other operation protocol in such a way that the operation protocol instructs to avoid such circumstances or otherwise avoid such circumstances (which probably led to the occurrence of a defect) when the execution protocol operations is used for one or more subsequent operations (eg, subsequent operations that are the same or similar to the completed and observed operation).

[00779] In one embodiment, one or more processors 5140 may obtain pre-weld condition profile data for a contact surface region 5136 (between pipes 1022a, 1022b) when the pre-weld condition profile data is based on a scan of the contact surface region 5136 in the field system 5000 before starting the welding operation. As an example, one or more processors may receive pre-weld condition profile data from field system 5000. As another example, one or more processors 5140 may generate pre-weld condition profile data based on verification data received from field system 5000. After receiving the data, one or more processors 5136 may analyze the pre-weld profile data to generate a response for the field system 5000. In one embodiment, one or more processors 5140 may compare one or more characteristics of the pre-weld profile data (e. pipe seam, weld fit characteristics, alignment characteristics, and other characteristics) with one or more characteristics of acceptable predetermined condition profiles before welding. Based on this comparison, the processors 5140 may send (via the transmitter) a response in the form of control system operation data to the field system 5000, instructing whether the field system 5000 should begin the welding operation.

[00780] By way of example, such a response may indicate that the contact surface area 5136 is within specification for a welding operation, indicating that the field system 5000 should begin the welding operation. As an additional or alternative option, the response may contain one or more welding protocols for the welding operation. As another example, the response may indicate that the area of contact surface 5136 is not within specification, indicating that the field system 5000 should not perform a welding operation on the area of contact surface 5136 in its current state. In one application, the response may indicate the need to change the area of the contact surface 5136 before the welding operation (for example, the need to rebuild pipes 1022a, 1022b or make other changes). Thus, the response may direct the field system 5000 to control the pipe engagement device in the field system 5000 to change the contact surface area 5136 prior to the welding operation so that the contact surface area 5136 is within specification for the welding operation.

[00781] In one embodiment of the invention, one or more processors 5140 can compare one or more profile data characteristics (derived from a scan of the contact surface area 5136 in the field system 5000) with one or more predefined profile characteristics to determine one or more matching characteristics. Based on matching characteristics, for example, one or more processors 5140 may automatically determine one or more weld protocols to weld the area of contact surface 5136 between pipes 1022a, 1022b and transmit (via a transmitter) one or more weld protocols to field system 5000 to prescribe a field system 5000 performing a welding operation in the area of the contact surface 5136 based on one or more welding protocols. As an example, a welding protocol may contain one or more input parameters such as wire feed speed, wire consumption, wave width, waveform, wave amplitude, welding time, gas flow, arc power levels, welding current, welding voltage, electric welding resistance, welding torch travel speed, position of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip relative to its plane of rotation, distance from the welding torch welding tip to the inner surfaces of the pipes to be welded, or other parameters.

[00782] In one embodiment, one or more processors 5140 may acquire on-the-fly profile data for a contact surface region 5136 (between tubes 1022a, 1022b) when the on-the-fly profile data is based on a scan. area of the contact surface 5136 in the field system 5000 during the welding operation. As an example, one or more processors 5140 may receive (via a receiver) on-the-fly profile data from field system 5000. As another example, one or more processors 5140 may generate on-the-fly profile data based on verification data received from field system 5000. Upon receipt of the data, one or more processors 5140 may parse the profile data received on the fly to generate a response for field system 5000. In one embodiment, one or more processors 5140 may compare one or more more on-the-fly profile data characteristics (e.g., pipe roundness characteristics, pipe groove profile characteristics, weld fit and alignment characteristics, weld shape characteristics, or other characteristics), with one or more acceptable predefined profile characteristics ( e.g. predefined status profiles before welding, pre-defined profiles after welding or other profiles). Based on this comparison, processors 5140 may send a response to field system 5000 containing on-the-fly data updates on one or more welding characteristics for the welding operation. As an example, the response may direct the field system 5000 to control the welding torch based on on-the-fly updated data on welding characteristics during the welding operation.

[00783] In one embodiment, one or more processors 5140 may acquire post-weld profile data for a land area 5136 (between pipes 1022a, 1022b) when the post-weld profile data is based on a scan of the land area 5136 in the field system 5000 after performing welding operations. As an example, one or more processors 5140 may receive (via a receiver) post-weld profile data from field system 5000. As another example, one or more processors 5140 may generate post-weld profile data based on verification data received from field system 5000. After data acquisition, one or more processors 5140 may analyze the profile acquired on the fly to generate a response for the field system 5000. In one embodiment, one or more processors 5140 may compare one or more characteristics of the profile data after welding weld or other characteristics) with one or more characteristics of acceptable predetermined profiles after welding. Based on this comparison, the processors 5140 may send (via the transmitter) a response to the field system 5000 indicating whether the result of the welding operation is acceptable. As an additional or alternative option, one or more 5140 processors may automatically determine one or more welding protocols for a subsequent operation (for example, an operation that eliminates or levels a defect resulting from a welding operation, an operation that usually follows the welding operation, if not significant defect detected, etc.) and include one or more welding protocols in the transmitted response.

[00784] As an example, if a root pass welding operation is performed, the response may indicate that the root bead resulting from the welding operation is within specification and also indicate that preparations for a subsequent hot pass welding operation should begin. Thus, the response may direct the field system 5000 to initiate a hot pass operation at the contact surface area 5136. As another example, the response may indicate that the received root roll is not within specification. In one application, for example, the response may indicate that, until further notice, the field system 5000 cannot continue the hot pass operation. In another application, the response may indicate that the 5000 field system should perform a different weld protocol (other than the one pre-planned for the hot run operation) when the other weld protocol eliminates or eliminates a root bead resulting from the operation that is not within specification. .

[00785] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors 5140 may communicate to a remote computer system test data associated with the test area (for example, the area of the contact surface 5136 or other area) between the pipes 1022a, 1022b. The transmitted verification data may, for example, comprise one or any combination of the verification data types described herein. In one embodiment, one or more processors 5140 may receive (via a receiver) a response from a remote computer system responsive to transmission of test data to the remote computer system (e.g., a response containing pre-weld condition profile data, on-the-fly profile data, profile data after welding, acknowledgment of transmitted profile data, welding protocol or other operation protocol, defect warning or other data). In one embodiment of the invention, the response may be derived from the transmitted verification data and additional data received by the remote computer system. By way of example, the additional data may be associated with observations of one or more operations performed on other pipes, inspections of other pipes, one or more inputs used to perform the observed operations, or other data (described herein). Thus, for example, one or more operations in a field system (eg, a 5000 field system or another field system) can be controlled based on previously unavailable large databases of data received from the same field system and/or other field systems. For example, databases (containing other pipe operation observation data, other pipe inspection data, monitored operation inputs, or other data obtained from the same field system or other field systems) can be used to generate and select one or more welding protocols or other follow-up protocols (described in this document) to prevent or reduce weld defects or create better welds for current and future customers. As another example, an extensive database from different field systems can be used to improve the testing and analysis (described in this document) to provide present and future customers with better products (for example, by reducing welding defects, detecting defects early in the process, etc.). .d.).

[00786] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors 5140 may transmit a contact area profile. surface 5136 between pipes 1022a, 1022b to a remote computer system (eg, a profile obtained from a scan of the contact surface area 5136). In response, one or more processors 5140 may receive (via a receiver) a confirmation of the contact area profile or a modified version of the contact surface area profile 5136 from a remote computer system. In one embodiment of the invention, one or more processors may direct the welding system welding torch 5004 to weld in the contact surface region 5136 based on an approval or a modified version of the contact surface region profile 3136.

[00787] As an example, one or more processors 5140 of the field system 5000 may cause one or more inspection devices to check the area of the contact surface 5136 between the pipes 1022a, 1022b to obtain inspection data (for example, preliminary data from the inspection devices, data from 2D or 3D -images, or other verification data). Verification devices used for verification may comprise one or any combination of the types of verification devices described herein. The received validation data may respectively comprise one or any combination of the types of validation data described herein. As yet another example, one or more processors 5140 may determine the profile of the contact surface region 5136 based on the received test data, but may also transmit the test data to a remote computer system for evaluation of the test data. One or more processors 5140 may send their determined contact surface area profile 5136 to a remote computer system for accuracy verification. Based on its own assessment of the test data, the remote computer system may respond to one or more processors 5140 containing a profile assertion of the contact surface area 5136, indicating that the provided profile is inaccurate, or provide a different response. As an additional or alternative option, if the provided profile is inaccurate, the remote computer system may respond with its own modified version of the contact surface area profile 5316 based on an evaluation of the verification data received from the remote computer system. In response to receiving an acknowledgment, for example, one or more processors 5140 may direct the welding torch of the welding system 5004 to start or continue a welding operation based on its determined contact surface area profile 5136 to weld in the contact surface area 5316. However, if a modified version of the profile is received, one or more processors 5140 may cause the welding torch of the welding system 5004 to begin or continue the welding operation based on the modified version of the profile to weld in the area of the contact surface 5316.

[00788] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors 5140 can communicate with the welding reference laser. a system 5004 for scanning the contact surface area 5136 between the pipes 1022a, 1022b to determine the profile of the contact surface area 5136 prior to the start of the welding operation and generating pre-weld condition profile data based on the scan. In a further embodiment of the invention, one or more processors 5140 may transmit pre-weld condition profile data to a remote computer system. In response, one or more processors 5140 may receive (via the receiver) an acknowledgment of the pre-weld profile data or a modified version of the pre-weld profile data from a remote computer system. In one embodiment, one or more processors may control the pipe engagement device 5052 and/or the pipe engagement device 5054 based on an assertion or modified version of the pre-weld condition profile data to change the region of the contact surface 5136 between the pipes prior to performing the welding operation.

[00789] As an example, one or more processors 5140 of the field system 5000 may cause one or more testers to check the area of contact surface 5136 between pipes 1022a, 1022b to obtain test data prior to the welding operation in the area of contact surface 5136. checks may include one or any combination of the types of check devices described in this document. The received validation data may, as appropriate, include one or any combination of the types of validation data described herein. One or more processors 5140 may generate pre-weld profile data based on the received test data, but may also transmit the test data to a remote computer system for evaluation of the test data. One or more processors 5140 may transmit their generated pre-weld condition profile data to a remote computer system for accuracy verification. Based on its own evaluation of the test data, the remote computer system may give one or more processors 5140 a response containing an acknowledgment of the pre-weld profile data, indicating that the pre-weld profile data is inaccurate, or provide a different response. Additionally or alternatively, if the provided pre-weld profile data is inaccurate, the remote computer system may respond with its own modified version of the pre-weld profile data based on an evaluation of the data provided by the remote computer system. As yet another example, if the pre-weld profile data indicates that the pipes 1022a, 1022b are misaligned and confirmation of the pre-weld profile data is obtained, then one or more processors 5140 may cause the pipe engagement devices 5052, 5054 to re-align the pipes 1022a , 1022b before starting the welding operation to weld in the area of the contact surface 5136. However, if a modified version of the pre-weld state profile data is received, one or more processors 5140 may instead use the modified version to perform subsequent operations, for example, using a modified version to determine if realignment is required and how it should be performed, select a welding protocol to use to weld in the area of the 5136 contact surface, etc.

[00790] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors may develop a welding protocol based on confirmation or modified version of the pre-weld profile data (received from a remote computer system). As an example, if confirmation of the pre-weld profile data is received, one or more 5140 processors can use their generated pre-weld profile data to develop a welding protocol to be used to perform the welding operation in the area of the contact surface 5136. As another example, if a modified version of the pre-weld profile data is received, one or more processors 5140 may use the modified version to develop a welding protocol to be used to perform the welding operation in the area of the 5136 contact surface.

[00791] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors 5140 can communicate with the reference laser. a welding system 5004 for scanning a contact surface area 5136 between pipes 1022a, 1022b to determine the profile of the contact surface area 5136 during a welding operation and generating on-the-fly profile data based on the scan. In yet another embodiment, one or more processors 5140 may transmit (via a transmitter) on-the-fly profile data to a remote computer system. In response, one or more processors 5140 may receive (via the receiver) an acknowledgment of the on-the-fly received profile data or a modified version of the on-the-fly received profile data from the remote computer system. In one embodiment of the invention, one or more processors 5140 may control the welding torch of the welding system 5004 based on an assertion or modified version of on-the-fly profile data during a welding operation.

[00792] As an example, one or more processors 5140 of the field system 5000 may cause one or more testers to check the area of the contact surface 5136 between the pipes 1022a, 1022b to obtain test data during a welding operation in the area of the contact surface 5136. Checkers used to checks may include one or any combination of the types of check devices described in this document. The received validation data may, as appropriate, include one or any combination of the types of validation data described herein. One or more processors 5140 may generate on-the-fly profile data based on the received test data, but may also transmit the test data to a remote computer system for evaluation of the test data. One or more processors 5140 may send their generated on-the-fly profile data to a remote computer system for verification of accuracy. Based on its own assessment of the verification data, the remote computer system may provide one or more processors 5140 with a response containing an acknowledgment of the on-the-fly obtained profile data indicating that the provided on-the-fly profile data is inaccurate, or another answer. Additionally or alternatively, if the post-weld profile data provided is inaccurate, the remote computer system may respond to provide its own modified version of the profile data on the fly based on the remote computer system's evaluation of the verification data.

[00793] As another example, if confirmation of on-the-fly profile data is received, one or more 5140 processors can use their generated on-the-fly profile data to update the welding parameters used to control the welding torch protocol. welding system 5004 (for performing the welding operation in the area of the contact surface 5136) during the welding operation. As yet another example, if a modified version of on-the-fly acquired profile data is received, one or more 5140 processors may use the modified version to update the welding parameters used to control the welding torch protocol of the 5004 welding system (to perform a welding operation in the contact area). surface 5136) when performing a welding operation.

[00794] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors 5140 can communicate with the reference laser. a welding system 5004 for scanning the contact surface area 5136 between the pipes 1022a, 1022b to determine the profile of the contact surface area 5136 after the welding operation and generating post-weld profile data based on the scan. In a further embodiment of the invention, one or more processors 5140 may transmit post weld condition profile data to a remote computer system. In response, one or more processors 5140 may receive (via a receiver) an acknowledgment of the post-weld profile data or a modified version of the post-weld profile data from a remote computer system.

[00795] As an example, one or more processors 5140 of the field system 5000 may cause one or more testers to test the contact surface area 5136 between the pipes 1022a, 1022b to obtain test data after a welding operation in the contact surface area 5136. , may include one or any combination of the types of test devices described in this document. The received validation data may, as appropriate, include one or any combination of the types of validation data described herein. One or more processors 5140 may generate post-weld profile data based on the received test data, but may also transmit the test data to a remote computer system for evaluation of the test data. One or more processors 5140 may transmit their generated post-weld condition profile data to a remote computer system for accuracy verification. Based on its own evaluation of the test data, the remote computer system may give one or more processors 5140 a response containing an acknowledgment of the post-weld profile data, indicating that the post-weld profile data is inaccurate, or provide a different response. As an additional or alternative option, if the provided post-weld profile data is inaccurate, the remote computer system may respond with its own modified version of the post-weld profile data obtained based on the remote computer system's evaluation of the test data.

[00796] In one embodiment, when one or more processors 5140 are local to field system 5000 (e.g., part of a computer system local to field system 5000), one or more processors 5140 may, based on confirmation or modified version of the post-weld profile data (received from the remote computer system) to direct another welding operation to be performed in the region of the contact surface 5136 between the pipes. As an example, if confirmation of the post-weld profile data is received, one or more processors 5140 can use their generated post-weld profile data to determine whether the result of the welding operation has one or more defects, whether the contact surface area 5136 is ready for the next step. operations, or for other definitions. In one application, for example, after a root pass operation is completed in the contact surface region 5316, the post-weld profile data of the root pass layer in the contact surface region 5316 may reveal that the root pass layer is not thick enough. In response, the post-weld profile data can be used to determine welding parameters for a welding operation to compensate for insufficient thickness or welding parameters for a hot pass operation to create a hot pass layer (on the root pass layer) that compensates for the insufficient thickness of the root pass layer. As another example, if a modified version of the pre-weld profile data is received, one or more processors 5140 may use the modified version to perform the above in place of their generated post-weld profile data.

[00797] In one embodiment, welding parameters that affect weld quality may include voltage, current, welding torch speed, wire feed speed, gas flow, and so on. In one embodiment of the invention, other welding parameters that affect the quality of the weld may include resistance, temperature, and so on.

[00798] In one embodiment of the invention, the voltage used in the welding process can influence the width of the weld bead and the shape of the weld bead. In one embodiment of the invention, the voltage is measured in volts. In one embodiment of the invention, the welding system may include a voltage sensor configured to measure the voltage of the power source used to create the welding arc.

[00799] In one embodiment of the invention, the current used in the welding process can affect the penetration of the weld bead. In one embodiment of the invention, the current is measured in amperes. In one embodiment of the invention, the welding system may include a current sensor configured to measure the current of the power source used to create the welding arc.

[00800] In one embodiment, the weld feed rate is the rate at which the welding electrode moves during welding along the joint to be welded. In one embodiment of the invention, the welding electrode is supplied from a welding torch. In one embodiment of the invention, the welding speed can be controlled by controlling the welding torch that supplies the welding electrode. In one embodiment of the invention, the welding speed during the welding process can influence the size of the weld bead and/or the penetration of the weld bead. In one embodiment of the invention, the welding speed is measured in millimeters/second or inches/minute.

[00801] In one embodiment, the wire feed rate/wire utilization is the rate at which welding electrode material is used (or fed into the weld) during the welding process. In one embodiment of the invention, the wire feed speed is measured in millimeters/second or inches/minute. In one embodiment of the invention, the welding system may include a wire feed speed sensor that is configured to measure the material flow of the welding electrode.

[00802] In one embodiment of the invention, the rate of change of the mass of the coil allows the welding system to measure the speed at which the welding wire 5007 is fed into the weld. In one embodiment, the feed motor is running at a certain/preset speed, but the wheel that pushes wire 5007 may slip due to minor changes in wire 5007 or wear on the feed wheel itself. These slips may be temporary and their presence may be recorded and used in the quality control feedback loop. If the slip is constant, one or more of the 5140 processors may be configured to increase the speed of the feed motor to compensate for it. Over time, the overdrive ratio can be increased. Eventually, compensation will no longer be possible and the 5004 welding system will be taken out of service for maintenance. In one embodiment of the invention, tracking the increase in overdrive ratio across all welding systems allows one or more processors to determine the best limit for the maximum allowable overdrive ratio. This setting can then be transferred to all welding systems in operation. In one embodiment of the invention, one or more processors 5140 may be configured to update a value at any time as data becomes available to minimize process interruptions and minimize the frequency of machine downtime for maintenance purposes.

[00803] In one embodiment of the invention, the welding system may include a gas flow sensor configured to determine/detect the flow rate of shielding gases used in the welding procedure. In one embodiment of the invention, the shielding gas may be an active gas that is configured to protect the molten weld pool. In one embodiment of the invention, the gas flow sensor is configured to provide a signal proportional to the gas flow rate in the shielding gas conduit. In one embodiment, one or more processors 5140 of field system 5000 are configured to stop welding when the shielding gas flow rate is outside a predetermined gas flow rate range.

[00804] In one embodiment, the pipes are preheated before the welding process begins. In one embodiment of the invention, the temperature of the pipes may be monitored by one or more temperature sensors of the welding system. In one embodiment of the invention, one or more temperature sensors are configured to measure the temperature of the pipe at each point along the entire length of the weld. In one embodiment, the one or more processors 5140 of the field system 5000 are configured to stop the welding process when the pipe temperatures are not within a predetermined temperature range.

[00805] In one embodiment of the invention, the welding system may include a resistance sensor configured to determine/detect the input electrical resistance of the welding system.

[00806] In one embodiment of the invention, the correct wire/welding electrode/filler must be used for each welding pass. For example, the only difference between two spools of wire is the difference in wire diameter, which is 0.1 millimeters. In the event that the manufacturer's label for a wire spool has been smudged or faded, the wrong spool may be loaded into the welding system. The RFID tag on the spool contains the spool ID. In one embodiment, the RFID tag on the spool can be read by a sensor in the welding system. In the event that the RFID tag contains an incorrect spool ID, the welding system is configured to not supply wire material and alert the user to change to the correct wire.

[00807] In one embodiment, the weight of the spool may be controlled by one or more processors 5140 of the field system 5000. If a filler wire runs out during the welding process, the voltage signal that the processor uses to control the distance between the welding tip and the work area goes to zero. In response, the processor moves the tip closer to the work area, which causes the tip to touch the molten weld metal and cause a copper inclusion defect. Therefore, knowing the exact weight of the wire remaining on the spool helps the welding system prevent the start of a welding pass that requires more filler wire than is available. Also, if the weight of the spool no longer changes, this may indicate an empty spool or wire feeder failure. In either case, one or more processors 5140 of field system 5000 are configured to stop the welding process.

[00808] In one embodiment of the invention, one or more processors 5140 of the field system 5000 are configured to track the mass of each coil in real time. Each weld pass in a weld requires a different amount of wire due to the variation in diameter and variation in the width of the weld slot to be filled.

[00809] If one or more of the processors 5140 of the field system 5000 determines that there will be very little wire left in the spool to complete the next weld pass, but there will be enough wire to complete another weld pass, the one or more processors 5140 of the field system 5000 may be configured to inform the operator of the need to remove the coil and transfer it to another operator. For example, a spool starts with 10 lbs of wire, and the weld system requires 1.3 lbs of wire for a weld pass. The welding system will be able to complete its weld passes at 7 welds before very little wire is left in the spool.

[00810] When the spool is removed after the 7th weld pass, there will be 0.9 pounds of wasted wire left in that spool. If there is another weld pass that requires, for example, 1.1 pounds of wire, then one or more processors 5140 of the field system 5000 are configured to alert the operator to remove the spool after 6 weld passes. In this case, the spool will still contain 2.2 pounds of wire. This spool can then be used for a weld pass requiring only 1.1 pounds of wire to make 2 such weld passes (without wasting wire).

[00811] In one embodiment, the welding wire 5507 passes through the welding tip 5503. The welding tip 5503 also has a high welding current. Both of these factors lead to wear on the 5503 welding tip. In this case, the contact point inside shifts, which inherently affects the characteristics of the arc and, therefore, the quality of the weld. In one embodiment of the invention, welding parameters such as voltage, current, wire feed, power and resistance are monitored in real time. This data is sent to the tablet via one or more processors and must be analyzed to compare signatures on the above variables due to the computationally intensive nature of the analysis. When the analysis detects an imminent problem, a message is sent to the internal 5004 welding system and the operator to replace the 5503 welding tip before starting the next welding. In addition, this data can be used in a quality control feedback loop. In one embodiment of the invention, the results obtained from the quality control feedback loop can be used to update welding tip wear signatures on the fly.

[00812] In one embodiment, exemplary welding parameters that are used in uphill and downhill welding processes are illustrated in FIG. 72D. For example, in one embodiment of the invention, at least one of the plurality of welding torches 5502 welds in the direction of rotation up (i.e., up), while at least one of the plurality of welding torches 5502 welds in the direction of rotation down (i.e., up). descent). In one embodiment of the invention, the welding parameters shown herein are given by way of example and are not optimized in any way and do not include anything that may require changes during these welding processes. In one embodiment, the travel speed for downhill welding is 13.5 inches/minute and for uphill welding is 10.0 inches/minute. In one embodiment of the invention, the amplitude of the transverse oscillation of the electrode is 0.09 inches for the downhill welding process and 0.15 inches for the uphill welding process. In one embodiment of the invention, the oscillation speed is 160 beats per minute for the downhill welding process and 130 beats per minute for the uphill welding process. In one embodiment of the invention wave control 1 (ie related to wire feed speed) is 400 for the downhill welding process compared to 370 for the uphill welding process. In one embodiment of the invention, the weld passes were welded at 16.5 volts with a voltage controlled power supply.

[00813] The following describes the operation of the internal welding system 5004. In one embodiment of the invention, the internal welding system 5004 is configured to be controlled through a repetitive cycle of operation.

[00814] After it is determined that the welding of the current welding joint is completed, one or more processors 5140 are configured to send communication signals to the electronic wire feed module 5046 to control (via control signals) the welding torch motors 5512, 5550, 5588 (by) for return welding torches 5502 to their original, retracted positions. One or more processors 5140 are also configured to send communication signals to the forwardmost electronics module 5014 to control/disable (via control signals) the front clamp control valve 5018 to retract the first engagement device 5052 to its rest, retracted position and send the communication signal to the central electronics module. section 5064 to control/disable (via control signals) the rear clamp control valve 5062 to retract the second engagement device 5054 to its original, retracted position. The 5004 internal welding system (containing 5502 welding torches and 5144, 5142 clamps) must be moved to the next weld.

[00815] In one embodiment of the invention, one or more processors 5140 are configured to transmit communication signals to the drive section electronics module 5118 to control (via control signals) the drive motors 5124 to accelerate the internal welding system 5004 to move it at a given speed, and also the subsequent slowdown and stop at the next welded joint. In one embodiment of the invention, the target speed at which the internal welding system 5004 accelerates may be 6 feet/second.

[00816] When the second engagement device 5054 is located on the next weld, the drive section electronics module 5118 sends communication signals to the wire feed electronics 5046 to check alignment with the pipe end. In one embodiment of the invention, the electronic wire feed module 5046 is configured to control one or more measurement sensors 5056 to measure exactly where the second engagement device 5054 is relative to the end of the pipe. In one embodiment of the invention, the pivot hub 5072 may not work when one or more sensors 5056 measure exactly where the second engagement device 5054 is relative to the end of the pipe.

[00817] In one embodiment, the wire feed electronics module 5046 is configured to send measured distance data to the drive section electronics module 5118. In one embodiment, the drive section electronics module 5118 is configured to control (via control signals) the drive motors 5124 to moving the first and second engagement devices 5052, 5054 based on the measured distance data.

[00818] In one embodiment, when the second engagement device 5054 is properly aligned and positioned relative to the end of the pipe, the drive section electronics module 5118 is configured to communicate to the center section electronics module 5064 that the internal welding system 5004 is in correct position on the next weld. In one embodiment, the center section electronics module 5064 controls (opens via control signals) the rear clamp control valve 5062 to lift the second engagement device 5054 and grip the old/existing pipe.

[00819] The work crew then inserts the next/new pipe segment 1002a and slides over the frontmost section 5006 of the internal welding system 5004 into position. At this time, one or more processors 5140 are configured to send communication signals to the electronic wire feed module 5046 to control one or more gauges 5056 to check pipe alignment. In one embodiment, one or more processors 5140 may rotate the pivot hub 5078 to take measurements at multiple locations.

[00820] If the pipe alignment data is within a predetermined tolerance, the wire feed electronic module 5046 sends communication signals to the frontmost electronic module 5014 to actuate the front clamp 5142. In one embodiment, the forwardmost electronic module 5014 controls/opens (via control signals) a front clamp control valve 5018 to lift the first engagement device 5052 and grip the new pipe segment 1002a.

[00821] If the pipe alignment data is not within a predetermined tolerance, the electronic wire feed module 5046 sends communication signals (message) to one or more processors 5140 identifying misalignment between pipes 1022a, 1022b. In one embodiment of the invention, this information may be communicated to the crane operator by conventional hand signals from the crane operator or by an electronic signal to a computer display terminal in the crane cabin.

[00822] After the pipes are clamped, one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to control one or more measurement sensors 5056 to measure the gap and radial offset of the stagger at several points along the circumference of the weld. In one embodiment of the invention, this data is reported to one or more processors 5140 and compared with allowed tolerances.

[00823] If the weld joint assembly (i.e., gap and radial offset of the step transition) is within a given tolerance, either one or more of the 5140 processors or the 5046 electronic wire feed module sends communication signals to the operator indicating that welding can begin, or sends communication signals to the 5046 electronic wire feed module to automatically start the welding process.

[00824] If the weld joint assembly (i.e. gap and radial offset of the step transition) is not within the specified tolerance, then an alert is sent to the operator and can restart the clamping sequence or disable the alert. In one embodiment of the invention, the internal welding system 5004 is capable of welding up to 4 millimeters of gap and radial offset of the stagger.

[00825] In one embodiment of the invention, the electronic wire feed module 5046 is configured to automatically start the welding process. In one embodiment of the invention, one or more processors 5140 are configured to send communication signals through the tether 5034 to the welding power source to turn on the welding power source for the welding torch(s) 5502. In one embodiment of the invention, the electronic wire feed module 5046 configured to control/move one or more welding torches 5502 in the radial, axial and/or angular direction to the proper position for welding. In one embodiment of the invention, the electronic wire feed module 5046 moves one or more welding torches 5502 in the radial, axial and/or angular direction to the proper working distance from the pipe and to the center of the weld, as measured by one or more measurement sensors 5056.

[00826] In one embodiment of the invention, the electronic wire feed module 5046 is also configured to control (turn on) the shield gas valve(s) 5042 to supply shield gas to the welding torch(s) 5502 and control the welding supply system motors 5044 to start feeding the welding wire or electrode to the welding torch(s) 5502.

[00827] In one embodiment, the wire feed electronic module 5046 sends communication signals to both the frontmost section electronic module 5014 and the center section electronic module 5064 to start rotation of the rotary hub 5078. In one embodiment, the wire feed electronic module 5046 sends communication signals to both the forwardmost section electronics module 5014 and the center section electronics module 5064 to synchronize the front rotation motor 5030 and the rear rotation motor 5074. In one embodiment, the forwardmost section electronics module 5014 sends control signals to control the front motor rotation motor 5030, and the center section electronics module 5064 sends control signals to control the rear rotation motor 5074. 5142, 5144 remain stationary. In one embodiment of the invention, the rotary hub 5078 continues to rotate until the full extent of the weld.

[00828] In one embodiment, the electronic wire feed module 5046 is configured to control one or more measurement sensors 5056 to locate the center of the weld and move the welding torch 5502 axially toward the weld.

[00829] In one embodiment of the invention, the electronic wire feed module 5046 is configured to measure the welding power voltage. The measured voltage data can be used by the 5046 Wire Feed Electronics Module to determine the distance from the 5502 welding torch to the pipe. In one embodiment of the invention, the electronic wire feed module 5046 is configured to adjust the welding torch 5502 in the radial direction to maintain a constant distance from the welding torch 5502 to the pipe. In one embodiment of the invention, the electronic wire feed module 5046 may cause the welding torch 5502 to oscillate in the axial direction to improve the quality of the weld.

[00830] In one embodiment, the electronic wire feed module 5046 is configured to change the angle of the welding torch 5502 based on which portion of the weld is being welded. For example, the angle of the welding torch 5502 in the plane of travel is adjusted to compensate for gravity.

[00831] In one embodiment of the invention, the electronic wire feed module 5046 may be configured to change the wire feed speed or send communication signals to the welding power source (via cable 5034) to change the welding current based on measurement data received from one or more measuring sensors 5056.

[00832] In one embodiment of the invention, the welding process can be performed by one welding torch in one welding pass with a rotation of 360 ^o . In one embodiment of the invention, welding can start and end anywhere along the weld.

[00833] In one embodiment of the invention, the welding process can be performed using N equidistant welding torches 5502, when the rotary hub 5078 rotates (360/N) degrees to perform one welding pass. In one embodiment of the invention, the welding process can be performed using N equidistant welding torches 5502, when the rotary hub 5078 rotates (2 times (360/N)) degrees to make two welding passes. For example, in one embodiment of the invention, when the internal welding system 5004 includes three equidistant welding torches 5502, the rotary hub 5078 rotates 120 ^° for one weld pass and rotates 240 ^° for two weld passes.

[00834] When the welding torches 5502 reach the point where the previous welding torch 5502 began its welding pass, one or more measurement sensors 5056 detect the existing weld bead and the electronic wire feed module 5046 is configured to move the welding torches 5502 in the radial direction to alignment.

[00835] In one embodiment of the invention, two welding passes can be performed as above, with a short stop between welding passes to achieve full laser and visual inspection of the post-weld condition. In one embodiment, ^a 360° weld may be performed using N unequally spaced torches 5502, with each welding torch 5502 performing a subsequent weld pass to achieve a total of N 360° weld passes plus ^the distance from the first torch to the Nth torch.

[00836] After it is determined that the welding is completed, one or more processors 5140 are configured to send communication signals to the electronic wire feed module 5046 to control (via control signals) the welding torch motors 5512, 5550, 5588 (by) to return the welding torches 5502 to their original, retracted positions. For example, welding torches 5502 can be retracted to their original home positions for each axis (radial, axial, oblique).

[00837] In one embodiment of the invention, the rotary hub 5078 continues to rotate while the electronic wire feed module 5046 controls one or more measurement sensors 5056 and one 2D camera 5112 to check the quality of the weld. In one embodiment of the invention, if certain types of weld defects are detected (e.g., loose filler, insufficient weld reinforcement), one or more 5140 processors are configured to send communication signals to the 5046 electronic wire feed module to move the 5502 welding torch to that location and apply additional material to eliminate the defect.

[00838] After the inspection and any repairs are completed and confirmed by the operator, the operator can send communication signals to the frontmost electronic module 5014 to control/disable (via control signals) the front clamp control valve 5018 to retract the first engagement device 5052 into its home retracted position and send communication signals to the center section electronics module 5064 to control/disengage (via control signals) the rear clamp control valve 5062 to retract the second engagement device 5054 to its home retracted position.

[00839] In subsea pipeline applications, errors in both angular and positional alignment of pipes can be corrected by sending control signals from one or more processors 5140 to platforms 5330 or platforms 6010A and 6010B (to control associated rollers 5332).

[00840] In one embodiment, the purge and test system 7001 or internal welding system 5004 may include a single clamp that is designed and configured to grip the inside surface of the first pipe 1022b. In one embodiment of the invention platforms 5330 or platforms 6010A and 6010B are configured to move the second/incoming pipe 1022a to the desired position. In one embodiment, one or more processors 7062 or 5140 are configured to communicate with a 5056 or 7042 measurement sensor to check alignment between pipes and provide control signals to platforms 5330 or platforms 6010A and 6010B to correct any pipe alignment errors (corner or positional). In one embodiment of the invention, the control signals from one or more processors 5140 are configured to adjust the relative position between the pipes (correcting their alignment errors). In one embodiment, this process can be applied to thin or thick wall pipes that have a very low (<20) diameter to wall thickness ratio since no amount of clamping force will appreciably change the shape of the low D/t pipe.

[00841] In one embodiment, the purge and test system 7001 or internal welding system 5004 may include two clamps. For example, one clip is designed and configured to grip the inner surface of the first pipe 1022b. In one embodiment of the invention platforms 5330 or platforms 6010A and 6010B are configured to move the second/incoming pipe 1022a to the desired position. In one embodiment, the second clamp is designed and configured to grip the inner surface of the second/inlet pipe 1022a. In one embodiment of the invention, one or more processors 7062 or 5140 are configured to interact with a measurement sensor 5056 or 7042 to check alignment between pipes. For example, if the alignment is not acceptable, the second clamp releases the second tube 1022a. One or more processors 7062 or 5140 are configured to send control signals to platforms 5330 or platforms 6010A and 6010B to correct any pipe alignment errors (angle or position). In one embodiment of the invention, control signals from one or more processors 5140 are configured to correct relative positioning between pipes (correcting their alignment errors), for example, by changing the position of pipe 1022a. This process may continue until an acceptable alignment of the tubes is achieved with the gauge or a predetermined number of attempts (eg, 10), at which time the second tube 1022a is removed and a new second tube is moved in its place.

[00842] In one embodiment of the invention, the alignment of the faucet and clamp is used in the process of alignment and welding of the onshore pipeline. In onshore pipeline applications, pipeline angular alignment error can be corrected by giving commands to the crane operator, and positional alignment error can be corrected by giving commands to workers to install a gasket between the clamp and the pipe.

[00843] In one embodiment, the purge and test system 7001 or internal welding system 5004 may include a single clamp that is designed and configured to grip the inside surface of the first pipe 1022b. In one embodiment of the invention, the crane operator moves the second/incoming pipe 1022a to the desired position, and the workers apply an external clamp around the joint. In one embodiment of the invention, one or more processors 7062 or 5140 are configured to interact with a measurement sensor 5056 or 7042 to check alignment between pipes. If the 5056 or 7042 transducer detects a pipe misalignment/alignment error, commands are sent to the crane operator to correct the misalignment/pipe alignment error and workers release the clamp while moving the pipe. If the 5056 or 7042 gauge detects a pipe misalignment/alignment error, commands are sent to workers to install and shim thickness needed to correct the pipe misalignment/alignment error. Workers remove the clip, install gaskets, and replace the clip. This process is repeated until the measuring sensor accepts the alignment of the pipe.

[00844] In one embodiment, the purge and test system 7001 or internal welding system 5004 may include two clamps. For example, one clip is designed and configured to grip the inner surface of the first pipe 1022b. In one embodiment of the invention, the crane operator moves the second/incoming pipe 1022a to the desired position. In one embodiment, the second clamp is designed and configured to grip the inner surface of the second/inlet pipe 1022a. In one embodiment of the invention, one or more processors 7062 or 5140 are configured to interact with a measurement sensor 5056 or 7042 to check alignment between pipes. If the 5056 or 7042 transducer detects a pipe misalignment/alignment error, the second clamp releases the second pipe and commands are sent to the crane operator to correct the misalignment. If the 5056 or 7042 transducer detects a pipe misalignment/alignment error, the second clamp releases the second pipe and instructions are given to workers to install and shim thickness needed to correct the pipe misalignment/alignment error. The crane operator moves the second pipe away from the first pipe and the workers install the spacers. The crane operator moves the second pipe back. The second clamp grips the second pipe. This process is repeated until the measuring sensor accepts the alignment of the pipe.

[00845] In FIG. 103B illustrates alignment, welding, and verification of the 5004 internal welding system.

[00846] In one embodiment, the measurement sensor 5056 scans 360 ^about the contact surface area 5136 between pipes 1022a, 1022b before any welding is performed. In one embodiment, during the pre-weld profile data generation process, the measurement sensor 5056 is positioned between the clamps and/or seals of the internal welding system 5004 and turned on. In one embodiment, the welding torch(s) 5502 are turned off during the pre-weld state profile data generation process. In one embodiment of the invention, one or more processors 5140 are configured to interact with the measurement sensor 5056 to scan the area of the contact surface 5136 in order to obtain pre-weld condition profile data after engagement, respectively, of the first clamp 5142 and the second clamp 5144 with the first pipe 1022a and the second pipe 1022b.

[00847] In one embodiment, platforms 5330 (as illustrated in FIGS. 10A and 10B) and 6010A and 6010B (as illustrated in FIG. 73) are controlled (or otherwise controlled) by one or more processors 5140 to engage with external surfaces 5346 and/or 5348 (as illustrated in FIG. 2G) of the first pipe 1022a and/or the second pipe 1022b to adjust the relative position of the pipes 1022a, 1022b when the pre-weld condition profile data determines that adjustment is required. In one embodiment, the inner surface 5130, 5132 of the first tube 1022a and/or the second tube 1022b engages with and is controlled by the first clip 5142 and the second clip 5144, respectively, to adjust the relative position of the tubes 1022a, 1022b when the profile data pre-weld conditions determine that adjustment is required.

[00848] In one embodiment of the invention, during the on-the-fly profile data generation process, the measurement sensor 5056 is located between the clamps and/or seals of the internal welding system 5004 and is turned on. In one embodiment, one or more processors 5140 are configured to control the position and speed of movement of the welding torch 5502 (or 7502) based on on-the-fly welding profile data. In one embodiment of the invention, the on-the-fly scan/verify procedure is performed during the root pass procedure. In one embodiment, an optional radiographic inspection procedure (e.g., 1044, as illustrated and described with reference to FIG. 1B) may be performed between the on-the-fly scan/inspection and root pass procedure and the on-the-fly scan procedure. »/ checks and filling and facing pass.

[00849] In one embodiment of the invention, the measuring sensor 5056 scans 360 ^{about the} area of the contact surface 5136 between the pipes 1022a, 1022b after performing the welding operation. In one embodiment, during the post-weld profile data generation procedure, the measurement sensor 5056 is positioned between the clamps and/or seals of the internal welding system 5004 and is turned on. In one embodiment, the welding torch(s) 5502 is turned off during a post-weld state profile data generation procedure.

[00850] In one embodiment, a weld check procedure (eg, 1008, as illustrated and described with reference to FIG. 1B) may be performed after a post weld scan/check procedure.

[00851] The procedures illustrated in FIG. 103B are described with respect to the internal welding system 5004. However, as illustrated in FIG. 103B, it is assumed that the same procedures apply to the pipe string welding system 3001 and the purge and test system 7001, and therefore will not be described again with reference to the pipe string welding system 3001 and the purge and test system 7001.

[00852] Since, in one or more embodiments of the invention, the pipe is internally welded (i.e., the root pass is made inside the pipe), the resulting root weld can be superior because it better accommodates any mismatch and/or areas of mismatch or step transition, inside the pipe. In addition, if a hot weld pass (second weld layer over the root bead) is also applied internally, the pipe can also be provided with a secure root reinforcement over the root pass. A hot weld pass, as well as an additional weld pass made inside, can provide a small curved protrusion that protrudes slightly into the pipe to further strengthen the pipe. For example, the inside diameter of the pipe may be designed to be slightly smaller in the area of the weld than the inside diameter of the welded pipe in areas where there is only tubular material without welding. In one aspect of the present application, the hot weld pass of the weld metal has at least a portion of it in regions located closer to the longitudinal axis of the pipe than the inner surfaces of the welded pipes in regions of the welded pipes immediately adjacent to the weld metal on opposite sides of the placement of the weld metal .

[00853] In some embodiments, the internal welding system 5004 disclosed herein is capable of welding pipes at least 30' feet long. In other embodiments, the internal welding system 5004, 3001 disclosed herein is capable of welding pipes with a diameter of 26″ or less. In still other embodiments of the invention, the internal welding system 5004 can weld pipes with a diameter of less than 24" inches. In yet other embodiments, the internal welding system 5004 disclosed herein is capable of welding pipes that are at least 30' feet long and less than 24'' in diameter.

[00854] FIG. 73-85 illustrate and disclose another embodiment of an internal welding system in accordance with another embodiment of the present patent application.

[00855] This patent application provides a system for leveling and welding the surfaces of two pipe segments. This system contains an external leveling mechanism and a welding mechanism. The external alignment mechanisms can be as complex as the control modules illustrated in the drawings, or as simple as the tip-to-ton clamp as illustrated in US Pat. No. 1,693,064. coast or sea. US Pat. No. 1,693,064 is incorporated herein by reference in its entirety. Regardless of which mechanism is used, an external alignment mechanism maintains and adjusts each segment so that the segments are effectively collinear or axially aligned along their longitudinal axes.

[00856] The external alignment mechanism may support the pipe segment and may include feeders that allow the position and orientation of the pipe to be adjusted. In particular, the outer alignment mechanism may include rollers that allow the pipe to move in the longitudinal direction. The pipe may also be supported by rollers which allow the pipe to be rolled around its longitudinal axis and moved up and down. Position and orientation adjustment can be automated using motor power or hydraulic power controlled at the operator station or fed to a central controller that automatically controls and aligns the segments based on preset alignment parameters or feedback from an internal laser reading the contact surface or connection profile.

[00857] The welding mechanism is an internal welding machine that uses welding (e.g., metal arc welding in shielding gas "GMAW") from the inside of the pipe segments to the front seam or edge connection of the segment inside the v-shaped hole formed by the beveled edges of the two segments pipes (other cross-sectional shapes other than V-shaped can also be used). The welding mechanism includes a cargo carriage capable of engaging the inner walls of the pipe in order to be fixed or fixed inside the pipe in a fixed position, and a welding part rotatably supported by the carriage inside the pipe. In particular, the inner welder is positioned inside the aligned pipe and then positioned longitudinally such that the welding head or torch is longitudinally in close proximity to the edge joint. The welding mechanism also contains a rotating mechanism for rotating the welding part relative to the carriage. The welding head or torch is rotatably supported on the welding portion near the longitudinal axis of the pipe such that the welding torch can closely follow the entire inner surface of the joint in orbital rotation. In particular, during welding, the articulated head torch follows the edge joint around the entire circumference of the pipe, depositing the weld metal. In addition to circular rotation about the carriage, various control elements can move the welding head axially along the pipe relative to the carriage in a radial direction towards and away from the connection and pivotally around a point or axis (for example, an axis parallel or perpendicular to the longitudinal axis A-A of the pipe ). The controller can control the rotation of the burners. These degrees of free play of the swivel contribute to a very efficient and productive work of the welding head in filling the profiles of the contact surfaces in the optimal mode and where it is needed.

[00858] The welding mechanism also includes a laser tracking mechanism that operates in conjunction with the torch of the welding portion to detect the profile of the contact surface and/or the profile of the weld metal to apply the weld metal to the edge joint in the appropriate location and amount. The laser mechanism examines the weld and sends a signal to the articulated weld head controller to control the movement of the head around the entire edge joint. In particular, the torch follows the laser while the welding head control constantly receives information about the weld profile from the edge joint. The information is then used to continually adjust the torch to achieve the desired weld pattern.

[00859] In addition to the laser tracking mechanism, the system may include a 2D camera to visually check the weld. The 2D camera is mounted on the welding part and follows the torch so that the operator can check the welding status immediately after the torch is done. The visual signal is given to the operator's external display. For example, the 2D camera may be a color camera and the color change may indicate to the operator that a welding defect has occurred. A suspected profile change may also indicate a defect.

[00860] As illustrated in FIG. 73-75, the following describes a system for welding pipe segments. On FIG. 73 illustrates an external alignment mechanism 6010A and 6010B that is configured to support, position, and move multiple pipeline strings. Each mechanism 6010A and 6010B may include supports (eg, rollers) on which a string of conduit may be supported. The longitudinal roller 6012 movably supports the pipeline segment 6105 so that the segment 6105 can be re-positioned along its longitudinal direction, indicated by arrow A. In addition, the rotary rollers 6014 are rotatable about an axis parallel to the axis A-A of the support segment 6105 at each from the sides of the segment 6105, allowing them to rotate or adjust the angular orientation of the segment 6105 about the axis AA. The external leveling mechanism 6010 is configured to automatically manipulate multiple segments into various positions and orientations using motors, hydraulic mechanisms, etc. For example, segments can be raised, lowered, rotated, tilted, scrolled, and so on.

[00861] As illustrated in FIG. 73, external alignment mechanisms 6010A and 6010B support multiple segments 6105, 6110 and adjust their position and orientation until both segments 6105, 6110 are aligned such that their longitudinal axes AA are collinear and one end of each of the segments 6105, 6110 rested on the edges of the contact surface. In particular, in FIG. 74 is an enlarged view of the detail 6100 illustrated in FIG. 73, where the edges form the contact surface of the pipe 6120 (known as a “seated” joint).

[00862] The pipe alignment and welding system of this patent application performs welding on the inside of the contact surface 6120 from the inside of the seated segments 6105, 6110. as illustrated in FIG. 75. The second segment 6110 is then placed on the outer alignment mechanism 6010B and manipulated until both segments 6105, 6110 are properly aligned. An external force may then be applied to the drive rod 6345 of the internal welding mechanism 6300, or the mechanism may comprise an automatic self-propelling means to adjust its axial position in the aligned segments 6105, 6110.

[00863] As illustrated in FIG. 76-79, the welding mechanism 6300 includes a carriage 6301 and a welding portion 6302. The carriage 6301 includes at least one alignment mechanism 6340A, 6340B, which can expand in the radial direction to engage with the inner surface of the segment 6105 or 6110. This expansion and engagement provides axial / longitudinal position of the welding mechanism 6300 relative to the segment 6105, 6110 and aligns or radially centers the welding mechanism 6300 in the segments 6105, 6110. The carriage 6301 also includes a housing 6311 on which the rotation mechanism 6335 is supported. The housing 6311 consists of several elongated structural support elements that pass between the 6340A and 6340B alignment mechanisms. As described below, welding piece 6302 contains a similar corresponding design 6313.

[00864] The welding part 6302 is rotatably connected to the carriage 6301 and extends from the end of the carriage 6301. The relative rotation between the carriage 6301 and the welding part 6302 is facilitated by the rotation mechanism 6335. The rotation mechanism 6335 is attached to the carriage 6301 and is automatically (by motor and gearing) rotates the welding part 6302 relative to the carriage 6301 about the longitudinal axis AA. The welding portion 6302 may be cantilevered on the carriage 6301 or may be supported by an additional leveling mechanism 6340C positioned such that the torch 6305 is positioned between the leveling mechanisms 6340B and 6340C. When a 6340C alignment mechanism is provided, the welding portion 6302 rotates with respect to and between both alignment mechanisms 6340B and 6340C as alignment mechanisms 6340B and 634°C expand to secure themselves within the segment. In addition, the carriage 6301 may include an actuating link 6345, which may be an elongated extension from the carriage 6301, which the operator may grasp to insert/push or withdraw/pull the welding mechanism 6300 with respect to its axial position in the segment 6105, 6110.

[00865] In FIG. 76 is an enlarged view of the section 6200 illustrated in FIG. 75 in which only segment 6105 is present and segment 6110 is absent. As illustrated in FIG. 76, the welding part 6302 includes a welding unit 6303, which includes a torch 6305, a laser sensor 6310, and a color camera 6320. The welding part 6302 further has a housing 6313 on which the torch 6305, the laser sensor 6310, and the color camera 6320 are supported. The laser sensor 6310 monitors the internal connection of segments 6105, 6110 and detects the profile of the contact surface that should be used to place the torch 6305 when welding is performed on the contact surface of the connection. The 6313 housing runs between the 6340B and 6340C alignment mechanisms. In section 6200, a welding mechanism 6300 is illustrated positioned within segment 6105, with torch 6305 generally directed radially outward and positioned to weld mating surface 6120. FIG. 77 illustrates an embodiment of a general schematic cross-section of the welder 6300 through section B-B, which illustrates the welder 6303 in the insertion direction of the welder 6300. FIG. 77 also illustrates the direction D of rotation of the 6303 welding unit when rotated by the 6335 rotation mechanism. Therefore, the welding process at a certain point along the 6120 weld joint will be performed first by the 6310 laser sensor, followed by the 6305 torch and, finally, 2D- inspection chamber 6320.

[00866] FIG. 82-84 illustrate several views of the welding portion 6302. FIG. 82 illustrates a 6322 wire delivery system. The 6322 wire feed system includes a 6323 wire spool, a 6325 wire straightener accessory, and a 6330 wire feed mechanism that is automatically controlled to deliver the correct amount of wire to a 6305 torch. rotates the 6302 welding end, the 322 wire delivery system feeds the wire to the 6305 torch.

[00867] As mentioned above, the burner 6305 can be positioned and oriented in a variety of ways using a variety of mechanisms. The 6305 burner is supported on a manipulator. The manipulator contains a radial positioner, an axial positioner and a rotation device. In particular, the radial positioner 6307 (for example, rack and pinion) on which the torch 6305 is supported is capable of moving the torch in a radial direction towards and away from the inner surface of the segments 6105, 6110. In other words, towards and away from the contact surface of the segments 6105, 6110 to be welded. In addition, an axial positioner 6309 (eg, rack and pinion) can move the torch 6305 axially within the segments 6105, 6110. The arm also includes a rotation device 6308 that allows the torch to rotate (eg, about an axis parallel to the longitudinal axis AA of the segment). The torque may be driven by the motor and gearing 6306 using the rotation device 6308. For example, the motor may be a stepper motor.

[00868] The torch manipulator can combine the manipulation movements of the above elements by interdependent support of the elements. For example, housing 6313 may support an axial positioner which in turn supports a radial positioner which in turn supports a rotation device which in turn supports a burner. Likewise, an axial positioner may be supported by a radial positioner. In addition, any support order may be used.

[00869] The elements of the manipulator are controlled by a controller that receives as input a series of signals, including a signal from a 6310 laser, and then processes the information before transmitting the signal to at least a 6307 radial positioner, a 6309 axial positioner, a 6308 rotary device, and a wire delivery system 6322. The torch 6305 then re-travels and continuously reorients itself according to the set parameters of the controller based on the signals received from the profile reading laser 6310.

[00870] Next, the operation of the present internal welding system will be described. On FIG. 73, 80, and 81 illustrate the process of positioning and welding segments 6105 and 6110 together. In operation, one or more of the following lettered steps may be performed such that: a) a pipe segment 6105 is placed on a pipe aligner/stand 6010A; b) the internal welder 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 drive rod 6345 or automatically actuated so that the torch 6305 as a whole is connected to the mating surface 6120 of the pipe segments 6105, 6110; d) the alignment mechanisms 6340A, 6340B (and, if necessary, 6340C) are then engaged to secure the welding mechanism 6300 within the pipe segments 6105, 6110; e) in one (optional) embodiment of the invention, the rotation mechanism 6335 rotates the welding head 6305 to perform an initial scan of the joint of the contact surface 6120 of the pipe segments 6105, 6110 with the laser sensor device 6310 to ensure an optimal fit; f) if desired, steps (c), (d) and (e) may be repeated, ie the pipe segments 6105, 6110 are re-aligned/rotated and re-scanned by the laser 6310 to improve "fit"; g) optionally, an internal 634° C. leveling mechanism on the back of the welder 6300 engages to hold the welder 3600 in axial position with respect to both pipe sections 6105, 6110; h) With the 6300 welder attached to the pipe segments 6105 and 6110, the root weld (first weld) cycle begins so that the 6310 laser sensor scans the 6120 pipe contact surface, the 6305 torch follows the 6310 laser sensor, and the output from the laser sensor 6310 is used to control the position of the articulated torch 6305, while the position and orientation of the torch 6305 relative to the contact surface 6120 is controlled in such a way as to provide the best welding quality; i) in addition to the signal from the 6310 laser sensor, the arc current end-to-end can also be used to control the position of the torch; j) after 360° welding is completed, the welding head 6305 rotates back to its original position; k) profile (using the 6310 laser sensor) and visual checks (using the 6320 2D color camera) are performed either in the preceding step (j) or in a separate proof run; l) after verification, the mechanism is aligned 6340A-C is released and the welding mechanism 6300 is extended or advanced to the open end of the welded pipe 6105, 6110 with the nose cone of the welding mechanism 6300 exposed, similar to step (b), the pipe segment 6110 is placed on the outer alignment mechanism 6010B and advances to the next connection; m) then steps (c) to (l) are repeated for the entire production cycle.

[00871] In one embodiment of the invention, a signal from the laser sensor 6310 is sent to the electronic controller of the external alignment mechanism 6010 to automatically reposition one or both segments 6105, 6110 for a more desirable position of the mating surface 6120. In addition, the above steps can be performed in the order shown. However, variations of this order are also considered.

[00872] In another embodiment of the invention, instead of stopping after the first 360° weld, the rotation continues to perform another weld pass, and the 6310 laser sensor can be used simultaneously for verification and tracking, while the rear 2D color camera continues to check after the second welding.

[00873] In another embodiment of the invention, instead of welding a full 360° weld, welding is performed in two passes of 180° with the same start position. This implementation would either require multiple laser sensors for tracking, or a mechanism to physically oscillate the laser and/or torch to maintain the position of the master tracking sensor in both directions of rotation (i.e. rotate the torch and laser sensor so that they switch to other positions). ).

[00874] In one embodiment, the present patent application discloses a pipe string welding system 3001. In one embodiment, the pipe string welding system 3001 includes all elements of the internal welding system 5004. In one embodiment, additional elements of the pipe string welding system 3001 may include incorporates a large capacity battery so that the 3001 pipe string welding system can travel long distances and has autonomous welding power. In one embodiment of the invention, the pipe string welding system 3001 is configured to operate autonomously so that no external cables are connected to the pipe string welding system 3001.

[00875] As a result of the welding power, travel capability, and other required power available in the system (complete framed battery system), the pipe string welding system 3001 can be used to travel along very long pipe runs and perform the welding operation at such locations. This is achievable because the system does not need to be powered by an external power source.

[00876] In one embodiment, the pipe string welding system 3001 may also include a pipe tightening device to close any gaps. In one embodiment of the invention, a pipe tightening device for closing any gaps may be referred to as a tightening device. In one embodiment of the invention, the tightening device is designed and implemented in such a way that one of the clips is movable with respect to the other clip. In one embodiment of the invention, the tightening device is designed and configured to be external to the main welding section. In one embodiment of the invention, the tightening device is designed and configured to be inside the pipes.

[00877] In one embodiment of the invention, the pipe string welding system 3001 includes a front section 3002, a center section 3004, and a drive section 3006, which are similar to sections of the internal welding system 5004. In one embodiment of the invention, the design, configuration, components, and operation of the front section 3002, the center section 3004 and drive section 3006 of the string welding system 3001 are similar to the front section, center section and drive section of the internal welding system 5004 detailed above, and therefore the design, configuration, components and operation of the front section 3002, center section 3004 and section actuator 3006 welding system strings of the pipeline 3001 in this document are not described in detail. In one embodiment, front section electronics 3002, center section electronics 3004, and drive section electronics 3006 each comprise one or more processors.

[00878] For example, the pipe string welding system 3001 includes a frame that is configured to be placed inside the pipes 1022A, 1022b, a set of rollers 3125 that are rotatable to support the pipe string welding system frame 3001, a drive motor 3124 that drives the rollers 3125 to move the frame of the 3001 string welding system in pipes 1022A, 1022b, a braking system that prevents the frame of the 3001 string welding system from moving to the desired location inside the pipes 1022A, 1022b, a measuring sensor that is attached to the frame of the 3001 string welding system and is configured to determine one or another characteristic of the contact surface area between the pipes 1022A, 1022b, as well as the welding torch attached to the frame of the pipe welding system 3001. In one embodiment of the invention, similar to the internal welding system 5004, the brake system conduit 3001 may include clamps of the pipe welding system 3001, which are made with the possibility of clamping, respectively, in pipes 1022a, 1022b. In one embodiment of the invention, similar to the internal welding system 5004, the brake system of the pipe welding system 3001 may include a brake cylinder and brake valve of the pipe welding system 3001. In one embodiment of the invention, the structure, configuration and/or operation of the rollers 3125, the drive motor 3124 , sensor, and welding torch of the pipe string welding system 3001 are similar to the above features of the internal welding system 5004 and, therefore, will not be described in detail in this document.

[00879] In one embodiment, the pipe string welding system 3001 may also include one or more processors that are operatively associated with a drive motor 3124, a measurement sensor, and a welding torch. The configuration and operation of one or more of the processors of the string welding system 3001 is similar to the configuration and operation of the internal welding system 3004 and, therefore, will not be described in detail herein.

[00880] In one embodiment, the pipe string welding system 3001 is completely self-contained. In particular, the string welding system 3001 need not include a drive rod or halyard, and all communications with the string welding system 3001 are completely wireless. In one embodiment of the invention, the pipe string welding system 3001 may comprise a transmitter that is configured to transmit all communication signals in a completely wireless manner from the pipe string welding system 3001 to a remote uLog processing system and a receiver that is configured to receive all communication signals in a completely wireless manner. from a remote uLog processing system. In one embodiment, one or more of the processors and/or all of the electronic modules of the pipe string welding system 3001 are configured to communicate completely wirelessly with the remote uLog processing system. In one embodiment of the invention, the measurement sensor, control chamber, all sensors, all motors, all valves and/or other components/elements of the pipe welding system 3001 are configured to communicate completely wirelessly with the remote uLog processing system.

[00881] In one embodiment, any information can be wirelessly transmitted from the pipe string welding system to systems outside the pipe, such as via Wi-Fi, Bluetooth, NFC, radio frequency, or cell tower transmissions. In some embodiments of the invention, when appropriate, information is communicated by signal regenerators or spreaders when a transmission signal is to be transmitted over long distances or through tortuous areas.

[00882] In one embodiment of the invention, one or more processors and one or more sensors of the pipe welding system 3001 are configured to monitor the charge levels of the built-in welding power source, the built-in power source to assist mobility, and other built-in power sources. For example, the output voltage of these power supplies can be monitored (continuously or at regular intervals). In one embodiment of the invention, the pipe welding system transmitter 3001 transmits monitored life/battery level information completely wirelessly to a remote uLog processing system for further processing. For example, the monitored charge level information of the built-in power supplies may be used to determine the estimated remaining run time of the string welding system 3001. In one embodiment, one or more processors of the string welding system 3001 may be configured to determine the estimated remaining run time of the string welding system. conduit 3001 locally in the conduit welding system 3001. In one embodiment, the remote uLog processing system can be configured to determine the estimated remaining run time of the conduit welding system 3001 based on wirelessly transmitted battery life/battery level information. In one embodiment, the remote uLog processing system may be configured to communicate the estimated remaining run time of the pipe welding system 3001 to one or more processors of the pipe welding system 3001. In one embodiment, the remote uLog processing system may also be configured to transmitting (completely wirelessly to the string welding system 3001) further commands to operate the string welding system 3001 based on the estimated remaining run time of the string welding system 3001.

[00883] In one embodiment of the invention, one or more processors and one or more sensors of the pipe welding system 3001 are configured to monitor the gas level in the built-in inert (shielding/purge gas) source, the built-in air source, and other built-in gas sources (for example, pressure level of the compressed air in the built-in compressed air tanks, pressure level of the shielding or purge gas in the built-in shielding/purge gas tanks, etc.). For example, the flow of gas from these gas sources can be monitored (continuously or at regular intervals). In one embodiment of the invention, the pipe welding system transmitter 3001 transmits the monitored gas level information in a completely wireless manner to a remote uLog processing system for further processing. For example, information about the monitored gas level in the built-in gas source can be used to determine the estimated remaining run time of the pipe welding system 3001. string welding system 3001 locally in the string welding system 3001. In one embodiment, the uLog remote processing system can be configured to determine the estimated remaining run time of the string welding system 3001 based on wirelessly transmitted gas level information. In one embodiment, the remote uLog processing system may be configured to communicate the estimated remaining run time of the pipe welding system 3001 to one or more processors of the pipe welding system 3001. In one embodiment, the remote uLog processing system may also be configured to transmitting (completely wirelessly to the string welding system 3001) further commands to operate the string welding system 3001 based on the estimated remaining run time of the string welding system 3001.

[00884] In one embodiment, the one or more processors and one or more sensors of the string welding system 3001 are configured to monitor the level of filler wire material in the string welding system 3001. For example, rotating the wire feed motor (which distributes the welding wire) and the weight of the remaining filler wire in the string welding system 3001 can be monitored (continuously or at intervals) to determine levels of filler wire material in the string welding system 3001. welding wire completely wirelessly to the uLog remote processing system for further processing. For example, information about the monitored level of filler wire material can be used to determine the estimated remaining run time of the 3001 pipe string welding system (i.e., before the filler wire material runs out or is below the minimum threshold level for operation of the 3001 pipe string welding system). ). In one embodiment, one or more of the processors of the string welding system 3001 may be configured to determine the estimated remaining run time of the string welding system 3001 locally within the string welding system 3001. In one embodiment, the ULog processing system may be configured to determining an estimated remaining operating time of the welding welding system based on the wirelessly transmitted information about the level of material of the welding wire. In one embodiment, the remote uLog processing system may be configured to communicate the estimated remaining run time of the pipe welding system 3001 to one or more processors of the pipe welding system 3001. In one embodiment, the remote uLog processing system may also be configured to transmitting (completely wirelessly to the string welding system 3001) further commands to operate the string welding system 3001 based on the estimated remaining run time of the string welding system 3001.

[00885] In one embodiment of the invention, the uLog remote processing system receives battery data from a number of pipe welding systems located in different locations (for example, in different locations around the country or around the world), and creates a database based on them . This database is used by the uLog processing system to determine, based on a large set of data, the estimated battery life based on various operating parameters of the internal welding system. This may be used by the uLog processing system and/or one or more processors of the string welding system 3001 to predict battery life for various components based on the current operating conditions of those components. This information may be used by one or more processors to reduce or regulate the power consumption of one or more components by changing one or more operating parameters. For example, welding speed, wire feed speed, voltage, and current may be adjusted (eg, reduced) to extend battery life if one or more processors determine that such operating conditions can be changed without affecting the respective operation being performed.

[00886] In one embodiment, battery life, output voltage, and any operating parameters are sent wirelessly to a user interface, such as a computer monitor having a computer display, so that they can be controlled by the user.

[00887] In one embodiment of the invention, the string welding system 3001 also includes a power section 3008 adjacent to the drive section 3006 (ie, on the rear side of the string welding system 3001).

[00888] In one embodiment of the invention, with reference to FIG. 101, front section 3002 includes a front section frame 3522, center section 3004 includes a center section frame 3524, drive section 3006 includes a drive section frame 3526, and power section 3008 includes a power section frame 3528. In one embodiment, the frame or frame assembly of the system 3001 includes a front section frame 3522, a center section frame 3524, a drive section frame 3526, and a power section frame 3528. .

[00889] In one embodiment, power section 3008 includes universal joint 3010, motor power supply 3012, welding torch power supply 3014, welding power supplies 3016, and adjustable wheels 3018.

[00890] In one embodiment, the drive section 3006 may be coupled to the power section 3008 via a universal joint 3010. In one embodiment, the universal joint 3010 is designed and configured so that the pipe string welding system 3001 can pass bends in the pipeline.

[00891] In one embodiment, the welding torch power supply 3014 may comprise a plurality of welding torch batteries 3014a-3014e. In one embodiment, the welding torch power supply 3014 is configured to power the welding torch(s) 3502. In one embodiment, the welding torch power supply 3014 is mounted on the frame assembly of the pipe welding system 3001. In one embodiment, the welding torch power supply 3014 is The number of welding torch batteries may vary. In one embodiment, the welding torch power supply 3014 is configured to supply electrical power to the welding torch power supplies 3016 to generate a welding arc. In one embodiment, the welding torch power source 3014 is separated from other electrical systems such that if the welding torch power is depleted, the rest of the pipe string welding system 3001 can continue to operate.

[00892] In one embodiment, motor power supply 3012 is configured to power a drive motor 3124 in drive section 3006. In one embodiment, motor power supply 3012 may include a plurality of motor batteries 3012a-3012e. In one embodiment of the invention, the motor power supply 3012 may also be referred to as a drive power supply. In one embodiment, the motor power supply 3012 is attached to the frame assembly of the string welding system 3001. In one embodiment, the number of motor batteries may vary. In one embodiment, the motor power supply 3012 is used for drive only (i.e., to power the drive motors 3124 in the drive section 3006) so that if the other batteries 3014a-3014e are drained, the conduit welding system 3001 will not get stuck in the conduit.

[00893] In one embodiment, the motor power supply 3012 (including batteries 3012a-e) and the welding torch power supply 3014 (including batteries 3014a-e) are mounted on the frame of the string welding system 3001. In one embodiment, one or more battery elements (eg, motor power supply 3012, welding torch power supply 3014, batteries 3514, etc.) of the pipe string welding system 3001 are configured to power a drive motor 3124, a measurement sensor, and a welding torch. In one embodiment of the invention, one or more battery cells 3514, 3012, or 3014 of the internal welding string welding system 3001 may comprise a plurality of independent battery cells. In one embodiment, the welding torch batteries 3014, 3014a-e are independent of the drive motor and sensor batteries 3012, 3012a-e, 3514. In one embodiment, the battery cells 3012, 3012a-e for the drive motor 3124 are independent of the battery cells 3514 for the sensor. That is, in one embodiment of the invention, the battery cells 3012, 3012-E are configured to power the drive motors 3124, the battery cells 3514 are configured to power the measuring sensor, and the battery cells 3014, 3014a-e are configured to power the welding torch of the pipe welding system. 3001.

[00894] In one embodiment of the invention, with reference to FIG. 101, the drive motors 3124 are configured to drive the rollers 3125 so as to move the frame or frame assembly of the pipe welding system 3001, the first pipe engaging device 3127, the second pipe engaging device 3129, and the measurement sensor 3130 of the pipe welding system 3001 along along at least one of the pipes 1022a, 1022b within it. In one embodiment of the invention, the drive rollers 3125 are configured to interact with the internal surfaces 5130, 5132 of one or more pipes 1022a, 1022b. In one embodiment, the string welding system 3001 includes a plurality of drive rollers 3125 that are rotatable to support the frame of the string welding system 3001.

[00895] In one embodiment, the welding power sources 3016 are configured to receive DC power from the power source of the welding torch 3014 and convert the DC power into the proper current and voltage forms for the welding procedure performed by the welding torches 3502.

[00896] In one embodiment, the adjustable wheels 3018 are designed and positioned for adjustment so that the force section 3008 of the string welding system 3001 runs straight and level in the pipeline.

[00897] In FIG. 103 is a diagram showing the flow of power, including welding power, communication data, and control data through the 3001 string welding system, with some components of the 3001 string welding system omitted for ease of presentation and to better illustrate other components and/or functions of the string welding system. pipeline 3001.

[00898] The flow of communication and control data through the string welding system 3001 illustrated in FIG. 103 is similar to the flow of communication and control data through the internal welding system 5004 illustrated in FIG. 71, except for the differences noted below.

[00899] In one embodiment, the drive section electronics module 3126 is configured to operably communicate with the drive batteries 3012 located in the power section 3008 of the conduit welding system 3001.

[00900] In one embodiment, the batteries 3012 of the power section 3008 are connected to the drive motors 3124 of the string welding system 3001 via the drive section electronics module 3126.

[00901] The flow of welding power through the string welding system 3001 illustrated in FIG. 103 and 103A is different from the welding power flow through the internal welding system 5004 illustrated in FIG. 71.

[00902] For example, welding power is supplied from different directions to the internal welding system 5004 and the welding system of piping strings 3001. back of the 3001 string welding system. A configuration in which the welding power comes from the rear of the 3001 string welding system can be achieved by adding a second slip ring or by rotating the welding part and pushing it back through the pipe (which can make access to spools of welding wire for maintenance).

[00903] In one embodiment, the welding power is received by the welding torches 3502 of the string welding system 3001 from the built-in welding torch power supply 3014. In one embodiment, the welding power from the built-in welding torch power supply 3014 is supplied to the welding power sources 3016. embodiment of the invention, the sources of welding power 3016 are configured to generate a welding arc. That is, the welding power sources 3016 are configured to receive DC power from the power source of the welding torch 3014 and convert the DC power into the proper current and voltage forms for the welding procedure performed by the welding torches 3502. In one embodiment of the invention, the proper current and voltage forms from the welding power sources 3016 are fed to the welding torches 5502 through the rear slip ring 3512.

[00904] Similar to the internal welding system 5004, in one embodiment, the batteries 3514 of the drive section 3006 are configured to supply power to all electronic modules of the string welding system 3001, including the front electronic module, the wire feed electronic module, the center section electronic module, and the electronic 3126 drive section module, and is configured to supply power to all drive motors for the 3001 string welding system, including front rotation motor, wire feed system motors, rear rotation motor, welding torch thrust motor, welding torch radial motor, and welding torch tilt motor . In one embodiment of the invention, the batteries 3514 are configured to power the test chamber and/or the measuring sensor of the pipe welding system 3001. However, the batteries 3006, 3514 of the drive section are not configured to supply power to the drive motors 3124 of the pipe welding system 3001. In one embodiment, the batteries 3012 of the power section 3008 are configured to supply power to the drive motors 3124 of the string welding system 3001. In one embodiment, the batteries 3012 of the power section 3008 are connected to the drive motors 3124 of the string welding system 3001 via the drive section electronics module. 3126.

[00905] In one embodiment of the invention, the batteries used in the string welding system 3001 can be electrically connected to each other to obtain higher current and higher energy intensity. For example, two 12 volt batteries can be connected together to produce 24 volts. In one embodiment of the invention, both batteries are mounted on the same frame and connected in series. In one embodiment of the invention, the batteries may also be connected to each other (for example, through a universal joint or otherwise) in such a way that the batteries can be hinged to each other for maneuvering inside the pipe.

[00906] In one embodiment, the string welding system 3001 may comprise four batteries, one of which can be used to power the string welding system 3001, and the remaining three batteries can be connected in parallel and can be used for welding procedures in the welding system. lashes of the pipeline 3001.

[00907] In one embodiment, the pipe string welding system 3001 may use internal (located inside the pipes) clamps or external (located outside the pipes) clamps. For example, in one embodiment of the invention, the pipe string welding system 3001 may use internal (located within the pipes) clamps during welding procedures. In one embodiment of the invention, the pipe string welding system 3001 may use external (located on the outside of the pipes) clamps during an internal scanning procedure (when the internal laser/sensor and/or other device is configured to scan the weld inside the pipes).

[00908] Pipe string welding is performed to weld long pipe strings to other long pipe strings. Typically, the new pipe to be welded is at least 120 feet long and may be over two miles long. The internal welder disclosed herein has built-in battery power and can be used to hold the bundle in the root weld and optionally the hot weld pass within the pipe.

[00909] In one embodiment, the pipes are aligned on the outside. Like the internal welder disclosed herein, the pipe string welder may be provided with only one welding head (with one welding torch) or multiple welding heads (eg anywhere from 2 to 8).

[00910] As illustrated in FIG. 103C and 103D and will be understood from the description above in this document, the pipe string welder 9000 has a nose cone section 9002 for electronics, support wheels 9004, an integral welding power source 9006, and a pair of clamps 9008, which ensures that the internal pipe string welder concentric shape to match the shape of the pipe. As will be described in more detail later, the pipe string welder comprises clockwise and counterclockwise interchangeable welding head elements 9010 with separate lasers and 2D color cameras. On FIG. 103C and 103D, the pipe string welder is illustrated in a slightly curved (eg, 30D curved) pipe 9012 that has an inside diameter of 38 inches. As also illustrated in FIG. 103C and 103D, the pipe string welder has a 9014 drive and brake system that is offset 90 degrees to reduce length, and an integrated power source (eg, battery pack) 9020 for the drive motor and brakes.

[00911] As will be understood from FIG. 103E-J and the following description, the illustrated model has four welding heads, with two of them turning clockwise (welding heads 9022 and 9024) during the welding operation and two of them turning counterclockwise (welding heads 9032 and 9034) during the welding operation. welding operation time. In an alternative embodiment of the invention, all 4 welding heads rotate in the same direction of rotation, as described elsewhere in this application. In addition, in the embodiment of the invention illustrated in FIG. 103E-J, there are four built-in welding power/power supplies (such as batteries) designated 9042, 9044, 9046, 9048. The more welding heads/torches provided, the shorter the welding cycle time. This applies both when welding is performed in one direction of rotation and when it is performed in both clockwise and counter-clockwise directions. However, it should be understood that turning in one direction of rotation can be faster than turning both clockwise and counter-clockwise, the latter of which can use a change in the direction of rotation of the motor.

[00912] Each of the welding heads 9022, 9024, 9032 and 9034 has the following equipment: a welding torch, at least one torch motor of the type described above to provide angular, axial and lateral movement of each torch, a wire feeder, wire dressing devices and a wire spool for supplying the welding wire material to the welding torch. A laser control/sensor device of the type described above is also provided for guiding the welding torch and checking the welding. In addition, a CCD/CMOS color camera is used to check welding in the manner described above.

[00913] Each welding head is attached to and connected to one of four power sources 9042, 9044, 9046, and 9048. Four welding heads and four power sources are mounted on a 9050 rotation assembly. The rotation assembly performs the same function as the 5078 rotation hub described above. The rotation assembly may be driven by one or more orientation motors as described above.

[00914] To perform the welding operation, the pipe string welder is fed into one open end of one of the pipes, such as a shorter pipe or a pipe with fewer obstructions to be removed. The end of the second pipe is matched and aligned (outside) with the end of the first pipe. The pipeline string welding machine is directed to where the welding heads are located directly in the area of the pipe contact surface. The laser sensor provides feedback and at least one welding torch motor aligns the welding torch tips into their respective positions on the contact surface. The 9008 clamps are actuated and expanded (they function as an expander) to make the string welder coaxial with the pipes, and the clamps are actuated to hold the string welder in position. When the pipe string welder is clamped, the axis of rotation of the rotation mechanism 9050 is aligned with the longitudinal axis of the pipe 9012.

[00915] In one embodiment of the invention, welding is carried out by primarily controlling the welding heads 9032 and 9034 counterclockwise. As illustrated in FIG. 103H, four welding heads are rotated apart from each other at an angle of 90 degrees. Weld heads 9032 start at 12 o'clock and weld heads 9034 start at 9 o'clock, as illustrated in FIG. 103H as they start welding. Rotary assembly 9050 rotates 90 degrees until weld head 9032 finishes 9 o'clock and work head 9034 finishes 6 o'clock (see progress in Figs. 103H and 103I). At this point, weld heads 9032 and 9034 stop welding (FIG. 103I) and welding starts 9022 and 9024 (FIG. 103I). The one or more orientation motors then rotate the rotating assembly 9050 in a clockwise direction as illustrated in FIG. 103J until welding head 9022 finishes 3 hours and welding head 9024 finishes 6 hours. This completes the complete root pass.

[00916] After performing the root welding pass, the rest of the welding operation can be performed externally, either using automatic welding machines or manually. The expanders or clamps are then released and the string welder is pushed out to the open end of the pipe.

[00917] In one embodiment of the invention, each of the power supplies 9042, 9044, 9046 and 9048 contains a replaceable rechargeable battery cell that can be inserted into the respective opening 9062, 9064, 9066 and 9068. When the replaceable element is inserted into the hole, it has electrical connection to the corresponding welding head. Each replaceable battery cell can be easily removed for recharging and then replaced.

[00918] As illustrated, the pipe string welder has a self-contained drive and brake mechanism 9014 powered by a built-in welding power source 9020. This pipe string welder may have all the features of an internal welding mechanism without the built-in power source in various prior embodiments. described in this document.

[00919] It is easy to understand that in this described embodiment of the pipe welding apparatus, several (for example, two) welding torches are designed for welding in a clockwise direction, while the other several (for example, two) welding heaters are designed for welding in a counterclockwise direction. In addition, as described, all welding torches perform downward welding. Thus, the welding torches may optionally be fixed at a given welding angle (this applies to any of the internal welding machines described in this document, either stand-alone or non-standalone type), so that the torch tip points towards the direction of welding forward (weld pool "pushed"). Alternatively, as discussed above with reference to FIG. 56A, the welding torches can be set to rotate about the point P so that the axis A of the welding torch can be located on both sides of the radial line R. This alternative allows the same welding torch to be used for both clockwise welding and welding counterclockwise by turning the welding torch so that it can turn in the direction of welding, whether welding is clockwise or counterclockwise.

[00920] In one embodiment of the invention, the welding torch is configured to be placed outside the first pipe 1022a and/or the second pipe 1022b to provide an external welding operation. In one embodiment of the invention, an externally located welding torch is mounted on the outer surface of the pipes 1022a, 1022b.

[00921] In one embodiment of the invention, with reference to FIG. 86, the present patent application provides a purge and test system 7001. For example, in one embodiment of the invention, each of the first pipe segment 1022a and the second pipe segment 1022b may be made entirely or partially of some corrosion resistant alloy (CRA) materials, which may require the use of a protective gas on both sides of the weld. In one embodiment, a purge and test system 7001 may be located within conduits 1022a, 1022b to provide a purge gas chamber 7054 (as illustrated in FIG. 89) within conduits 1022a, 1022b and around a contact surface area 5136 (as illustrated in FIG. 97) while the external welding system 7500 (as illustrated in FIG. 97) performs a welding procedure (including a root pass procedure 1002, a hot weld procedure 1004, and a fill and finish multi-layer weld procedure 1006) in the area contact surface 5136 on the outside of pipes 1022a, 1022b.

[00922] In one embodiment, the purge and test system 7001 also provides internal clamps that are located inside the pipes 1022a, 1022b to be welded. That is, in one embodiment, the clamps 7050 and 7052 of the purge and test system 7001 are configured to clamp the inner surfaces 5130, 5132 (as illustrated in FIG. 33) of the pipes 1022a, 1022b to be welded.

[00923] In one embodiment of the invention, the purge and test system 7001 also provides a measuring sensor 7042 and/or test chamber 7044, which are located inside the pipes 1022a, 1022b. In one embodiment, the measurement sensor 7042 and/or test chamber 7044 of the purge and test system 7001 are located in the purge gas chamber 7054 of the purge and test system 7001. In one embodiment, one or more processors 7062 (as illustrated in FIG. 90) purge and test system 7001 is configured to interact with a measurement sensor 7042 and/or test chamber 7044 to scan the area of contact surface 5136 between pipes 1022a, 1022b to determine the profile of the area of contact surface 5136 between pipes 1022a, 1022b before, during and after the welding procedure to generate pre-weld state profile data, on-the-fly acquired weld profile data and post-weld state profile data based on scanned data and to control or operate the 7500 External Welding System based on generated pre-weld state profile data, weld profile data received "n on the fly”, and post-weld condition profile data.

[00924] In one embodiment, the purge and test system 7001 may be used for a first pipe segment 1022a and a second pipe segment 1022b having an outside diameter of 26 to 28 inches. In one embodiment, the purge and test system 7001 may be used for first pipe segment 1022a and second pipe segment 1022b having an outside diameter of less than 24 inches.

[00925] In one embodiment, the purge and test system 7001 includes a front section 7002, a center section 7004, and a drive section 7006. In one embodiment, the design, configuration, components, and operation of the front, center, and drive sections of the purge and test system 7001 are similar to the same features of the front section, center section, and drive section of the 5004 internal welding system detailed above, and therefore the design, configuration, components, and operation of the front section, center section, and drive section of the 7001 purge and test system will not be described in detail. in this document, except as noted below.

[00926] Unlike the center section of the internal welding system 5004, the center section 7004 does not include a welding torch assembly mounted on a rotary assembly. In one embodiment of the invention, the central section 7004 of the purge and test system 7001 includes a measurement sensor 7042 mounted on the rotary assembly 7012. 7012. In one embodiment of the invention, the central section 7004 of the purge and test system 7001 includes a test chamber 7044 mounted on the rotary assembly 7012.

[00927] In one embodiment, the front section 7002 contains all purge support components. In one embodiment, the center section 7004 is part of the purge and test system 7001 that lines the pipe, seals the purge zone, and tests the weld. In one embodiment, the drive section 7006 contains the batteries, compressed air, and purge gas that the rest of the purge and test system 7001 needs to operate.

[00928] In Fig. 87 illustrates a detailed view of the front section 7002 of the purge and test 7001 cleaning and control system, and FIG. 88 illustrates a detailed view of the front section purge assembly 7002. In one embodiment, the front section 7002 of the purge and test system 7001 includes a hitch, a front electronics module, a front slip ring, a front clamp control valve, a forward position sensor, adjustable rails, a front section frame , front rotation motor and front pivot hub 7104, and the design and operation of each of these components is similar to the design and operation of the components of the front section of the internal welding system 5004.

[00929] In one embodiment, the front section 7002 of the purge and test system 7001 does not include a wire feed assembly. Instead, the front section 7002 of the purge and test system 7001 includes a purge assembly 7014.

[00930] In one embodiment, the purge assembly 7014 is rotatably coupled to the pivot hub 7012 of the center section 7004 such that when the pivot hub 7012 is rotated by the first and second rotation motors, the purge assembly connected to the pivot hub 7012 is also swivel with swivel hub 7012.

[00931] In one embodiment, the purge assembly 7014 is configured to accommodate valves, sensors, and regulators to control the flow of purge gas to the purge gas chamber 7054. In one embodiment, the purge assembly 7014 is also configured to accommodate electronics for operation all components in the purge assembly and the 7012 rotary assembly.

[00932] In one embodiment of the invention, with reference to FIG. 88, purge assembly 7014 includes a low purge valve 7016, a primary low purge regulator 7018, a secondary low purge regulator 7020, a high purge valve 7022, a high purge regulator 7024, an oxygen sensor 7026, a pump 7028, a purge assembly frame 7030, and an electronic purge module 7032.

[00933] In one embodiment, the low purge valve 7016 is configured to control the flow of purge gas into the purge gas chamber 7054. In one embodiment, low purge is commonly referred to as purge when the purge and test system 7001 maintains an inert atmosphere within the purge gas chamber 7054. In one embodiment, the output from the low blowdown valve 7016 flows to the primary low blowdown regulator 7018. In one embodiment, the low blowdown valve 7016 is always open (or on) except when seals 7046 and 7048 are not inflating ( as illustrated in Fig. 89) and there is no purge in the purge and test system 7001.

[00934] In one embodiment, the low purge primary regulator 7018 is configured to reduce the purge gas pressure from 5 psi to 5 psi. inch to 0.5 psi inch. In one embodiment, the effluent from the primary low blowdown controller 7018 passes to the secondary low blowdown controller 7020. In one embodiment, the primary low blowdown controller 7018 is manually adjustable.

[00935] In one embodiment, the secondary low purge regulator 7020 is an electronic device that is configured to control the pressure (0.1 to 0.5 psi) of the purge gas entering the purge gas chamber 7054 through a closed circuit. feedback loop. In one embodiment, the effluent from the secondary low purge regulator 7020 enters the purge gas chamber 7054.

[00936] In one embodiment, the high purge valve 7022 is configured to control the flow of purge gas into the purge gas chamber 7054. In one embodiment, high purge is commonly referred to as a purge when the purge and test system 7001 establishes an inert atmosphere within the purge gas chamber 7054 In one embodiment, the effluent from the high blowdown valve 7022 flows to the high blowdown regulator 7024. In one embodiment, the high blowdown valve 7022 is configured to shut off when the oxygen (measured by the oxygen sensor 7026) in the purge gas chamber 7054 is not below set value of oxygen content.

[00937] In one embodiment, the high purge regulator 7024 is configured to reduce the purge gas pressure from the supply pressure (up to 75 psi) to the maximum low purge pressure required (typically 5-20 psi). In one embodiment, the effluent from the high blowdown controller 7024 enters the purge gas chamber 7054. In one embodiment, the high blowdown controller 7024 is manually adjustable. In one embodiment, the high purge regulator 7024 is configured to open or operate until oxygen (measured by oxygen sensor 7026) in purge gas chamber 7054 is below a predetermined oxygen content.

[00938] In one embodiment, the oxygen sensor input 7026 is connected to the purge gas chamber outlet 7054. In one embodiment, the oxygen sensor 7026 is operatively coupled to one or more processors 7062. In one embodiment, the oxygen sensor is configured to detect which is the amount of oxygen between the first seal and the second seal 7046 and 7048. In one embodiment, the oxygen sensor 7026 is configured to measure the oxygen content of the gas in the purge chamber 7054 and send oxygen content data that is indicative of the oxygen content of the gas in the purge chamber chamber 7054 to one or more processors 7062. In one embodiment, the oxygen sensor 7026 is configured to measure the level of oxygen present in the gas leaving the purge gas chamber 7054 and send the oxygen content data to the electronics module. purge 7032.

[00939] In one embodiment of the invention, one or more processors 7062 are configured to provide a welding operation after a certain amount of oxygen between the first seal and the second seal 7046 and 7048 falls below a threshold level or setpoint for the oxygen content. In one embodiment, one or more processors 7062 are configured to receive oxygen data, compare the supplied oxygen data to its oxygen setpoint, and generate an excess oxygen gas signal if the data-based oxygen content exceeds the oxygen setpoint. oxygen. In one embodiment, based on the excess oxygen gas signal, the purge and test system 7100 may be configured to open the high purge regulator 7024 to allow purge gas (from purge gas source/reservoir 7070) to flow into purge chamber 7054 until until the measured oxygen content falls below the set oxygen content. In one embodiment of the invention, based on the excess oxygen gas signal, one or more processors 7062 of the purge and test system 7100 may send communication signals to the external welding system 7500 to stop the welding procedure.

[00940] In one embodiment, the oxygen target is 500 parts per million (ppm). In one embodiment of the invention, the value of the oxygen content may be within a predetermined range of 50 to 100 ppm.

[00941] In one embodiment, during low purge, low pressure in purge gas chamber 7054 does not generate sufficient flow through oxygen sensor 7026. In one embodiment, pump 7028 is used to draw gas through oxygen sensor 7026 from purge gas chamber 7054. B In one embodiment, pump 7028 may be used continuously or intermittently. In one embodiment, pump 7028 is used for a low purge operation.

[00942] In one embodiment, the purge electronics module 7032 is configured to transmit upstream communication via the front slip ring 7034 to the front section electronics module 7036. In one embodiment, the purge electronics module 7032 is configured to transmit downstream communication via rear slip ring 7038 into the electronic module of the center section 7040.

[00943] In one embodiment, the electronic purge module 7032 is configured to control all sensors and valves attached to the pivot assembly 7012 of the center section 7004. For example, in one embodiment, the electronic purge module 7032 is configured to control an oxygen sensor 7026, a pump 7028, a low blowdown valve 7016, a high blowdown valve 7022, and a secondary blowdown controller 7020. In one embodiment, the electronic purge module 7032 is configured to communicate with and control one or more measurement sensors 7042 and a camera 7044.

[00944] In FIG. 89 and 90 illustrate a front view and a cross-sectional view of the center section 7004 of the purge and test system 7001, with the design and operation of each of these components similar to the design and operation of the center section of the internal welding system 5004. FIG. 91 illustrates a detailed view of a 7046 or 7048 gas seal, and FIG. 92 illustrates a detailed view of the 7012 swing hub.

[00945] In one embodiment, as described above, the frame of the front section 7002 is connected to the front clip 7050 (as illustrated in Fig. 95) of the center section 7004, and the purge assembly 7014 is rotatably connected to the pivot hub 7012.

[00946] In one embodiment of the invention, the central section 7004 of the purge and test system 7001 includes a front clamp 7050, first and second pipe engagement devices 7050 and 7052, a measurement sensor 7042, a test chamber 7044 (as illustrated in Fig. 92), a back clamp 7052 and 7058 rear clamp control valve, 7040 center section electronics, idler wheels, center section cage, adjustable rails, 7072 rear pivot hub, rear rotation motor, rear encoder, 7012 rotation module, 7046 and 7048 gas seals, and rear slip ring 7038.

[00947] In one embodiment, gas seals 7046 and 7048 are configured to inflate simultaneously with actuation of clamps 7050 and 7052. When both gas seals 7046 and 7048 swell, they are designed and positioned to engage internal surfaces 5130, 5132 tubes 1022a, 1022b, respectively forming a chamber 7054 therebetween. In one embodiment, the gas seals 7046 and 7048, when inflated, engage opposite sides of the contact surface region 5136. In one embodiment, the chamber 7054 is a closed volume that may be referred to as a purge gas 7054. In one embodiment of the invention, the chamber 7054 is designed and configured to receive purge gas (or inlet gas).

[00948] In one embodiment, the 7056 front clamp control valve and 7058 rear clamp control valve are continuous 4-way directional valves (e.g., having four hydraulic connections corresponding to inlet (P), actuator ports (A and B), return port (T) and one physical signal connection (S)). For example, in one embodiment of the invention, one of the actuator ports A or B is used to expand their respective clamps 7050 or 7052 and pump their respective seal 7046 or 7048, and the other of the actuator holes A or B is used to retract their respective clamps 7050 or 7052 and deflate your respective 7046 or 7048 seal.

[00949] In FIG. 93 illustrates a detailed side view of the drive section 7006 of the purge and test system 7001. In one embodiment, the drive section 7006 of the purge and test system 7001 includes shielding gas cylinders 7070, batteries, drive section electronics 7064, pneumatic valves, drive wheels, drive motors. 7068, brakes, and compressed air reservoir, each of which is similar in design and operation to the drive section components of the 5004 internal welding system.

[00950] In FIG. 94 is a diagram showing the flow of purge gas through the 7001 purge and test system, with certain components of the 7001 purge and test system omitted for clarity and to better illustratively represent other components and/or functions of the 7001 purge and test system.

[00951] In one embodiment, the inert/purge gas supply line is configured to communicate the purge/inlet inert gas source 7070 with the region 7054 between the first seal and the second seal 7046 and 7048. In one embodiment, gas from the inert/purge gas source 7070 is directed to the area 7054 between the first seal and the second seal 7046 and 7048 to reduce the oxidation reaction during the welding process.

[00952] As illustrated in FIG. 94, purge gas tanks 7070 are illustrated in the actuator section 7006 of the purge and test system 7001. In one embodiment, the high pressure regulator 7074 may be located in the actuator section 7006 of the purge and test system 7001. In one embodiment, the high pressure regulator 7074 may be located in the center section 7004 of the purge and test system 7001. In one embodiment, the rear pivot hub 707, pivot hub 7012, purge gas chamber 7054, front and rear clamps 7050 and 7052, and front and rear seals 7046 and 7048 are illustrated in central section 7004 of the 7001 purge and check system. 7001 checks.

[00953] In one embodiment, the purge gas tanks 7070 are configured to be pressurized between 500-2400 psi. inch. The purge gas reservoir 7070 is in fluid communication with the rear pivot hub 7072 through fluid passages. In one embodiment, the purge gas reservoirs 7070 are in fluid communication with the rear pivot hub 7072 via a valve 7071 and a high pressure regulator 7074. In one embodiment, of the invention, the high pressure regulator 7074 is configured to automatically cut off the purge gas flow at 75 psi. inch. That is, the high pressure regulator 7074 is typically set to reduce the pressure in the purge gas tanks 7070 to about 75 psi. inch downstream of the 7074 high pressure regulator and 7072 rear pivot hub to the 7016 low blowdown valve and 7022 high blowdown valve.

[00954] In one embodiment, the rear pivot hub 7072 is in fluid communication through the fluid passages to the low blowdown valve 7016 and the high blowdown valve 7022. In one embodiment, the purge gas stored in the purge gas tanks 7070 is sent through the channels to move fluids to the 7072 rear swing hub and then duct fluid from the 7072 rear swing hub to the 7016 low blowdown valve and 7022 high blowdown valve.

[00955] In one embodiment, the high blowdown regulator 7024 is connected to the outlet of the high blowdown valve 7022. That is, the high blowdown regulator 7024 is located downstream of the high blowdown valve 7022. In one embodiment, the high blowdown regulator 7024 is installed to reduce pressure at the outlet of the 7022 high blowdown valve, typically up to 5-30 psi. in the fluid passage downstream of the 7024 high blowdown regulator and between the 7024 high blowdown regulator and the 7054 purge gas chamber.

[00956] In one embodiment, the fluid passage extends from the low blowdown valve 7016 to the primary low blowdown regulator 7018. In one embodiment, the primary low blowdown regulator 7018 is connected to the outlet of the low blowdown valve 7016. That is, the primary low blowdown regulator 7018 is located downstream of the low blowdown valve 7016.

[00957] In one embodiment, the low blowdown primary regulator 7018 is typically set to reduce downstream pressure through the low blowdown valve 7016 to about 0.5-5 psi. in the fluid passage downstream of the 7018 Primary Low Blowdown Regulator and between the 7018 Primary Low Blowdown Regulator and the 7020 Secondary Low Blowdown Regulator.

[00958] In one embodiment, the fluid flow path extends from the primary low blowdown regulator 7018 to the secondary low blowdown regulator 7020. In one embodiment, the secondary low blowdown regulator 7020 is located downstream of the primary low blowdown regulator 7018.

[00959] In one embodiment, a secondary low blowdown regulator 7020 is installed to reduce downstream pressure through the primary low blowdown regulator 7018, typically to 0.1-0.5 psi. in the fluid passage downstream of the secondary low blowdown regulator 7020 and between the secondary low blowdown regulator 7020 and the purge gas chamber 7054.

[00960] In one embodiment of the invention, the welding procedure begins at a pressure of about 0.5 psi. inch and during a welding procedure when purge gas leakage through the weld joint is retarded by welding (e.g. depending on how much gap between pipe ends is welded), the 7020 Secondary Low Purge Regulator can then be throttled back to 0.1 lb. / sq. inch.

[00961] In one embodiment, pump 7028 is in fluid communication (via fluid passages) on one side with the outlet/outlet of purge gas chamber 7054 and, on the other side, is in fluid communication (via fluid passages) with oxygen sensor 7026 In one embodiment, pump 7028 is in fluid communication with the outlet of purge gas chamber 7054 such that pump 7028 is configured to operate (either continuously or intermittently) to draw a gas sample from purge gas chamber 7054.

[00962] In one embodiment, purge gas from purge gas tanks 7070 is used only to fill and maintain purge gas in purge gas chamber 7054. In one embodiment, compressed air is used to inflate seals 7046 and 7048 and to expand clamps 7050 and 7052. In one embodiment, the drive section 7006 of the purge and test system 7001 may contain both purge gas tanks 7070 and compressed air tanks.

[00963] In FIG. 95 is a diagram showing the flow of compressed air through the 7001 purge and test system, with certain components of the 7001 purge and test system omitted for clarity and to better illustratively represent other components and/or functions of the 7001 purge and test system.

[00964] Compressed air flow through purge and test 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.

[00965] In one embodiment, the valve 7076 is located on the fluid passage 7078. In one embodiment, the fluid passage 7078 is located between the back jaw control valve 7058, the back jaw 7052, and the rear seal 7046, and is configured to supply compressed air to expand the rear seal 7046 of the rear jaws 7052. In one embodiment of the invention, one outlet of valve 7076 is configured to supply compressed air to expand the rear jaws 7052, and the other outlet of valve 7076 is configured to supply compressed air to inflate the rear seal 7046.

[00966] In one embodiment, the valve 7082 is located on the fluid passage 7084. In one embodiment, the fluid passage 7084 is located between the front clamp control valve 7056, the front clamp 7050, and the front seal 7046, and is configured to supply compressed air to expand the front jaws 7050 and the front seal 7046. In one embodiment of the invention, one outlet of valve 7082 is configured to supply compressed air to expand the front jaws 7050, and the other outlet of valve 7082 is configured to supply compressed air to inflate the front seal 7046.

[00967] In Fig. 96 is a diagram showing the flow of purge gas through the purge and test system 7001, where some components of the purge and test system 7001 are omitted for clarity and better illustrative representation of other components and/or functions of the purge and test system 7001. For example, in one embodiment of the invention the smaller 7001 purge and test systems use purge gas not only to fill and retain purge gas in the 7054 purge gas chamber, but also to inflate 7046 and 7048 seals and expand the 7050 and 7052 clamps.

[00968] The purge gas flow through the purge and test system 7001 illustrated in FIG. 96 is similar to the flow of purge gas through the purge and test system 7001 illustrated in FIG. 94, except for the differences noted below.

[00969] In one embodiment, the rear swing hub 7072 is in fluid communication with the low blowdown valve 7016, the high blowdown valve 7022, and the front swing hub 7104 through fluid passages. In one embodiment, the purge gas stored in the purge gas tanks 7070 is directed through the fluid passages to the rear pivot hub 7072 and then through the fluid passages from the rear pivot hub 7072 to the low purge valve 7016 and to the high purge valve 7022. fluid movement from the rear pivot hub 7072 to the front pivot assembly 7104. The front pivot hub has essentially the same components and the same principle of operation as the front pivot hub 5032 illustrated in FIG. 25 and is therefore not illustrated in the same detail as the 5032 front pivot hub.

[00970] In one embodiment, purge gas is directed through fluid passages from the rear pivot hub 7072 to the rear clamp control valve 7058. In one embodiment, purge gas from the rear clamp control valve 7058 is passed through fluid passage 7088 for inflation rear clamp 7048. In one embodiment, a pressure regulator 7092 is located on the fluid passage 7090 and is configured to automatically cut off the purge gas flow from the seal 7048 at a predetermined pressure. In one embodiment, purge gas from the back jaws 7052 is received by the back jaw control valve 7058 through the fluid passage 7094 to retract the back jaws 7052.

[00971] In one embodiment, purge gas is directed through fluid passages from the front pivot hub 7104 to the front clamp control valve 7056. In one embodiment, purge gas from the front clamp control valve 7056 is supplied through fluid passage 7098 to expand front clamp 7050 and applied through fluid passage 7100 to inflate front seal 7046. In one embodiment of the invention, a pressure regulator 7102 is located on fluid passage 7100 and configured to automatically cut off the purge gas flow from seal 7046 at a given pressure. In one embodiment, purge gas from the front jaws 7050 is received by the front jaw control valve 7056 through fluid passage 7096 to retract the front jaws 7050.

[00972] In FIG. 97 illustrates a partial view of the purge and test system 7001, in which the measurement sensor 7042 and chamber 7044 are configured to test the pipes from the inside, while the external welding torch 7502 of the external welding system 7500 is configured to weld from the outside of the pipes 1022a, 1022b. In one embodiment of the invention, an externally located welding torch 7502 may be mounted on the outer surface of one of the first pipe and second pipe 1022a, 1022b.

[00973] For example, in FIG. 97 illustrates the ideal alignment of a welding torch 7502 with a groove 7106 (along the longitudinal axis A-A of pipes 1022a, 1022b). On FIG. 98 illustrates a close-up view of a welding torch 7502 in alignment with a groove 7106. The tubes 1022a, 1022b illustrated in FIG. 97 and 98 are fully aligned and do not have a step transition.

[00974] In FIG. 99 and 100 illustrate close-up views of the external welding torch of the external welding system used in the prior art system and the purge and test system 7001, respectively, where the pipes have gap and radial offset (stagger) alignment. For example, as illustrated in FIG. 99 and 100, pipes 1022a, 1022b have a gap of 1 millimeter and a radial offset (staggered transition).

[00975] As illustrated in FIG. 99, in the prior art system, the raised end of the work protects the right side of the welding edge, resulting in reduced weld penetration. As illustrated in FIG. 100, an external welding system 7500, used in conjunction with a purge and test system 7001, is configured to receive welding profile data (e.g., before, during, and after a weld procedure) from the purge and test system 7001 and is biased based on the received weld profile data, its external welding torch 7502, and/or the tilt of its external welding torch 7502 to achieve full weld penetration. Thus, weld profile data obtained from the purge and test system 7001 can be used by the external welding system 7500 to improve the weld.

[00976] The following describes the operation of the purge and test system 7001. In one embodiment of the invention, the purge and test system 7001 is configured to operate on a repetitive cycle of operation.

[00977] After it has been determined that a weld has been completed on the current weld, one or more processors 7062 (computer system 7060) are configured to send communication signals to the electronic purge module 7032 to control (via control signals) the low purge valve 7016, a 7022 high blowdown valve and a 7020 secondary low blowdown regulator to deflate the 7046 and 7048 purge seals. One or more 7062 processors are also configured to send communication signals to the 7036 front section electronics module to control/disable (via control signals) the 7056 front clamp control valve to retract the first engagement device 7050 to its home, retracted position and/or to deflate the purge seal 7046. One or more processors 7062 are also configured to send communication signals to the center section electronics module 7040 to control/disable (via control signals) the control valve back clamp 7058 to retract the second engagement device 7052 to its original, retracted position and/or to deflate the 7048 purge seals. The 7001 purge and test system (including 7046 and 7048 purge seals and 7050 and 7052 clamps) must be moved to the next weld.

[00978] In one embodiment of the invention, one or more processors 7062 are configured to send communication signals to the drive section electronics module 7064 to control (via control signals) the drive motors 7068 to accelerate the purge system and check 7001 to move at a given speed, and then slow down and stop at the next weld. In one embodiment of the invention, the target rate at which the purge and test system 7001 accelerates may be 6 ft/sec.

[00979] When the second engagement device 7052 is located on the next weld, the drive section electronics module 7064 sends communication signals to the electronic purge module 7032 to check alignment with the end of the pipe. In one embodiment, the electronic purge module 7032 is configured to monitor (turn on) one or more test sensors 7042 to detect where the second engagement device 7052 is connected to the end of the pipe. In one embodiment, the pivot hub 7012 may not operate when one or more sensors 7042 detect where the second engagement device 7052 is connected to the end of the pipe.

[00980] In one embodiment, the purge electronics module 7032 is configured to send measured distance data to the drive section electronics module 7064. In one embodiment, the drive section electronics module 7064 is configured to control (via control signals) the drive motors 7068 to move the second engagement device 7052 according to the measured distance data.

[00981] In one embodiment of the invention, when the second engagement device 7052 is properly aligned and positioned relative to the end of the pipe, the drive section electronics module 7064 is configured to send communication signals to the center section electronics module 7040 so that the purge and control system 7001 is located. in the desired position on the next weld. In one embodiment, the center section electronics module 7040 controls (opens via control signals) the rear clamp control valve 7058 to lift the second engagement device 7052 and grip the old/existing pipe. In one embodiment, the center section electronics module 7040 controls the rear jaw control valve 7058 to simultaneously inflate the rear seal 7048.

[00982] The next/new pipe segment 1002a is then inserted and advanced along the front section 7002 of the purge and test system 7001 to the desired position by the work crew. At this time, one or more processors 7062 are configured to send communication signals to the electronic purge module 7032 to control one or more gauges 7042 to check pipe alignment. In one embodiment of the invention, one or more processors 7062 can rotate the rotary hub 7012 to perform measurements at multiple locations.

[00983] If the pipe alignment data is within a predetermined tolerance, the electronic purge module 7032 sends communication signals to the front electronic module 7036 to actuate and control the front clamp 7050. In one embodiment of the invention, the front electronic module 7036 controls/opens (via control signals) a front clamp control valve 7056 to lift the first engagement device 7052 and grip the new pipe segment 1002a. In one embodiment, the front electronics module 7036 controls/opens (via control signals) the front clip control valve 7056 to simultaneously inflate the front seal 7046.

[00984] If the pipe alignment data is within a predetermined tolerance, the electronic purge module 7032 sends communication signals (message) to one or more processors 7062 identifying a mismatch between pipes 1022a, 1022b. In one embodiment of the invention, this information may be communicated to the crane operator by conventionally received hand signals from the crane operator or as an electronic signal to a computer display terminal in the crane cabin.

[00985] After the pipe is clamped, one or more processors 7062 are configured to send communication signals to the electronic purge module 7032 to control one or more measurement sensors 7042 to measure the gap and radial displacement (staggering) at a plurality of points along the circumference of the welded joint . In one embodiment of the invention, this data is reported to one or more processors 7062 and compared with allowed tolerances.

[00986] If the joint fit (i.e. gap and radial offset (stagger)) is within a given tolerance, either one or more of the 7062 processors or the 7032 electronic purge module send(s) communication signals to the operator indicating that welding can begin .

[00987] If the fit of the joint (ie clearance and radial offset (stagger)) is not within the specified tolerance, then an alert is sent to the operator and may restart the clamping sequence or cancel the alert.

[00988] In one embodiment, the electronic purge module 7032 is configured to provide control signals to the high purge valve 7022 to open and control the high purge regulator 7024. In one embodiment, the electronic purge module 7032 is configured to continuously monitor an oxygen level reading. in the 7054 purge gas chamber via the 7026 oxygen sensor. When the 7026 oxygen sensor measurements are below a set oxygen value (eg, 500 ppm), the 7032 electronic purge module is configured to send control signals to the 7022 high purge valve to close and open the low purge valve 7016. In one embodiment of the invention, the measurement data of the oxygen sensor 7026 must be within a predetermined range (for example, from 50 to 100 ppm).

[00989] In one embodiment, while the high blowdown valve 7022 is open, the electronic purge module 7032, along with the front section electronics module 7036 and the center section electronics module 7040, are configured to use one or more measurement sensors 7042 to measure clearance and stepwise transition of the welded joint at several points along the circumference of the welded joint. The scan results are reported to one or more 7062 processors for pre-programming of the external 7500 welding system.

[00990] In one embodiment, after the low blowdown valve 7016 is closed, the secondary low blowdown regulator 7020 is configured to maintain a constant setpoint pressure in the purge gas chamber 7054. In one embodiment, the secondary low blowdown regulator 7020 is configured to maintain pressure range from 0.1 to 0.5 psi inch and is configured to stop its work when the pressure exceeds 0.5 psi. inch.

[00991] In one embodiment of the invention, the pressure starts at a relatively high value (eg, 5 psi) and gradually moves to lower values as welding continues. In one embodiment, the secondary low blowdown regulator 7020 may include a pressure sensor that is configured to communicate with one or more processors 7062. In one embodiment, the pressure sensor is configured to measure purge gas pressure in purge chamber 7054 and send pressure data, which are indicative of purge gas pressure in purge chamber 7054 to one or more processors 7062. In one embodiment, one or more processors 7062 are configured to receive pressure data, compare the received pressure data with a pressure setpoint, and generate an overpressure signal in the event that when the pressure data exceeds the pressure setpoint of 0.5 psi. inch. In one embodiment, based on the overpressure signal, the purge and test system 7100 may be configured to open the vent valve structure to depressurize the purge chamber 7054 until the sensed pressure drops below a predetermined pressure. In one embodiment of the invention, based on the overpressure signal, the purge and test system 7100 may be configured to send communication signals to an external welding system to terminate the welding procedure.

[00992] In one embodiment of the invention, communication signals are sent to the halyard that the correct purge gas level has been reached and the welding procedure can begin. In one embodiment of the invention, the operator sends commands to the external welding system 7500 to begin the execution of the welding procedure. In one embodiment of the invention, commands are automatically sent to the external welding system 7500 by one or more processors 7062 to begin executing a welding procedure.

[00993] In one embodiment, the purge electronics module 7032, along with the front section electronics module 7036 and the center section electronics module 7040, are configured to use one or more measurement sensors 7042 to measure the gap and stagger of a weld a short distance ahead of that location. where the 7500 Outdoor Welding System is currently welding. In one embodiment, the test data may be transmitted in real time by the measurement sensor 7042 to one or more processors 7062, which use the test data to send updated welding parameters to the external welding system 7500.

[00994] In one embodiment, the external welding system 7500 is configured to communicate its position to one or more processors 7062, which communicate this information to the electronic purge module 7032 so that the electronic purge module 7032 can maintain proper pressure in the purge gas chamber. and accordingly control the position of the measuring sensor 7042.

[00995] In one embodiment of the invention, the welding procedure can be performed in several different ways.

[00996] In one embodiment of the invention, the welding procedure can be performed from top to bottom on one side of the pipes, and then from top to bottom on the other side of the pipes. In one embodiment of the invention, the first weld ends before the second weld begins. In this situation, the 7042 probe performs a pre-weld scan in real time.

[00997] In one embodiment of the invention, the welding procedure may be performed from top to bottom on each side of the pipe, with the second welding beginning before the completion of the second welding. In one embodiment of the invention, the measurement sensor 7042 scans the distance ahead of one weld faster than the welder is moving, and then quickly changes position and switches to another weld to scan it. In one embodiment of the invention, the measuring sensor 7042 may switch between two weld locations until the first weld is completed.

[00998] In one embodiment of the invention, the welding procedure can be performed along the entire pipe around in one pass, while the measuring sensor 7042 scans a short distance in front of the welding site.

[00999] In one embodiment, after the welding is completed, the rotary hub 7012 continues to rotate while the electronic purge module 7032 checks the progress of the welding using the measurement sensor 7042 and the camera 7044. In one embodiment of the invention, the weld test data is reported to one or more 7062 processors.

[001000] In one embodiment of the invention, if one or more weld defects are found in the weld test data, these weld defects can be eliminated while clamps 7050 and 7052 are still in position and purge gas chamber 7054 is still full inert gas.

[001001] In one embodiment of the invention, after the inspection and any repairs are completed and confirmed by the operator, the operator sends a command to the front section electronics module 7036 and the center section electronics module 7040 to turn off the control valves of the front and rear clamps 7056 and 7058, lower / retract clamp shoes 7050 and 7052 and deflate seals 7046 and 7048.

[001002] In one embodiment, one or more purge and test system processors 7062 7100 may be operatively coupled to the forward purge and test system electronics 7100, purge electronics 7032, purge and test center section electronics 7100, and section electronics. drive 7064.

[001003] In one embodiment, the field system of this patent application may include one or more distributors/nodes/routers configured to transfer data, control signals, and communication signals between one or more 5140 or 7062 processors and one or more electronic modules described in this application.

[001004] During pipe forming procedures (e.g., in offshore or land (onshore) applications, one section of pipe 1022a or 1022b is connected to another section of pipe 1022b or 1022a when welding the pipeline strings (the location where two pipe sections are welded to each other) another) by aligning the two opposite ends of the pipe sections with respect to each other and forming a welding joint 1026. Such a welding joint 1026 connects both pipe sections 1022a, 1022b at their opposite ends in such a way that the welding joint 1026 provides a watertight hydraulic seal and thus , creates a continuous channel for the movement of fluids between two connected pipe sections.Each of the pipe sections 1022a, 1022b can be quite long (for example, hundreds or thousands of feet, or even up to 1 mile in length), which makes it difficult to provide internal cooling within the pipe sections 1022a , 1022b at or near the welding site of the pipe strings water after the weld 1026 has been formed. In particular, the placement of a cooling device, as well as the removal of such a device from the inside of the pipe sections 1022a, 1022b for cooling, at the weld 1026 can be a complex task.

[001005] The internal cooling system of the present invention provides internal cooling within the pipe sections 1022a, 1022b after the pipe sections are bonded to each other via weld 1026. In one embodiment, the internal cooling system may be an internal heat exchanger, which may be referred to as IHEX. In one embodiment of the invention, the internal cooling system includes a cooling section for providing direct cooling of the internal surface areas of the pipe sections 1022A, 1022b, and a control section or controller that is configured to control the components of the cooling section and is additionally configured to with the possibility of promoting the mobility of the internal cooling system within the pipe sections 1022a, 1022b. In one embodiment of the invention, the cooling section uses a cooling agent to provide cooling within the tubular sections 1022a, 1022b. In one embodiment of the invention, the internal cooling system may also include a coolant supply section containing a coolant that is supplied to the cooling section during operation of the internal cooling system. In one embodiment of the invention, the internal cooling system according to the present patent application includes a mechanism configured to internally cool the pipe sections 1022a, 1022b after they are welded together, as well as a mechanism for placing the internal cooling system inside and extracting the internal cooling system from the pipe sections 1022a , 1022b during the pipeline forming process, resulting in a reduction in the time required to cool the pipe sections after heating, as well as a faster workflow on the fabrication workstations.

[001006] In Fig. 104 illustrates an exemplary internal cooling system 2010 of the present patent application. In one embodiment of the invention, the internal cooling system 2010 includes a suitable rigid frame that houses the components of the internal cooling system, and this frame contains a plurality of longitudinal or longitudinally located bars 2019, 2021, made of one or more suitable materials (for example, metal, such as steel, or other suitable rigid and durable materials) and is suitably configured to allow the frame to be inserted inside the pipe sections to promote internal cooling within the pipe sections 1022a, 1022b.

[001007] The first frame section 2011 comprises one or more refrigerant supply sources 2012 comprising one or more reservoirs (one reservoir is illustrated in FIG. 104) secured in the first section 2011. The refrigerant source reservoirs may contain any suitable refrigerant, including but not limited to water and cryogenic liquid such as liquid argon or liquid nitrogen, etc. The second cooling section 2016 is fixed at an intermediate location of the frame adjacent to the first section 2011 and communicates with the coolant supply 2012 through a suitable valve structure 2014 (for example, illustrated in Fig. 104 as one or more valves, regulators, pipe assemblies, etc. ) that facilitates the supply of coolant from the coolant supply source 2012 to the outlet nozzles 2007 of the cooling section 2016 at one or more suitable pressures and/or fluid flow rates.

[001008] The third frame section 2018 is located adjacent to the cooling section 2016 and includes a plurality of rods 2021 that form an insulated housing surrounding the controller 2020. The pneumatic and/or electronic drive system 2022 may also be at least partially housed within the third section 2018 and may comprise one or more motor-driven rollers 2025 and/or any other suitable self-propelled structure(s) configured to engage portions of the inner surface of the pipe sections when the internal cooling system 2010 is positioned within such pipe sections to control movement of the internal cooling system 2010 in the forward and backward directions inside the pipe sections during the procedures described in this document. In one embodiment of the invention, the drive system 2022 may be in communication (eg, via a wired or wireless connection) with the controller 2020 to facilitate control through the controller 2020 of the back and forth movements of the internal cooling system 2010 during procedures (eg, motor control of the drive system 2022 through controller 2020 controls the rotation of the roller(s) and thus the forward or backward movement of the internal cooling system 2010). In one embodiment of the invention, the drive system 2022 may actually be enclosed within and/or be part of the frame of the internal cooling system 2010. In one embodiment, the drive system 2022 may include a structure extending beyond the frame. In one embodiment of the invention, the drive system 2022 may include a suitable cable structure that extends from the internal cooling system 2010 through one or more pipe sections to the open end of the pipe section, where the cable structure is used to facilitate forward and/or backward movement of the internal cooling system 2010 inside pipe sections (for example, by means of a winch structure provided within the frame of the internal cooling system and/or in a fixed location outside the pipe sections and connected to the cable structure). In one embodiment of the invention, rollers can also be provided at one end of the internal cooling system 2010 (for example, rollers 2023 provided on the cable lug of the first frame section 2011, as illustrated in Fig. 104) to increase the mobility of the internal cooling system 2010 in pipe sections 1022a , 1022b.

[001009] In one embodiment of the invention, the controller 2020 may include at least one suitable processor that controls the operations of the internal cooling system 2010 through suitable control logic stored in the memory of the controller, as well as electronic signals provided remotely through another user interface located at a suitable distance from the internal cooling system. In one embodiment of the invention, the controller 2020 may be configured to communicate with a remote control device that is controlled by the user (for example, a computer, a hand control device, or any other suitable electronic device) via electronic signals, while the electronic signals are transmitted wirelessly or wired. between 2020 controller and remote control device. In one embodiment of the invention, the remote control device is illustrated in FIG. 104 as a computer 2030 (eg, laptop, notepad, personal digital assistant, smartphone, etc.) that communicates with the controller 2020 via a wireless link (illustrated by a dotted line in FIG. 104). Communication via electronic signals may include two-way communication between the controller 2020 and the remote control device such that the controller 2020 is configured to provide information to the remote control device (such as information about the measured internal temperature and/or other types of measured conditions inside the pipe sections) , as well as received control information to perform remote control operations of the internal cooling system 2010.

[001010] In one embodiment of the invention, one or more electronic sensors 2017 may be provided at one or more suitable locations within the frame of the internal cooling system and may communicate (via wired or wireless communication) with the controller 2020 to provide information about the conditions inside the pipe sections during procedure execution time. For example, in one embodiment, one or more electronic sensors 2017 may include one or more temperature sensors (e.g., infrared temperature sensors, RTD temperature sensors, thermocouples, etc.) that may be provided in one or more different places in the first section 2011, the cooling section 2016 and/or the third section 2018 of the internal cooling system 2010, while the temperature sensors are configured to measure temperature and provide information about such a measured temperature to the controller 2020 during the execution of procedures. In one embodiment, the one or more electronic sensors 2017 comprise pressure sensors and/or flow sensors that may be provided at one or more suitable locations in the coolant source tank(s) 2012 2012 in the valve structure 2014 and/or near outlets. nozzles 2007 of the cooling section 2016, while the data of the measured pressure and/or fluid flow are provided by such sensors to the controller 2020 during the execution of procedures. It should be appreciated that the sensors 2017 may also include a combination of temperature and pressure sensors. In one embodiment of the invention, one or more cameras 2027 controlled by the controller 2020 (and remotely controlled by a remote control device) may also be provided in one or more suitable locations to facilitate viewing inside pipe sections (for example, to determine a suitable location for placing internal cooling system 2010 inside the pipe sections 1022a, 1022b during procedures). Exemplary pressure/temperature sensors and/or chambers are generally illustrated at locations 2017 and 2027 in FIG. 104.

[001011] In one embodiment, the internal cooling system 2010 may comprise a suitable power source to provide power to the controller 2020, drive system 2022, electronic sensors, valve structure 2014 (e.g., to electronically control one or more valves and thus controlling the flow of refrigerant from the refrigerant supply 2012 to the cooling section 2016). In one embodiment of the invention, the power supply may be contained within the internal cooling system frame (for example, one or more batteries may be located in the battery pack provided in the third section 2018 or any other suitable location within the internal cooling system frame). In one embodiment of the invention, the power supply may be located outside the pipe sections, with an electrical cable connecting the power supply to the internal cooling system 2010 to provide power to various components of the internal cooling system.

[001012] In one embodiment, the cooling section 2016 may comprise any suitable structure that facilitates cooling by heat exchange with the interior of the weld as well as with other portions of the interior wall of the pipe sections. In one embodiment, coolant is provided from a coolant supply source 2012 through valve section 2014 to cooling section 2016. In one embodiment, cooling section 2016 includes a plurality of nozzles 2007 located around the outer periphery of cooling section 2016 to facilitate coolant agent at a suitable flow rate (controlled by the valve valve section 2014 and nozzle design in the cooling outlet nozzle section 2007) from the cooling section 2016 towards the internal surfaces of the weld and other internal parts of both connected pipe sections.

[001013] The operation of the internal cooling system 2010 in connection with the pipeline welding procedures is further described with reference to FIG. 105-107. The two pipe sections 1022a, 1022b are axially aligned with each other in preparation for welding the open end of the first pipe section 1022a against the open end of the second pipe section 1022b. In one embodiment of the invention, both pipe sections 1022a, 1022b can be held in such alignment by a pipe string clamp (not illustrated in FIGS. 105-107). A suitable pipe string clamp (e.g., clamps 5302 (located external to the pipe) described elsewhere in this application) may be externally attached to the end ends of the pipe sections 1022a, 1022b to hold the sections 1022a, 1022b in place in relation to each other. during the welding procedure. In one embodiment of the invention, an internal clamp of conduit strings (eg, internal clamps 5142, 5144 (located inside the pipe) disclosed elsewhere in this application) can be used to hold the end ends in place during the welding procedure. Both types of pipe string clamps (external and internal) are known in the art of pipe welding and are therefore not described in more detail in this document. After a string clamp is applied to hold the ends of the pipe sections 1022a, 1022b in place relative to each other, a welding joint 1026 is formed at the weld location (ie, at both opposite open ends of the first and second pipe sections). The weld joint 1026 is configured as detailed above and may include a root pass, a hot pass weld layer, a fill pass weld layer(s), and a cover pass weld layer to ensure that a proper weld is formed. In one embodiment, forming the weld 1026 may include preheating the opposite ends of the first and second pipe sections 1022a, 1022b to a minimum temperature of about 150°C. The remainder of the welding procedure may cause the temperature around the weld to rise up to about 300°C. Once the weld 1026 is formed, the weld 1026 is typically AUT (Automatic Ultrasonic Testing) and/or radiographically inspected, as described elsewhere in this application, to confirm the quality/integrity of the weld 1026. In one embodiment, the weld inspection The AUT may not be conducted above a temperature range of about 50° C. to about 75° C. (T _max ), where T _max is the highest temperature at which the test can be effectively performed. In addition, the AUT weld inspection procedure during pipe manufacturing must be stopped until the temperature of the weld joint 1026 drops to a temperature close to that inspection temperature range. The internal cooling system of the present invention is configured to remove heat from the weld zone to reduce the temperature of the weld area of the pipe to at least an acceptable test temperature AUT (T _max ).

[001014] In one embodiment, following the weld inspection procedure, weld joint insulation (FJC) is also applied to the outer portions of pipe sections 1022a, 1022b surrounding weld joint 1026 to provide an insulating barrier to prevent or minimize corrosion in weld zones. Such insulation can generally only be effectively applied when the pipe temperature is above the minimum pipe temperature T _min . Therefore, the temperature in the weld zone rises until the temperature of the pipe in the weld area to be insulated again rises to a temperature of about 220-240°C (T _min ), where T _min is the lowest temperature at which the insulation can be effectively applied in the area of isolation.

[001015] After the coating/insulation procedure, the pipe can be wound on a spool for installation in the field. However, at temperatures around T _min , the bobbin winding procedure cannot be efficiently performed while maintaining the integrity of the weld. Therefore, the pipe manufacturing procedure can again be stopped until the temperature of the pipe gradually drops naturally (relative to ambient temperature) from T _min to an acceptable winding temperature (T _max ), where T _max is the highest/maximum temperature at which the pipe can be effectively wound on a spool. In one embodiment of the invention, the internal cooling system of the present invention is configured to re-remove heat from the weld area to reduce the temperature to a maximum temperature of about 50 to about 75° C. (T _max ) acceptable for efficient winding (winding the pipe onto a spool). Therefore, the internal cooling system of the present application is configured to lower the temperature prior to the weld test procedure and/or lower the temperature prior to the winding procedure to minimize the time required to weld, test, insulate and coil the pipe segments.

[001016] During the period of operation when the pipe sections 1022a, 1022b are welded together (followed by coating/insulation), the internal cooling system 2010 is loaded into the open end of the pipe section 1022a, as illustrated in FIG. 105. In one embodiment, one or both pipe sections 1022a, 1022b may comprise a single pipe assembly. In another embodiment of the invention, one of the pipe sections 1022a, 1022b may comprise a plurality of pipe assemblies welded together. In one embodiment of the invention, when one of the pipe sections 1022A or 1022b contains a plurality of pipe assemblies already welded together, it may be desirable to load the internal cooling system 2010 into the pipe section 1022a or 1022b containing a single pipe node (or the pipe section with the smallest length) to shorten the time required for the internal cooling system 2010 of the pipe section to reach the welding location of the pipe strings. Thus, in one embodiment, pipe section 1022a may comprise a single pipe assembly that is connected to a longer pipe section represented by pipe section 1022b (eg, two or more pipe assemblies joined by welded joints).

[001017] In one embodiment, the internal cooling system 2010 is loaded into the open end of pipe section 1022a (i.e., the end that is opposite the open end opposite the open end of pipe section 1022b that defines the weld location of the pipe strings) such that the first section The internal cooling frame 2011 serves as the front end and thus enters first into the pipe section 1022a. In one embodiment of the invention, the internal cooling system 2010 is moved (moved along with the first section 2011) within the pipe section 1022a to a suitable location near the welding location of the pipe strings, as illustrated in FIG. 106. In one embodiment of the invention, the controller 2020 (which can be remotely controlled by a user) is configured to control the operation of the drive system 2022 (for example, by controlling one or more motors that bring the rollers 2025 into contact with portions of the inner wall of the pipe section 1022a) to to facilitate the advancement of the internal cooling system 2010 within the pipe section 1022a towards the weld of the pipe strings. Once a suitable location has been reached close to the weld of the pipe strings (e.g., the location of the internal cooling system, as illustrated in FIG. 106), the controller 2020 may control the drive system 2022 to stop further movement of the internal cooling system 2010 until cooling procedures will not start. For example, a camera 2027 suitably mounted on the first section 2011 and controlled by the controller 2020 can provide video images to the remote control so that the user can determine how close the internal cooling system is to weld 1026. In one embodiment of the invention, in combination with the video images provided by the camera 2027, one or more temperature sensors 2017, suitably placed on the frame of the internal cooling system 2010, measure the internal temperature in the pipe section 1022a and provide information about this temperature to the controller 2020. In the case of , when one or more measured temperatures reach a threshold value (eg, about 100° C. or higher), this may indicate that the internal cooling system 2010 has reached a location near weld 1026. Any other suitable mechanism may also be used to provide a suitable indication the location of the internal cooling system 2010 in the pipe section 1022a during its movement towards the welding location of the pipeline strings.

[001018] After reaching the desired location, which is in close proximity to or near the weld of the pipeline strings, a cooling procedure can be performed after the weld 1026 has been formed and before the AUT/ check has been (if necessary) performed. radiography. In one embodiment of the invention, the cooling procedure can be performed after the pipe is reheated for overcoating, and then (if required) FJC is applied. In one embodiment of the invention, when the internal cooling system 2010 reaches a suitable location in the section of pipe 1022a that is near the weld of the pipe strings, and until the welding procedure is completed, the internal cooling system 2010 is held in position and ready for use for cooling purposes as soon as the welding or reheating procedure will be completed. The cooling procedure is performed by first placing the cooling section 2016 in a suitable location (eg, relative to the weld 1026, as illustrated in Fig. 107). This can be achieved by advancing the internal cooling system 2010 from its location illustrated in FIG. 106 to its location illustrated in FIG. 107 by means of a controller 2020 (which is controlled by the user via a remote control device) operating the drive system 2022 until the internal cooling system 2010 is in the desired location. Movement to such a location (eg, as illustrated in Fig. 107) can be achieved based on video images within the pipe sections 1022a, 1022b that are provided to the remote control device, with data from the temperature sensor being sent to the remote control device and/or through any other suitable device.

[001019] Upon reaching the desired location within the pipe sections 1022a, 1022b (for example, where the cooling section 2016 is located in close proximity to the weld 1026, as illustrated in Fig. 107), the controller 2020 (which can be controlled by the user through a remote control device ) controls the operation of the valve structure 2014 (for example, by controlling one or more electronic valves) to promote the flow of coolant from the coolant supply source 2012 at a suitable pressure and/or flow rate to the cooling section 2016, where the coolant flows from the nozzles 2007, located in the cooling section 2016 and appropriately oriented so as to direct the flow of the coolant from the cooling section 2016 to parts of the inner surface of the walls inside the pipe sections 1022a, 1022b. The temperature sensor(s) monitors the internal temperature of the internal cooling system 2010 within the pipe sections 1022a, 1022b and provides the measured temperature information to the controller 2020. T _max °C or lower) the controller 2020 may control the valve structure 2014 to stop the flow of refrigerant into the cooling section 2016.

[001020] In one embodiment of the invention, the internal cooling system 2010 can be moved forward or backward by controlling the drive system 2022 through the controller 2020 to allow additional cooling procedures (as needed and based on measured temperatures inside the tubes) to be performed at other locations along the interiors. walls of pipe section 1022a and/or pipe section 1022b. The internal cooling system 2010 may be withdrawn from the connected pipe sections 1022a, 1022b when it has been determined that sufficient cooling has been achieved. For example, the internal cooling system 2010 can be moved backwards, or backwards, by operating the drive system 2022 through the controller 2020 to move towards the free and open end of the pipe section 1022a so that the third section 2018 exits the pipe section 1022a first. The other section of pipe can then be aligned (the internal cooling system can remain inside section 1022a while the new section is fitted to 1022a) with the free and open end of pipe section 1022a (at this stage connected by welding 1026 to pipe section 1022b) to forming a pipe string weld, and then repeating the process in which the internal cooling system 2010 enters through the free and open end of the additional pipe section and advances to the pipe string weld to perform cooling procedures on the weld formed between the pipe sections.

[001021] Although the drive system 2022 illustrated in the embodiment illustrated in FIG. 104-107 includes rollers 2025 controlled by a motor system that is controlled by controller 2020, the drive system 2022 for the internal cooling system may also employ any suitable mechanism capable of providing user-controlled movements of the internal cooling system within the pipe sections. For example, one or more cable/winch systems may be used, in which one or more winches may be provided as part of an internal cooling system and/or located at one or more anchor points that are external to the pipe sections. The cable is routed between each winch and a connection point (either in the internal cooling system or at a connection point outside the pipe sections) in such a way as to facilitate the placement of the internal cooling system inside and/or the withdrawal of the internal cooling system from the pipe sections during procedures.

[001022] It should be noted that the procedures described above in relation to the internal cooling system can be performed for any type of welding of pipeline strings between pipe sections in a pipeline system. For example, an internal cooling system can be used to create piping in marine, subsea, and mainstream applications. In one embodiment, the internal cooling system 2010 may be used for a spool welding sequence (as illustrated in the described embodiment with reference to FIG. 6) and a barge welding sequence (as illustrated in the described embodiment with reference to FIG. .7).

[001023] In a general application, sections of pipe ranging in length from 40 feet (12 meters) to 80 feet (24 meters) are welded together to form long sections of "strands" of pipeline. In scenarios where a tether may be required to control movement procedures and/or other procedures in connection with the internal cooling system, the detachable cable may be at least 240 feet (72 meters) long. The procedure for loading the internal cooling system into the pipe section and moving the internal cooling system into position for cooling after the welding procedure (with optional AUT/X-ray weld inspection and coating/insulation/FJC application) is similar to the previously described procedures with reference to FIG. 104-107.

[001024] In 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 embodiments described above, except for the differences that will be noted below. In one embodiment of the invention, the internal cooling system 2010-1 is configured to be connected to the internal clamp of the pipeline strings 2060 in the end section 2024 of the third frame section 2018 of the internal cooling system 2010-1. In one embodiment, the inner string clamp 2060 includes a suitably configured frame 2062 that allows the string clamp 2060 to be inserted into pipe sections (e.g., pipe sections 1022a and 1022b) and includes a section 2064 that is configured to align and hold two the open and end ends of pipe sections 1022a, 1022b at the weld of the pipe strings (e.g., by expanding to form frictional engagement with portions of the inner wall surface of the pipe sections at their end ends when the pipe string clamp 2060 is appropriately placed inside the pipe sections 1022a and 1022b) . In one embodiment, section 2064 and clamp 60 correspond to sections of internal welding system 5004, having a first pipe clamp 5142 and a second pipe clamp 5144. clamping the lashes of the pipeline 2060 with the end section 2024 of the frame of the internal cooling system 2010-1.

[001025] In one embodiment of the invention, the internal cooling system 2010-1 may be a trailer for clamping the strings of the pipeline 2060. For example, the connecting clamp 2060 with the internal cooling system 2010-1 attached to it (via the connecting element 2080) can be inserted at its end 2065 (i.e., the end of the frame that is opposite the end of the frame 2066 that connects to the internal cooling system 2010-1 through the connecting element 2080) into the pipe section, when the movement of the pipe string clamp 2060 inside the pipe section also results in a corresponding movement of the internal cooling system 2010- 1 in the pipe section. In one embodiment of the invention, the internal cooling system 2010-1 can be inserted through its first frame section 2011 into the pipe section and then moved to the desired position so as to bring the pipe string clamp 2060 into proper alignment with the pipe string welding location between both aligned pipe sections. In one embodiment of the invention, the drive system 2022 of the internal cooling system 2010-1 can be used to move the combined string clamp structure 2060/internal cooling system 2010-1 to a suitable location within the pipe sections or, alternatively, any other suitable drive mechanism can also be used to move such a structure inside pipe sections (eg one or more cable/winch systems).

[001026] In one embodiment, pipe string clamp 2060 holds the ends of pipe sections 1022a, 1022b together to form a welded joint 1026. In one embodiment, section 2064 and clamp 60 correspond to sections in an internal welding system 5004 having a first pipe clamp 5142 and second pipe clamp 5144. After the weld joint 1026 has been formed (and, if necessary, the coating has been formed), the pipe string clamp 2060 can be detached from the inner surface of the pipe walls of the pipe sections to facilitate moving the internal cooling system 2010-1 to a suitable location (for example, so that the cooling section 2016 is aligned with the weld) to initiate internal cooling within the pipe sections 1022a, 1022b.

[001027] In Fig. 109 discloses another embodiment of the invention for connecting an internal cooling system to an internal string clamp, which provides a longer connector 2082 (for example, an elongated rod) for connecting the internal cooling system 2010-1 to the pipe string clamp 2060. In one embodiment of the invention connector 2082 has a larger longitudinal dimension than connector 2080 (illustrated in Fig. 108), which minimizes heating of the internal cooling system 2010-1 during welding procedures (due to the greater separation distance between the internal cooling system and the whip clamp pipeline).

[001028] In one embodiment, the procedure comprises loading the string clamp 2060, along with the internal cooling system 2010-1, into one of the pipe sections and aligned so that the string clamp 2060 holds both ends of the pipe sections facing each other at the weld pipeline strings. Once certain welding procedures have been completed (e.g., root pass and hot pass procedures), the 2060 pipe string clamp with internal cooling system 2010-1 can be moved together and away from the pipe string weld to avoid further exposure to heat due to the ongoing process. welding required to complete the welded joint. In one embodiment of the invention, if the connector is long enough (e.g., connector 2082 in FIG. 109), the string clamp 2060 with internal cooling system 2010-1 can be moved so that the string clamp is on one side and the internal cooling system was located on the other side of the weld of the pipeline strings (only with the condition that the connecting element 2082 is located directly below the bottom or in close proximity to the weld of the pipeline strings). Upon completion of welding and AUT/X-Ray inspection(s) (if required), and after any coating/insulation/FJC has been applied, the 2060 Internal Coolant Clamp 2060 can be moved to the desired location so that the cooling section 2016 of the internal cooling system was in close proximity to the weld and cooling procedures could be performed (for example, in a manner similar to that previously described with respect to the embodiment of the invention illustrated in Figs. 104-107).

[001029] In one embodiment of the invention, the cooling section of the internal cooling system can be implemented with any kind of cooling design for fast and/or efficient cooling of pipe sections at the site of the newly formed welded joint and, therefore, is not limited to the exemplary embodiments of the invention, illustrated in FIG. 104-109. For example, in one embodiment of the invention, the cooling structure integrated as part of the internal cooling system may include, without limitation, cooling fans (for example, fans 2122, illustrated and described below) that force air flows through areas of the inner surface of the pipe sections and/ or through heat exchanger fins or other cooling elements of the internal cooling system, releasing liquid and/or gaseous fluids (for example, cryogenic fluids, liquids, air) at appropriate pressures and temperatures from the nozzles 2007 or 2318 of the cooling section 2016 or 2316 towards areas of the internal surface sections of pipes using cooling fluids in a closed recirculation loop (for example, pump 2212, manifold 220 and finned elements 2218, as illustrated in Fig. 111A and 111B) and through the heat exchange design of the cooling section, using thermoelectric cooling (for example, through a Peltier devices in direct contact with sections of the inner surface of the walls of pipe sections), etc.

[001030] In Fig. 110A and 110B illustrate an internal cooling system 2110 in accordance with another embodiment of the present patent application. The internal cooling system 2110 is similar to the previously described embodiments of the invention, with the exception of the differences that will be noted below. In one embodiment of the invention, the cooling section 2116 of the internal cooling system 2110 includes a heat sink that includes a plurality of finned elements 2118 located along the perimeter and extending radially outward from the central support element 2120 of the cooling section 2116, and contains curved sections of the outer surface that correspond to the curved the interior surfaces of the tube sections to which the fins 2118 extend. In one embodiment, each finned element 2118 includes a plurality of thin material sections extending from the location of the central heat sink of the cooling section 2116 radially outward towards the curved end wall section of the finned element 2118. In In one embodiment of the invention, the finned elements 2118 are made of a material having an appropriate thermal conductivity (for example, copper, aluminum, etc.) to facilitate a high rate of heat transfer from the internal portions of the wall of the ce sections of pipe 1022a, 1022b to the heat sink of the cooling section 2116. In one embodiment of the invention, the finned elements 2118 include open channels 2120 defined between adjacent sections of thin material, and open channels 2120 extend in the longitudinal direction through the finned elements. In one embodiment, the electric fans 2122 may be mounted on the central support member 2123 proximate the ends of the finned elements 2118 and in alignment with the finned channels 2120. In one embodiment, the electric fans 2122 provide airflow through the finned channels 2120 to cool the finned elements 2118 and thus cause heat to move via convective air currents from the heat sink of the cooling section 2116. In one embodiment of the invention, the fans 2122 are in communication (for example, via a wired or wireless link) with the controller 2020 to facilitate the selective operation of the fans 2122 during cooling time. In one embodiment of the invention, each fan 2122 may be configured to operate at a variable speed to selectively control the fan speed and the corresponding airflow through the finned elements 2118 differently and as needed during a cooling procedure.

[001031] The operation procedure of the internal cooling system 2110 illustrated in FIG. 110A and 110B is similar to the procedure previously described for the embodiment illustrated in FIG. 104-107 in relation to the placement of the internal cooling system during the welding procedure and positioning for cooling after completion of the welding procedures. During cooling, the fans 2122 may be activated to provide one or more desired flow rates of cooling air through the channels 2120 of the finned elements 2118. including the weld 1026) and direct it to the central support element 2123 of the cooling section 2116, and forced moving air flows provided by the fans 2122 remove heat from the finned elements 2118, thereby cooling the pipe sections 1022a, 1022b at the location of the cooling section 2116 As described in prior embodiments, the internal cooling system temperature sensors may provide sensed temperature information to the controller 2020, and such sensed temperature information may be used to control the operation of the fans 2122 (including changes e rotation speed of one or more fans 2122) during the cooling procedure. When the desired temperature is reached in the pipe sections 1022a, 1022b, the fans 2122 can be turned off via the controller 2020. In one embodiment of the invention, the internal cooling system 2110 can be further moved to different locations as needed within the pipe sections 1022a, 1022b for cooling at different locations. .

[001032] In Fig. 111A and 111B illustrate an internal cooling system 2210 in accordance with another embodiment of the present patent application. The internal cooling system 2210 is similar to the embodiments described above, except for the differences that will be noted below. In one embodiment of the invention, the internal cooling system 2210 includes a cooling section 2216, which contains a number of finned elements 2218 located along the periphery and extending radially outward from the central support element 2223 of the cooling section 2216, while the finned elements 2218 have the same external shape or profile, like the ribbed elements 2118 of the embodiment illustrated in FIG. 110A and 110V. In one embodiment of the invention, the ribbed elements 2218 can also be made of a material having an appropriate thermal conductivity (eg, aluminum or copper). However, each finned member 2218 may have a hollow and sealed inner layer to facilitate flow of coolant through the finned member 2218. In one embodiment, each finned member 2218 includes an inlet at one end and an outlet at the other end, and is provided with a suitable design. pipes to assist in the operation of the recirculation loop for the flow of coolant from the pump 2212 to the finned element 2218, with the coolant flowing through the finned element 2218 and back to the pump 2212. Any suitable type of coolant can be used (for example, water and a cryogenic liquid, such as liquid nitrogen or liquid argon, etc.).

[001033] In one embodiment, pump 2212 (illustrated in Fig. 111A) may be located external to pipe sections 1022a, 1022b, with supply and return flow paths 2214 extending between pump 2212 and manifold structure 2220 (illustrated in Fig. 111B) . In one embodiment, the manifold structure 2220 includes a plurality of tubular connections that connect to the inlets and outlets of the finned elements 2218. Thus, the cooling section 2216 facilitates heat exchange between the circulating coolant flow within the finned elements 2218 and portions of the inner wall surface of the tube sections 1022a , 1022b (eg, at or near weld 1026) during cooling procedures.

[001034] In one embodiment of the invention, pump 2212 may be controlled (via a suitable wired or wireless link) via internal cooling system controller 2210. Alternatively, pump 2212 may be externally controlled (because it is easily accessible to the user). The flow of coolant controlled by pump 2212 may be controlled based on sensed temperature information provided by one or more temperature sensors in internal cooling system 2210. Once the desired temperature has been reached in pipe sections 1022a, 1022b, the pump may be deactivated or turned off to stop recirculation flow. coolant and facilitate movement of the internal cooling system 2210 within the pipe sections 1022a, 1022b.

[001035] In Fig. 112A and 112B illustrate an internal cooling system 2310 in accordance with another embodiment of the present patent application. The internal cooling system 2310 is similar to the embodiments described above, with the exception of the differences that will be noted below. In one embodiment, the internal cooling system 2310 includes a cooling section 2316 that has a plurality of spray nozzles 2318 arranged around a central support member 2323 of the cooling section 2316. longitudinal direction along the central support member 2323. A suitable pipe structure is provided at each end of each linear row of spray nozzles 2318 where the pipe structure connects to a manifold 2320. The manifold 2320 is connected via liquid line 2314 to a coolant pump 2312 provided outside or outside of the pipe sections . In one embodiment, operation of the coolant pump 2312 provides a flow of coolant (e.g., water and a cryogenic liquid such as liquid nitrogen or liquid argon, etc.) from the coolant source through the manifold 2320 and from the spray nozzles 2318 towards to areas of the inner surface of the pipe sections 1022a, 1022b (including at the welded joint 1026). Although the embodiment of the invention illustrated in FIG. 112A and 112B show a pump 2312 located outside of the pipe sections 1022a, 1022b, it should be noted that the cooling section 2316 with alignment of the spray nozzles 318 can also be easily implemented for the embodiment of the invention illustrated in FIG. 104-107 (ie, when manifold 2320 and spray nozzles 2318 receive coolant from coolant source 2012). The procedures for cooling the internal cooling system 2310 may be performed in a manner similar to that described in connection with the previous embodiments of the invention, in which the pump 2312 can be controlled through the controller of the internal cooling system 2310 and / or from outside and from where the flow of coolant can be directed on the basis information about the measured temperature provided by the temperature sensors located on the internal cooling system 2310.

[001036] Thus, the internal cooling system of the present patent application is configured to provide improvements to pipeline welding procedures, including improving cooling of associated pipe sections after weld formation by providing internally controlled cooling in the pipe sections and reducing production time (because cooling can faster and more efficiently, it is possible to increase the number of welds between pipe sections that can occur in a certain period of time). In addition, the number of workstations associated with welding procedures and the resources associated with such welding procedures can be reduced. For example, the workspace required to weld pipe sections to each other can be reduced, and this can be especially practical in scenarios where workspace is limited (eg, on barges or in relation to water tanks).

[001037] In one embodiment of the invention, a method is provided for welding a pair of insulated pipes (eg, pipes 1022a, 1022b, as illustrated in Fig. 113) to each other. As illustrated in FIG. 113, each pipe 1022a, 1022b includes an inner metal pipe portion 5244 surrounded by insulating material 5246. In one embodiment, end portions 5248, 5250 of pipes 1022a, 1022b to be welded have an exposed or exposed inner metal pipe 5244.

[001038] In one embodiment, with reference to FIG. 113-34, the method comprises aligning the open ends of metal pipes 5248, 5250 intended for welding, welding together the open ends of metal pipes 5248, 5250, heating the open ends 5248, 5250 of the welded pipes 1022a, 1022b, applying insulator 5246 to the heated open ends sections 5248, 5250 of welded pipes such that the insulator 5246A (as illustrated in Fig. 118) engages with the outer surface 5254 of the inside of the metal pipe 5244, thus insulating the previously exposed end portions 5248, 5250 of pipes 1022a, 1022b, and applying cooling energy inside pipes 1022a, 1022b to the inner surface 5130a, 5130b of metal pipes 1022a, 1022b.

[001039] In one embodiment of the invention, the application of cooling energy inside the pipes to the inner surface of the metal pipes is performed after the application of the insulator. In one embodiment of the invention, the method also comprises performing a pipeline deployment procedure. In one embodiment of the invention, the application of cooling energy reduces the waiting time between the application of the insulator and the execution of the pipeline deployment procedure. In one embodiment of the invention, the tubing deployment procedure is a tubing spooling procedure. In one embodiment of the invention, the pipeline deployment procedure is an S-lay pipe procedure. In one embodiment of the invention, the pipeline deployment procedure is a pipeline lowering procedure. In one embodiment of the invention, the pipeline deployment procedure is described with respect to FIG. 1B of this patent application.

[001040] In one embodiment, platforms 5330 (as illustrated in FIGS. 10A and 10B) or platforms 6010A and 6010B (as illustrated in FIG. 73) are used to carry and move pipes 1022a and 1022b and to provide an open end of metal pipe 5248 inlet pipe 1022a for the open end of the metal pipe 5250 of pipe 1022b. That is, platforms 5330 or 6010A/6010B are used to align the open ends of metal pipes 5248, 5250 to be welded.

[001041] In one embodiment, alignment of the open ends of the metal ends 5248, 5250 to be welded may be automatically performed by one or more processors 5140, control platforms 5330 (or 6010A or 6010B), may be performed by hydraulic control of platforms 5330 (or 6010A , or 6010B), or can be performed by the operator using a crane and clamping device (internal or external). In one embodiment, once pipes 1022a, 1022b are aligned, pipes 1022a, 1022b may be clamped using external clamps 5302 (as illustrated in FIGS. 7A and 7B) and/or internal clamps 5142 or 5144. In one embodiment, as described in this application, one or more external or internal clamps may be used during alignment of the open ends of the metal pipes 5248, 5250 (to be welded). That is, one or more external or internal clamps may be used independently and/or in combination with platforms. In one embodiment of the invention, operation using one or more external or internal clamps and platforms may be controlled by one or more 5140 processors.

[001042] In one embodiment, one or more processors 5140 are configured to control platforms 5330 (or 6010A and 6010B) to adjust the relative position of pipes 1022a, 1022b based on pre-weld profile data. In one embodiment, pre-weld profile data may be acquired for one or more sensors that are operatively coupled to one or more processors 5140. ) may include adjustment along the longitudinal axis of the tubes 1022a, 1022b and/or adjustment along the radial axis of the tubes 1022a, 1022b. In one embodiment, after the pipes 1022a, 1022b have been adjusted, the pipes 1022a, 1022b are clamped with external and/or internal clamps. On FIG. 113 illustrates pipes 1022a, 1022b with their exposed metal pipe ends 5248, 5250 properly aligned and ready for the welding procedure.

[001043] In Fig. 114 illustrates pipes 1022a, 1022b with a welded joint 1026 formed between their open ends of metal pipes 5248, 5250. the open ends of the metal pipe 5248, 5250. In one embodiment, the outside (e.g., outside/outside of the pipes 1022a, 1022b) welding torch 7502 may be configured to weld the open ends of the metal pipe 5248, 5250 together. In one embodiment, of the invention, a combination of an internal welding torch 5502 and an external welding torch 7502 can be used to weld the open ends of a metal pipe 5248, 5250 together. or more 5140 processors.

[001044] In one embodiment of the invention, with reference to FIG. 115A and 115B, heater 5304 may be configured to heat open end portions 5248, 5250 of welded pipes 1022a, 1022b. In one embodiment, heater 5304 may be an induction heating system used to heat open end portions 5248, 5250 of welded pipes 1024a, 1022b of conduit 1024 in preparation for the application of the coating material(s) or insulator. In one embodiment, heater 5304 may include microwave induction coils that are configured to quickly heat open end portions 5248, 5250 of welded tubing 1022a, 1022b of conduit 1024 to a desired coating temperature. In one embodiment of the invention, the heater 5304 may use two induction coils. In one embodiment of the invention, heater 5304 may be an electrical heating system. In one embodiment of the invention, the heater 5304 may be a radiation heating system. In one embodiment, the induction coils 5307 of the heater 5304 are illustrated in FIG. 115A.

[001045] As illustrated in FIG. 115A and 115B, heater 5304 is configured to surround open end portions 5248, 5250 of welded pipes 1022a, 1022b of conduit 1024. In one embodiment, heater 5304 may include two semicircular annular heating elements 5304a and 5304b. In one embodiment of the invention, two semi-circular annular heating elements 5304a and 5304b are pivotally connected to each other by a joint 5305 at the top and releasably connected to each other via one or more connectors (not illustrated) from below.

[001046] In one embodiment, the heater 5304 is also configured to control the temperature of the open end portions 5248, 5250 of the welded pipes 1022a, 1022b of conduit 1024 to maintain a suitable coating temperature. In one embodiment, the heater 5304 may also include a heater feedback system configured to assist the heater 5304 to reach and maintain a desired coating temperature, and a temperature sensor operatively coupled to the heater feedback system. In one embodiment of the invention, the temperature sensor may be a contact or non-contact temperature sensor. In one embodiment of the invention, the heater feedback system may include other sensors that are configured to determine other parameters of the heating procedure, such as heating time, etc. In one embodiment of the invention, via feedback signals from one or more sensors, the heater feedback system is configured to control the current in the inductor coils to achieve the desired coating temperature. In one embodiment, heater 5304 and its feedback system may be operatively coupled to one or more processors 5140. In one embodiment, one or more processors 5140 may be configured to control the operation of heater 5304 and its feedback system.

[001047] In one embodiment of the invention, with reference to FIG. 116A, 116B, 117A, and 117B, insulator feeder 5306 is configured to apply insulating material 5312 to heated exposed end portions 5248, 5250 of welded pipe 1022a, 1022b such that insulator 5246A (as illustrated in FIG. 118) adheres to an outer surface. 5254 of the interior of the metal pipe 5244, thus insulating the pre-exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b. In one embodiment, the insulator supply device 5306 includes a container 5310 configured to receive insulating material 5312 and an outlet nozzle 5308 configured to spray insulating material 5312 onto open end portions 5248, 5250 of welded pipes 1022a, 1022b. In one embodiment of the invention, the container 5310 configured to accommodate the insulating material 5312 may be pressurized.

[001048] In one embodiment, the insulator supply device 5306 may include a feedback system configured to assist the insulator supply device 5306 to achieve desired coatings on conduit 1024, and one or more sensors operatively associated with the feedback system. In one embodiment of the invention, one or more sensors may be configured to determine the following parameters of the insulator application procedure: the temperature of the insulating material, the volume of the insulating material, and so on.

[001049] In one embodiment of the invention, with reference to FIG. 116A and 116B, insulator feeder 5306 is an automated system and includes a cover frame 5393 that is configured to be placed on the weld area 1026. welded joint 1026 so as to achieve the required dry film thickness of the insulating material. That is, the cover frame 5393 is designed and constructed to move evenly around the area of the weld 1026. In one embodiment, the spray head (including the container 5310 and outlet nozzle 5308) is mounted on the cover frame 5393 at a specific position (e.g., perpendicular to the heated open end sections 5248, 5250 of welded pipes 1022a, 1022b).

[001050] In one embodiment of the invention, the insulator supply device 5306 illustrated in FIG. 116A and 116B is configured to apply a weld-on epoxy insulation coating material to the heated exposed end portions 5248, 5250 of welded pipes 1022a, 1022b such that the weld-on epoxy insulator 5246A (as illustrated in FIG. 118) is bonded to the outer surface 5254 of the inner portion. metal pipe 5244, thus isolating the previously exposed end portions 5248, 5250 of welded pipes 1022a, 1022b.

[001051] In one embodiment of the invention, the insulator supply device 5306 illustrated in FIG. 117A and 117B is configured to apply injection molded polypropylene insulator material to the heated open end portions 5248, 5250 of welded pipes 1022a, 1022b such that the injection molded polypropylene insulator 5246 is bonded to the outer surface 5254 of the interior of the metal pipe 5244. In one embodiment of the invention, the insulator supply device 5306 illustrated in FIG. 117A and 117B can be used to apply injection molded polypropylene insulator material to the heated open end portions 5248, 5250 of welded pipes 1022a, 1022b such that the injection molded polypropylene insulator 5246 is bonded to the outside surface 5254 of the inside of the metal pipe 5244. .

[001052] With reference to FIG. 117A and 117B, in one embodiment, the insulator feeder 5306 is an automated system and includes a mold 5381 configured to wrap around the weld area 1026 and create an annular gap 5383 for filling it with injection molded insulating material 5246. In one embodiment, embodiment of the invention, a hydraulically operated valve (not illustrated) is configured to supply/inject molded insulating material 5385 into the annular gap 5383. connection 1026 and forming the inner/inner mold profile 5381. In one embodiment, chilled water may be supplied to the mold to cool the outer profile of the insulation material such that the injection molded polyurethane insulator 5246 bonds to the outer surface of the mold. 5254 of the inside of the metal pipe 5244, thus isolating the previously exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b.

[001053] In one embodiment, the insulator supply device 5306 illustrated and described above with reference to FIG. 116A and 116B may be used for above ground pipeline applications. In one embodiment of the invention, the insulator supply device 5306 illustrated and described above with reference to FIG. 117A and/or 117B may be used for offshore pipeline applications.

[001054] In one embodiment, the insulator supply device 5306 illustrated and described above with reference to FIG. 116A, 116B, 117A and/or 117B can also be used to apply other insulating materials described elsewhere in this application and/or other insulating materials, as would be understood by one skilled in the art, to heated open end portions 5248 , 5250 welded pipes 1022a, 1022b.

[001055] In one embodiment, the insulation feeder 5306 and its associated feedback system may be operatively coupled to one or more processors 5140. In one embodiment, one or more processors 5140 may be configured to control the operation of the insulator feeder 5306 and its corresponding feedback system.

[001056] In one embodiment, FIG. 118 illustrates a conduit 1024 in which an insulating material is applied to the heated exposed ends 5248, 5250 of welded pipes 1022a, 1022b such that the insulator 5246A adheres to the outer surface 5254 of the interior of the metal pipe 5244, thereby insulating the previously exposed ends of the pipes 1022a, 1022b.

[001057] In one embodiment of the invention, with reference to FIG. 119 and 120, the cooling system 6500 is configured to be placed inside the pipes 1022a, 1022b. In one embodiment, the cooling system 6500 includes a frame, a plurality of rollers 6530, a drive motor 6532, and a braking system. In one embodiment, front frame 6618, center frame 6634, and rear frame 6522 of cooler system 6500 may be collectively referred to as cooler system frame 6500.

[001058] For example, the carcass is configured to be placed inside the welded pipes 1022a, 1022b, a plurality of rollers 6530 are made to rotate the carcass, a drive motor 6532 drives the rollers 6530 to move the carcass inside the pipes 1022a, 1022b, and the braking system protects the carcass in desired location in pipes 1022a, 1022b from moving. The construction, configuration, and operation of the plurality of rollers, drive motor, and brake system of the Cooler 6500 are similar to those of the plurality of rollers, drive motor, and brake system of the internal welding systems described in this application, and therefore will not be described in detail herein. For example, in one embodiment, the braking system of the cooler system 6500 may include one or more clamps that clamp circumferentially located locations on the inner surface 5130, 5132 of the welded pipes 1022a, 1022b. In another embodiment of the invention, the brake system of the cooler system 6500 may include a wheel stop that prevents the rollers 6530 from rotating.

[001059] In one embodiment, the cooling system 6500 includes a cooler attached to the frame and supplies cooling energy to the inner surface 5130a, 5132a of the metal pipes 1022a, 1022b to help cool the welded metal pipes 1022a, 1022b. In one embodiment, the cooler includes a heat exchanger 6502 that contains a coolant and has a tube contact surface 6572 that contacts the inner surface 5130a, 5132a of the tube 1022a, 1022b to facilitate cooling of the welded tubes 1022a, 1022b. In one embodiment, the cooling system 6500 includes a heat exchanger motor 6552 configured to move the heat exchanger 6502 radially outward such that the pipe contact surface 6572 can move outward to engage with the inner surface 5130a, 5132a of the welded pipes 1022a, 1022b after how the frame is placed in the desired location in the tubes 1022a, 1022b.

[001060] In one embodiment, the cooling system 6500 comprises one or more processors that are operatively coupled to the drive motor 6532, brake system, and cooler 6502. In one embodiment, the one or more processors are configured to control the cooler 6502 to reduce the temperature of the welds. pipes 1022a, 1022b to a predetermined level. For example, in one embodiment of the invention, the refrigeration system includes one or more temperature sensors 2017a that are operatively linked (wired or wirelessly) to one or more processors to determine the temperature of the pipes. In one embodiment of the invention, the cooling power may be maintained until a predetermined threshold temperature is detected.

[001061] In one embodiment, one or more processors are communicatively coupled to a brake system, drive motor 6532, or cooler 6502 via one or more wired or wireless connections. Wireless connections may include, for example, a Wi-Fi connection, a Bluetooth connection, an NFC connection, a cellular connection, or another wireless connection.

[001062] In one embodiment, one or more processors that receive pipe temperature information from temperature sensor 2017a are communicable 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 one or more processors includes cooling time curve information. In one embodiment of the invention, the cooling time curve information comprises the change in temperature of the pipe over time. In one embodiment of the invention, the remote computer system contains cooling data from other welding systems and calculates the expected time until the temperature of the welded pipes is below a threshold level. In one embodiment of the invention, the expected time data is sent to one or more processors.

[001063] In one embodiment, the refrigeration system 6500 may include a user interface, with expected temperature and/or pipe temperature information sent to the user interface by one or more processors. The user interface may be a computer, for example, having a display.

[001064] In one embodiment of the invention, the expected time for cooling a pipe (at least a portion of the involved pipe) to a certain threshold temperature is calculated, at least in part, based on the size (e.g., circumference, thickness, thermal mass, or any combination thereof) of the welded pipes. In another embodiment of the invention, the cooling energy output may be based on the volume of water or gas directed to the surface of the pipe, the initial temperature of the pipe or gas, and so on. As another example, the cooling capacity for a closed fluid heat exchanger may be known in advance or calculated based on its operating parameters (liquid flow rate, fluid temperature, heat transfer efficiency, etc.).

[001065] In another embodiment of the invention, the cooling system cooling energy output and/or expected cooling time is based on information received from a remote cloud on a computer system that contains a large central database received from multiple remotely controlled chiller systems. In one embodiment of the invention, the cooling energy output is predetermined. In one embodiment, one or more processors are communicatively coupled to a remote computer system and configured to transmit coolant consumption data (e.g., the amount of water used to cool a pipe of known size required to reach a threshold temperature).

[001066] In one embodiment of the invention, the cooling system 6500 may be completely autonomous. In particular, the 6500 cooler system does not need to contain a drive rod or tether, and all communications with the 6500 cooler system are completely wireless. In one embodiment, the cooling system 6500 may include a transmitter configured to transmit all communications signals completely wirelessly from the cooling system 6500 to a remote uLog processing system and a receiver configured to receive all communications signals completely wirelessly from the remote uLog processing system. . In one embodiment of the invention, one or more processors and/or all electronic modules of the 6500 chiller system are configured to communicate in a completely wireless manner with a remote uLog processing system. In one embodiment of the invention, all sensors, all motors, all valves, and/or other components/elements of the 6500 chiller system are configured to communicate completely wirelessly with the uLog remote processing system.

[001067] In one embodiment, any information from the chiller system 6500 can be transmitted wirelessly by systems outside the conduit, such as via Wi-Fi, Bluetooth, NFC, radio frequency, or cellular communications. In some embodiments of the invention, when necessary, information is communicated through repeaters or expanders when the transmission signal must travel long distances or through tortuous areas.

[001068] In one embodiment of the invention, one or more processors and one or more sensors of the cooler system 6500 are configured to monitor the charge levels of the built-in cooling power supply, the built-in power supply to assist mobility, and other built-in power supplies. For example, the output voltage of these power supplies can be monitored (continuously or at regular intervals). In one embodiment, the cooler system transmitter 6500 transmits monitored battery life/battery level information completely wirelessly to a remote uLog processing system for further processing. For example, the monitored charge level information of the onboard power supplies may be used to determine the estimated remaining run time of the 6500 cooler system. 6500. In one embodiment of the invention, the remote uLog processing system may be configured to determine the estimated remaining run time of the 6500 cooler system based on wirelessly transmitted battery life/level information. In one embodiment, the remote uLog processing system may be configured to transmit the estimated remaining runtime of the 6500 cooler system to one or more processors of the 6500 cooler system. In one embodiment, the remote uLog processing system may also be configured to transmit (fully wireless way to the 6500 chiller system) further commands to operate the 6500 chiller system based on the estimated remaining runtime of the 6500 chiller system.

[001069] In one embodiment of the invention, one or more processors and one or more sensors of the coolant system 6500 are configured to monitor the levels of coolant stock/reservoir in the system. For example, the pressure and/or volume of the refrigerant storage tanks can be monitored (continuously or at intervals). In one embodiment, the 6500 chiller system transmitter transmits completely wirelessly the tracked coolant consumption data to a remote uLog processing system for further processing.

[001070] For example, tracked coolant consumption data can be used to determine the estimated remaining run time of the cooler 6500 system before refilling/replenishing coolant. In one embodiment, one or the processors of the 6500 chiller system may be configured to determine the estimated remaining run time of the 6500 chiller system (eg, before refrigerant replenishment) locally within the 6500 chiller system. In one embodiment of the invention, a remote uLog processing system may be performed with the ability to determine the estimated remaining time of the cooler 6500 system (for example, until the next replenishment of the refrigerant) based on the data on the consumption of the refrigerant transmitted wirelessly. In one embodiment, the remote uLog processing system may be configured to communicate the estimated remaining runtime of the 6500 chiller system (eg, before refrigerant replenishment) to one or more processors of the 6500 chiller system. In one embodiment, the remote uLog processing system may also be configured to transmit (fully wirelessly to the 6500 chiller system) further commands to operate the 6500 chiller system based on the estimated remaining runtime of the 6500 chiller system (eg, before refrigerant replenishment).

[001071] In one embodiment of the invention, the uLog remote processing system receives battery data from a number of cooler systems located in different locations (for example, in different locations around the country or around the world), and creates a database based on them. This database is used by the uLog processing system to determine, based on a large set of data, the estimated battery life based on various operating parameters of the cooler system. This can be used by the uLog processing system and/or one or more processors of the 6500 cooler system to predict battery life for various components based on the current operating conditions of those components. This information may be used by one or more processors to reduce or regulate the power consumption of one or more components by changing one or more operating parameters. For example, the cooling rate, voltage, and/or current may be adjusted (eg, lowered) to extend battery life if one or more processors determine that such operating conditions can be changed without affecting the underlying operation being performed.

[001072] In one embodiment, battery life, output voltage, coolant levels, and any operating parameters are sent wirelessly to a user interface, such as a computer monitor having a computer display, so that they can be controlled by the user.

[001073] In one embodiment, such as the 6500 cooling system, all other cooler systems (e.g., 2010, 2110, 2210, 2310) described herein are configured to wirelessly communicate with a remote uLog processing system.

[001074] In one embodiment of the invention, with reference to FIG. 120, the cooling system 6500 is configured to apply cooling energy to the inner surface 5130a, 5132a of the metal pipes 1022a, 1022b to facilitate cooling of the metal pipes 1022a, 1022b after application of the insulating material 5312. In one embodiment of the invention, the cooling system 6500 includes a heat exchanger or cooler 6502, configured to carry a moving fluid through it. That is, the cooling power is supplied by the fluid contained within the heat exchanger 6502. In one embodiment, the fluid may be a gas or a liquid.

[001075] For example, in one embodiment, as illustrated in FIG. 119-122, the heat exchanger 6502 may include fluid passages 2693 that carry a movable fluid therethrough, and cooling power is applied by the movable fluid in the fluid passages of the medium 6593 of the heat exchanger 6502. In one embodiment of the invention, as illustrated in Fig. 124, 125, the heat exchanger 6502 may have air passages 6576 that carry moving air through it, and the cooling power is supplied by the moving air contained within the air passages 6576 of the heat exchanger 6502.

[001076] In one embodiment, the contact surface 6572 of the heat exchanger 6502 is configured to contact the inner surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b.

[001077] In one embodiment of the invention, the contact surface 6572 of the heat exchanger 6502 may be a matched heat transfer surface. For example, in one embodiment of the invention, the contact surface 6572 of the heat exchanger 6502 is designed and formed to exactly match the internal surfaces of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. In one embodiment of the invention, the contact surface 6572 of the heat exchanger 6502 is designed and configured to conduct heat.

[001078] In one embodiment of the invention, the cooling power is applied by the fluid released into the inside of the pipes 1022a, 1022b such that the fluid directly contacts the inside surface 5130a, 5132a of the pipes 1022a, 1022b. In one embodiment of the invention, the fluid contains a liquid. In one embodiment, the fluid contains a gas. For example, in one embodiment, fluid nozzles 6562 (as illustrated in FIG. 123) are configured to apply (or spray) a cooling fluid (directly) to the inside surface 5130a, 5132a of welded pipes 1022a, 1022b to remove heat from welded pipes 1022a , 1022b. In one embodiment, blower 6505 (as illustrated in FIG. 133) is configured to apply (or purge) refrigerant gas (directly) to the inside surface 5130a, 5132a of welded pipes 1022a, 1022b to remove heat from welded pipes 1022a, 1022b.

[001079] In one embodiment, the contact surface 6572 of the heat exchanger 6502 is configured to contact the inner surface 5130a, 5163a of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. For example, as illustrated in FIG. 119-121, 124, 130 and 132, the contact surface(s) 6572 of each of these various types of heat exchangers 6502 is configured to contact the inner surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b.

[001080] With reference to FIG. 119-122, the heat exchanger 6502 of the coolant system 6500 may include a plurality of heat exchanger elements or fins 6580 located at peripherally spaced apart locations on the central frame 6634. In one embodiment of the invention, each heat exchange element 6580 may have one or more lines passing through it for coolant 6593. In one embodiment, each heat exchange element or fin 6580 is supported on a central frame 6634 and is operatively associated with a drive mechanism 6582. In one embodiment, the drive mechanism 6582 is configured to move each heat exchange element or fin 6580 between its retracted position (as illustrated in Fig. 120 and 121) and its retracted position (as illustrated in Fig. 122). In one embodiment of the invention, as illustrated in FIG. 122, there is a radial gap G between the contact surfaces 6572 of the heat exchange elements 6580 and the inner surfaces 5130a, 5132a of the pipes 1022a, 1022b when the heat exchange elements 6580 are in their retracted positions.

[001081] In one embodiment, the drive mechanism 6582 may include a piston 6586, a cylinder 6584, a plurality of first elements 6588, and a plurality of second elements 6590. In one embodiment, the number of first and second elements may depend on the number of heat exchange elements 6580 used.

[001082] In one embodiment, there may be two drive mechanisms, with one drive mechanism located (axially along the tube axis) on one side of the heat exchange element 6580, and the other drive mechanism located (axially along the tube axis) on the other side of the heat exchange element 6580. In one embodiment of the invention, both actuators may operate simultaneously to move the heat exchange elements 6580 between their extended and retracted positions. In one embodiment, there may be only one drive mechanism configured to move each heat exchange element or fin 6580 between its extended position (as illustrated in FIGS. 120 and 121) and its retracted position (as illustrated in FIG. 122).

[001083] In one embodiment of the invention, each second element 6590 is designed and configured to connect with a heat exchange element 6580 at one end and with a first heat exchange element 6588 at the other end. In one embodiment of the invention, each first element 6588 is designed and configured to be connected to a second element 6590 at one end and to a portion of the piston 6586 (or element moved by the piston 6586) at the other end.

[001084] In one embodiment of the invention, the second element 6590 is designed and configured to be placed in the radially extending hole 6592 in the (fixed) frame element 6594 so that the radially extending hole 6592 facilitates radial movement (for example, radial upward movement and down) of the second element 6590 located therein.

[001085] In one embodiment, the piston 6586 is axially movable in the cylinder 6584. In one embodiment, the first elements 6588 are moved by an axially located reciprocating piston 6586, such as driven by pressure (hydraulic or pneumatic ) fluid inside cylinder 6584.

[001086] The heat exchange elements 6580 move from their retracted positions (as illustrated in FIG. 122), where the contact surfaces 6572 of the heat exchange elements 6580 are not in contact with the interior surfaces 5130a, 5132a of the tubes 1022a, 1022b, to their extended positions (as illustrated in FIG. 201 and 121), where the contact surfaces 6572 of the heat exchange elements 6580 are configured to contact the internal surfaces 5130a, 5132a of the pipes 1022a, 1022b by actuating the cylinder 6584 so that the piston 6586 moves in the axial direction in the cylinder 6584. Compressed air entering into the opening 6503 causes the piston 6586 to move the heat exchange elements 6580 to their extended positions.

[001087] In one embodiment of the invention, the axial movement of the piston 6586 is translated into radial movements of the second elements 6590 through the first elements 6588. Thus, the radial contact forces are generated by the liquid pressure of compressed air acting on the piston 6586. The piston 6586 drives the first elements 6588, which convert the axial movement of the piston 6586 into radial movements of the second elements 6590. Because each heat exchange element 6580 is operatively associated with the second elements 6590, the radial movements of the second elements 6590 result in radial movements of the heat exchange element 6580 between its extended and retracted positions.

[001088] In one embodiment of the invention, the size of the cylinder, the applied fluid pressure, and the dimensions of the various components of the drive mechanism 6582 can be changed to control the extension and retraction of the heat exchange elements 6580.

[001089] In one embodiment of the invention, as illustrated in FIG. 123, the cooling system 6500 may include a fluid nozzle 6562 configured to apply coolant to the interior surface 5130a, 5130b of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. In one embodiment, the fluid nozzle 6562 is a water nozzle that inflates/sprays water onto the inner surface 5130a, 5132a of pipe 1022a, 1022b to facilitate cooling of welded pipes 1022a, 1022b.

[001090] In one embodiment, heat exchanger 6502 may include a plurality of fluid nozzles 6562 that are circumferentially and axially (along the axis of the pipe) spaced apart. In one embodiment, each fluid nozzle 6562 is configured to receive coolant from coolant source 6564 through coolant supply line 6566 and through one or more valves. In one embodiment of the invention, the cooling agent is a gas or liquid. In one embodiment, the resulting coolant is sprayed by fluid nozzles 6562 onto the interior surface 5130a, 5132a of welded pipes 1022a, 1022b to remove heat from welded pipes 1022a, 1022b.

[001091] In Fig. 124 and 125 illustrate a heat exchange element 6574 that is retractable, for example by means of an actuating mechanism 6582, illustrated and described with reference to FIG. 120-122. In one embodiment of the invention, the contact surface 6572 of the heat exchange element or rib 6574, when the heat exchange element 6574 is in the extended position, is configured to contact the inner surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. In one embodiment, the heat exchanger may comprise a plurality of such heat exchange elements or fins 6574 that are spaced circumferentially apart and that can be extended and retracted by an actuating mechanism (eg, pneumatic or otherwise). In one embodiment, the heat exchange element or fin 6574 may include a plurality of fluid (air) channels 6576 that are configured to allow fluid to pass through. In one embodiment, the channels 6576 may extend radially and be circumferentially spaced from each other.

[001092] With reference to FIG. 126-128, in one embodiment, the cooling 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 through one or more conduits 1022a, 1022b to an open end. 6606 pipes 1022a. In one embodiment of the invention, cable design 6604 is used to facilitate movement of the internal cooler system 6500 in conduits 1022a, 1022b.

[001093] In one embodiment, one or more cable/winch systems 6608 and 6604 may be implemented, in which one or more winches 6608 may be provided as part of the internal cooler system 6500 and/or located at one or more anchor points (e.g. , 6610) that are external to the pipes 1022a, 1022b. In one embodiment of the invention, a winch structure may be provided in the internal system of the cooler 6500.

[001094] For example, in one embodiment, a winch structure 6608 is provided at a support location 6610 outside the conduits 1022a, 1022b and is connected to the cable structure 6604. That is, with reference 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 the cooler 6500 system front frame member 6616. in pipes 1022a, 1022b.

[001095] In one embodiment of the invention, another cable design may be connected to back frame member 6620 6622 (as illustrated in FIG. 119) of cooler system 6500 to facilitate reverse movement of internal cooler system 6500 in conduits 1022a, 1022b. This cable structure may be controlled by another winch design (eg, provided at a support site at the back or outside of conduits 1022a, 1022b) to facilitate reverse movement of internal cooler system 6500 in conduit sections 1022a, 1022b.

[001096] Thus, the cable structure 6604 extends between the winch 6608 and the connection point (either at the internal cooler system 6500 or at the connection point external to the pipes 1022a, 1022b) to facilitate placement of the internal cooler system 6500 inside and/or out internal cooler system 6500 of pipes 1022a, 1022b during procedures.

[001097] In one embodiment of the invention, as illustrated in FIG. 129, the cooling system 6500 may include a plurality of rollers 6530 configured to interact with the inner surface 5130, 5132 of one or more pipes 1022a, 1022b and a drive motor 6532 configured to drive the rollers 6530 to move the frame assembly 6503 (including the front frame 6618, center frame 6634 and drive frame 6622) of the 6500 cooler system.

[001098] In one embodiment, the cooler electronics module 6528 is configured to control the operation of the drive system 6602 (for example, by controlling one or more motors 6532 (which bring the rollers 6530 into contact with the interior portions of the pipe walls) to assist in advancing the internal cooler system 2010 inside the pipe 1022a towards the weld site In one embodiment of the invention, 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 electronic modules (e.g., operatively associated with various welding systems operably connected to platforms, clamps or other pipe alignment systems and/or located at a remote location from these systems) as described in this application.

[001099] In the illustrated embodiment, each roller 6530 of the cooler system 6500 is operatively coupled to its respective drive motor 6532. That is, four drive motors 6532 are connected to four rollers 6330 as illustrated. connected to two drive motors 6532, and the other two rollers 6530 can be operatively connected to two rollers 6530, which are directly connected to the drive motors 6532.

[001100] In one embodiment of the invention, as illustrated in FIG. 130 and 131, the cooling system 6500 may include a power supply 6526 to provide power to the cooler electronics module 6528 of the cooler system 6500, drive system 6602, electronic sensors, valve structure (e.g., to electronically control one or more valves 6522 and thus controlling the flow of refrigerant from the refrigerant supply source 6524 to the heat exchanger 6502). In one embodiment, the power supply 6526 is contained in a frame assembly of the cooler system 6500. In one embodiment, the power supply 6526 comprises a plurality of battery cells or battery compartments that are contained in the back frame 6622 of the cooler system 6500. In one embodiment, seven batteries. In one embodiment, the number of batteries may vary. In one embodiment, the number of batteries may depend on the type of heat exchanger used and/or other energy requirements of the cooler system 6500. In the illustrated embodiment, the power supply 6526 is illustrated in a cooler system having a thermoelectric heat exchanger. However, it is contemplated that the 6526 power supply can be used with chiller systems having any type of heat exchanger as described herein.

[001101] In one embodiment, the one or more battery cells carried by the cooler system frame 6500 are configured to power the drive motor 6532 and brake system belonging to the cooler system 6500. In one embodiment, the one or more battery cells carried by the system frame cooler 6500 are configured to power the cooler 6502 of the cooler system 6500.

[001102] In one embodiment of the invention, as illustrated in FIG. 130 and 132, the heat exchanger 6502 of the coolant system 6500 may be a thermoelectric heat exchanger 6502. For example, the thermoelectric heat exchanger may be a Peltier device.

[001103] In one embodiment, the thermoelectric heat exchanger 6502 may have a plurality of frame members 6538 located at circumferentially spaced locations on the shaft member 6542 of the cooler system 6500. In the illustrated embodiment, six frame members 6538 are illustrated. In one embodiment, the number of members frame 6538 may vary. In one embodiment, each frame member 6538 may have a plurality of thermoelectric heat transfer elements 6544 located thereon. In the illustrated embodiment, six thermoelectric heat transfer elements 6544 are located on each frame member 6538. frame 6538 may vary.

[001104] In one embodiment of the invention, frame members 6538 may be supported on shaft member 6542 of cooler system 6500 via support members 6540 (eg, two). In one embodiment of the invention, the support elements 6540 can be extended and retracted by means of a drive mechanism. In one embodiment of the invention, the drive mechanism is configured to extend the support members 6540 such that the frame members 6538 and thermoelectric elements 6544 located thereon are in contact with the inner surface 5130a, 5132a of the welded pipes to remove heat from the welded pipes 1022a, 1022b. In one embodiment of the invention, the drive mechanism may be pneumatically controlled, or may be controlled in any other way that would be understood by a person skilled in the art.

[001105] In one embodiment of the invention, as illustrated in FIG. 133, the heat exchanger 6502 of the coolant system 6500 may be a blower 6505 configured to blow cooling gas onto the inner surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. In one embodiment, the blower blows air onto the inner surface 5130a, 5132a of the pipe 1022a, 1022b to facilitate cooling of the welded pipes 1022a, 1022b. In one embodiment, the blower 6505 may include a frame member 6550 having a plurality of holes 6552 thereon. In one embodiment, the frame member 6550 is designed and configured to receive air from an outlet of a compressed air source 6554 (e.g., at high pressure). In one embodiment of the invention, the frame member 6550 is designed and configured to receive air from the outlet of a motor-driven fan. In one embodiment, the openings 6552 formed on the frame member 6550 are configured to function as outlets for supplying received air to the inner surface 5130a, 5132a of the welded pipes to remove heat from the welded pipes 1022a, 1022b.

[001106] In one embodiment of the invention, as illustrated in FIG. 134, a camera 6556 mounted at location CL on the first section 6558 and controlled by the cooler electronics module 6528 can provide video images to the remote control so that the user can determine how close the internal cooling system 6500 is to the weld 1026.

[001107] In one embodiment of the invention, as illustrated in FIG. 135 and 136, the cooling system 6500 includes a blower 6650 configured to blow cooling gas onto the inner surface 5130a, 5132a of the welded pipes 1022a, 1022b to remove heat from the welded pipes 1022a, 1022b. In one embodiment, the blower 6505 includes a fan. In one embodiment of the invention, the design, location and operation of the blower 6505 may be similar to the functions of the fan 2122, as described in detail elsewhere in this application.

[001108] In one embodiment of the invention, with reference to FIG. 135 and 136, the heat exchange elements 6580 are moved from their retracted positions (as illustrated in FIG. 136), in which the contact surfaces 6572 of the heat exchange elements 6580 are not in contact with the interior surfaces 5130a, 5132a of the tubes 1022a, 1022b, to their extended positions, in which the contact surfaces The 6572 heat exchange elements 6580 are configured to contact the inner surfaces 5130a, 5132a of the tubes 1022a, 1022b by operating the drive mechanism 6664.

[001109] In one embodiment, the actuator 6664 may be a linear actuator. In one embodiment of the invention, the drive mechanism 6664 may include a motor 6652, a lead screw 6654, a screw nut 6656, a plurality of first elements 6664, and a plurality of second elements 6666. In one embodiment of the invention, the number of first and second elements may depend on the number of heat exchange element 6580 used. In one embodiment of the invention, each second element 6666 is designed and configured to connect to the heat exchange element 6580 at one end and to the first element 6664 at the other end. In one embodiment, each first element 6664 is designed and configured to connect to a second element 6666 at one end and to an element 6662 driven by motor 6652 at the other end.

[001110] In one embodiment, the motor 6652 is configured to (e.g., mechanically coupled to) rotate the lead screw 6654. In one embodiment, the motor 6652 is configured to rotate in either a clockwise or counterclockwise direction to cause the heat transfer elements 6580 to rise or fall, effectively perpendicular to the tube axis of the tubes 1022a, 1022b. In one embodiment, the motor 6652 is directly coupled to rotate the lead screw 6654. In another embodiment, the motor 6652 is indirectly coupled, such as through a series of gears or reduction gear, to turn the lead screw 6654.

[001111] In one embodiment of the invention, the lead screw 6654 includes a thread machined on its outer surface and extending along its length. In one embodiment, the screw nut 6656 is designed and configured to thread the lead screw 5514 and has additional threads machined into its inner surface.

[001112] In one embodiment of the invention, the screw drive nut 6656 is configured to interlock with a portion of the element 6662 in such a way that the rotation of the screw drive nut 6656 together with the lead screw 6654 is prevented. , so the screw drive nut 6656 is movable up and down the lead screw 6654. screw nuts 5516.

[001113] The operation of the drive mechanism 6664 is discussed in detail below. When the lead screw 6654 is rotated by the motor 6652, the screw drive nut 6656 is driven along the thread. In one embodiment of the invention, the direction of movement of the screw drive nut 6656 depends on the direction of rotation of the lead screw 6654 by the motor 6652. When the screw drive nut 6656 is locked in the hole of the element 6662, the element 6662 is configured to move the lead screw 6654 together with the screw drive nut 6656. That is element 6662 moves linearly (right to left or left to right) as motor 6652 rotates. In addition, when element 6662 is connected to first elements 6658, movement of element 6662 causes movement of first elements 6658. Since second elements 6660 are connected to first elements 6658, movement of first elements 6658 causes a radial (up or down) movement of the second elements 6660. That is, a linear movement of the element 6662 is translated into a radial (up or down) movement of the second elements 6660 through the first elements 6658.

[001114] When the heat exchange element 6580 is connected to the second elements 6660, the radial (up or down) movement of the second elements 6660 causes the radial (up or down) movement of the heat exchange element 6580. Thus, the motor 6652 is configured to move the contact surfaces 6572 of the heat exchange elements 6580 outwardly engaged with the inner surface 5130a, 5132a of metal pipes 1022a, 1022b.

[001115] In one embodiment of the invention, the time it takes for the chiller system to cool the pipes (eg, after the coating procedure and before the winding procedure) can range from 90 to 150 minutes.

[001116] Since the cooling system can be used to apply cooling energy to the inner surface of the metal pipes, inside the pipes, the cooling time of the metal pipes can be reduced (for example, compared to the allowable natural cooling of metal pipes or compared to applying a cooling agent over the insulating material) . This can, for example, facilitate the cooling of metal pipes after the insulating material has been applied to the welded pipe, which must be preheated prior to the application of the weld metal. As a result, the welded pipe can be put into service or otherwise further processed more quickly. In particular, after the welded pipe has been heated to apply the insulating material and the insulator has been applied, it should not be subjected to the high stresses that may occur during the deployment procedure. For example, in some embodiments of the invention, the welded pipe and its insulation (the insulation of which is applied only after the temperature of the welded pipe has been raised by heating to a temperature of at least 160° C.) is intended to be wound onto a spool during the winding operation. Such a winding operation is ideally performed only after the welded and insulated metal pipe has cooled below a threshold level (eg below 50°C). The use of an internal cooler can speed up the achievement of cooling of the metal pipe to a level below the threshold level. In another application of the internal cooler system, the pipes are then welded (also before applying the insulator).

[001117] The winding operation is one of a number of unwrapping procedures that can only be ideally performed after the temperature of the welded pipe has dropped below a threshold temperature (eg, through the operation of an internal cooler). Other deployment procedures may include an S-lay procedure and/or a J-lay procedure on a pipe-lay barge. The temperature of the welded pipe must be below the threshold temperature before the pipe is immersed in water (such as the sea or ocean).

[001118] In addition, in another application, it may be desirable to check the welding with an ultrasonic sensor in an ultrasonic inspection system. The ultrasonic testing station is configured to ideally operate below a threshold temperature (eg below 80°C) which can be reached more quickly (after the pipe is heated by the welding operation) using a cooler system. Thus, in one system, the coolant may be used prior to the ultrasonic inspection operation to be carried out after welding and before reheating the pipe to apply the insulation material.

[001119] In one embodiment of the invention, with reference to FIG. 136A, an ultrasonic testing station 6801 is provided that is configured to check the weld between the welded metal pipes 1022a, 1022b. In one embodiment, the cooling system 6500 is configured to facilitate cooling of the metal pipes 1022a, 1022b after the pipes 1022a, 1022b have been welded and before the weld is checked by the ultrasonic testing station 6801.

[001120] In one embodiment, a temperature sensor (eg, 2017a illustrated in FIGS. 104-109) can be used to detect the temperature of pipe 1022a, 1022b near weld 1026. For example, with reference to FIG. 107, the temperature sensor 2017a is configured to be placed on the internal cooler system and near the weld 1026. In one embodiment, the temperature sensor 2017a can be located near the heat exchange elements or fins of the internal cooler system to measure the temperature (inner diameter) of the inner surfaces 5130, 5132 of the pipe 1022a, 1022b. In another embodiment, the temperature sensor may be located at the ultrasonic testing station 6801. In one embodiment, the temperature sensor may be a contact or non-contact temperature sensor.

[001121] In one embodiment, the temperature sensor 2017a, which measures the temperature of pipes 1022a, 1022b, may be operatively associated with one or more processors. In one embodiment of the invention, one or more processors send operating instructions to the cooler 6502 based on the signals received from the temperature sensor 2017a. In one embodiment of the invention, one or more processors control the cooler until the sensor 2017a and the processor determine that the temperature of the pipes 1022a, 1022b is below the threshold temperature.

[001122] In one embodiment, one or more processors may be configured to determine that the temperature of pipe 1022a, 1022b near weld 1026 is below a predetermined temperature threshold. In one embodiment of the invention, the temperature sensor may be configured to detect that the temperature of the pipe 1022a, 1022b near the weld 1026 is below a predetermined temperature threshold.

[001123] In one embodiment, testing by ultrasonic testing station 6801 begins after temperature sensor 2017a detects that the temperature of pipe 1022a, 1022b near weld 1026 is below a predetermined temperature threshold.

[001124] In Fig. 136B illustrates a pipeline deployment method. On FIG. 136C and 136D are schematic views of an S-lay pipe deployment system and a J-lay pipe deployment system. On FIG. 136E illustrates S-lay and J-lay barges.

[001125] In one embodiment, pipes 1022a, 1022b (e.g., about 40 feet or 80 feet in length) are manufactured during pipe fabrication procedure 6902. In one embodiment, fabricated pipes are stored in pipe storage 6904 before the pipes are sent for further processing, for example, to the 6942 S-unwind barge (as illustrated in Fig. 136C), the onshore pipe welding depot, or the 6944 J-lay pipe barge (as illustrated in Fig. 136D). In one embodiment of the invention, the pipe storage may comprise a plurality of storage racks.

[001126] In one embodiment of the invention, during the procedure of the onshore pipe base 6914, the manufactured pipe sections are received by the onshore pipe base, these pipe sections are connected at the onshore pipe base to form long pipe sections, and these long pipe sections are then wound and loaded onto a ship, ship or barge. In one embodiment of the invention, an onshore pipe welding depot may include semi-automatic or automatic welding systems, field joint coating systems, non-destructive testing and testing systems, storage racks, roller systems and/or other pipe processing equipment for manufacturing, coiling and loading rigid pipelines before installation.

[001127] In one embodiment, the pipe strings are wound on large spools on barges (as illustrated in Fig. 136E) and are not unwound when the barge arrives at the job site. In one embodiment, strings of coiled tubing are not unwound on the vessel, ship, or barge during procedure 6916, and then the pipe sections are deployed during procedure 6918. In one embodiment, the "unwind" vessel, ship, or barge may be a barge with a J- pipe-lay barge or S-lay barge. On FIG. 136E, S-lay and J-lay barges are illustrated.

[001128] In one embodiment, the S-lay barge 6942 receives stored pipe sections from a pipe store. In one embodiment, during procedure 6906, the S-lay barge 6942 uses its onboard systems to produce long sections of pipe. In one embodiment, on the S-lay barge 6942, during procedure 6906, automatic welding systems, pipe laying systems, back-up clamps, purges, and/or other ancillary equipment are used to produce long sections of pipe. In one embodiment of the invention, the S-lay pipe deployment procedure is used for offshore pipelines. In one embodiment of the invention, the S-lay pipe deployment procedure is used in shallow and intermediate waters. In one embodiment of the invention, the S-lay pipe deployment procedure allows the pipe to leave the ship in a horizontal position. In one embodiment of the invention, the S-lay pipe deployment procedure provides high levels of productivity. As illustrated in FIG. 136C, a 6942 S-lay barge is designed and configured to deploy sections of S-lay pipe.

[001129] In one embodiment, the J-lay barge 6944 receives stored pipe sections from a pipe store. In one embodiment, during procedure 6908, J-lay barge 6944 uses its onboard systems to produce long sections of pipe. In one embodiment, on J-lay barge 6944, during procedure 6908, automatic welding systems, pipe laying systems, J-clamps, and/or other ancillary equipment are used to produce long sections of pipe. In one embodiment of the invention, the J-lay pipe deployment procedure is used for offshore pipelines. In one embodiment of the invention, the J-lay pipe deployment procedure is used in operations at greater depths. In one embodiment of the invention, the J-lay pipe deployment procedure allows the pipe to leave the laying system in a position very close to vertical. This means that the pipeline is installed with a very reduced load on the pipe. As illustrated in FIG. 136D, a 6944 J-lay barge is designed and configured to deploy sections of J-lay pipe.

[001130] Controlling, positioning, and communicating with the internal welding system, pipe string welding system, and/or pipe cooler systems, when located inside the pipe, can be performed in various ways, as described herein. In yet another embodiment of the invention, the position of the system inside the pipe can be detected by transmitting a low frequency electromagnetic signal from a loop antenna located in close proximity to the outer surface of the pipe. This signal is detected by a pair of orthogonal measuring loop antennas mounted on the system in the pipe, in close proximity to the inner surface of the pipe. The phases of the received signals relative to the transmitted signal and the amplitude ratio of the two received signals are used to estimate the relative positions of the transmitter and receivers. The control of the system inside the pipe (i.e. internal welder, pipe welder or cooling system, etc.) along with the transfer of information can also be performed using high-frequency radio communication via direct sequence wideband signals between one or more processors ( for example, inside a computer console) outside the pipe and one or more processors installed on the system in the pipe. Details of this deployment can be found in US Pat. No. 6,092,406, incorporated herein by reference in its entirety.

[001131] In one embodiment of the invention, the internal welding system 5004, 3001 may include a device for consuming weld metal. In one embodiment, the external welding system 7500 may include a weld metal consumer. In one embodiment of the invention, the weld metal consumer may be part of the wire feed assembly 5020 of the internal welding system 5004.

[001132] In one embodiment of the invention, the weld metal consuming device may be of the same structure and principle of operation as the device(s) illustrated and described with reference to FIG. 161A-165 of the present application. For example, in one embodiment, the design, configuration, and function of coil 5272 (as illustrated in FIG. 22A) used by internal welding system 5004 may be similar to that of coil 14480, as illustrated and described with reference to FIG. 161A. In one embodiment of the invention, the design, configuration, and operation of the motors of the wire feed assembly 5020 of the internal welding system 5004 may be similar to the functions of the motor 14490, as illustrated and described with reference to FIG. 162, 164A and 164B. In addition, in one embodiment of the invention, the wire feed assembly 5020 of the internal welding system 5004 may include a weight sensor that is configured to measure the exhaustion of consumable material. The design, configuration, and operation of the load cell of the internal welding system 5004 may be similar to the functions of the load cell 14484, as illustrated and described with reference to FIG. 161C. In one embodiment, the internal welding system 5004 may include other sensors (eg, illustrated in FIG. 161B) to determine the amount of consumable weld metal used by the internal welding system 5004 over a given period of time.

[001133] In one embodiment of the invention, one or more processors 5140 operatively associated with the internal welding system 5004 can be configured to determine the wire feed speed based on the speed of the motors of the wire feed assembly 5020, as described elsewhere in this application. In one embodiment of the invention, one or more processors 5140 operatively associated with the internal welding system 5004 can be configured to determine the amount of consumable weld metal used by the internal welding system 5004 during a given period of time, and generate consumption data based on this. weld metal. In one embodiment of the invention, the indoor welding system transmitter 5004 can wirelessly transmit weld metal consumption data to a remote uLog processing system for further processing. In one embodiment of the invention, the remote uLog processing system may also be configured to transmit (completely wirelessly to the internal welding system, external welding system and / or internal pipe welding system) additional instructions for operating the internal welding system, external welding system and / or an internal pipe welding system based on the processed data on the consumption of weld metal. For example, such instructions may include correcting the slip of the wire feeder motors by increasing the speed of the wire feeder motor of the internal welding system, the external welding system, and/or the internal pipe string welding system. In one embodiment of the invention, one or more processors 5140 of the internal welding system 5004 may use the procedures illustrated and described with reference to FIG. 163 and 165 to determine weld metal consumption data, processed weld metal consumption data, and so on.

[001134] In one embodiment, the design and operation of the weld metal consuming device are described above with respect to the internal welding system 5004. similar design and operation. That is, in one embodiment, the hub, electronics, software, and images sent by the weld metal consuming devices of the internal welding system and the external welding system are common to both devices. However, the shape and size of the weld metal consuming devices of the internal welding system 5004, 3001 and the external welding system 7500 may vary. In one embodiment, the weld metal consuming devices of the internal welding system 5004, 3001 and the external welding system 7500 may have different shape configurations and/or different geometries. In one embodiment of the invention, the weld metal consuming device may be configured to detect an unauthorized wire spool used in the internal welding system 5004, 3001 or external welding system 7500.

[001135] Field System Testing and Operations

[001136] In Fig. 137A illustrates a system 13700 for facilitating testing of a field system or its operations, in accordance with one or more embodiments of the invention. As illustrated in FIG. 137, system 13700 may 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 components of system 13700 can communicate with each other. The field system 13702 may include one or more field devices 13712, one or more control devices 13714, one or more field computer systems 13716, or other components. The remote computer system 13704 may comprise one or more processors 13730 configured to execute one or more subsystems, such as an object profile subsystem 13732, an operations manager subsystem 13734, an operation protocol subsystem 13736, an operation control subsystem 13738, an operation trigger subsystem 13740, a presentation subsystem 13742 or other components. As described below, in one or more embodiments of the invention, the operations of the respective components of the remote computer system 13704 may be performed by one or more processors of the remote computer system 13704. It should be noted that while one or more operations are described herein as being performed by components of the remote computer system 13704 , these operations may, in some embodiments, be performed by components of the 13702 field system (e.g., 13716 field computer system) or other components of the 13700 system.

[001137] In one embodiment, field system 13702 may be field system 5000. In one embodiment, when computer system 5138 is local to field system 5000, field computer system 13716 may be local computer system 5138, and the processors of the field computer system 13718 may be processors of the local computer system 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 processors of the remote computer system 13730 may be the processors of the remote computer system 5140.

[001138] In Fig. 137B illustrates communication links between a remote computer system 13730, a field computer system 13716 of a field system 13702, and other components of a field system 13702, in accordance with one or more embodiments of the invention. In one embodiment, the remote computer system 13704 (or its processors 13730) may communicate with one or more other components of the field system 13702 via the field computer system 13716 (and one or more wired or wireless links between the field computer system 13716 and the remote computer system). 13704). By way of example, the processors of the field computer system 13718 may receive test data, input parameters, operation monitoring data, or other data from one or more other systems of the field system 13702 (or their respective processors 13720), such as a welding system 3001 (e.g., an internal system 3001 Welding System), 5004 Welding System (for example, 5004 Internal Welding System), 6500 Cooling System (for example, 6500 Internal Cooling System), 7001 Purge and Check System, 7500 Welding System (for example, 7500 External Welding System), or other systems 13724 field system 13702 (for example, platforms or other pipe alignment systems, other control systems, etc.). The field computer system processors 13718 may transmit (via a transmitter) test data, input parameters, operation monitoring data, or other data to the remote computer system 13704 and receive a response containing profile data (e.g., pre-weld profile data, fly", post-weld status profile data, etc.), instructions for performing operations on the site, warnings (for example, indicating a defect when a defect exists, indicating the start or stop of an operation, etc.) or others data from the remote computer system 13704. In one case, if the response contains profile data, the processors of the field computer system 13718 can use the profile data to generate alerts (for example, indicating a defect when a defect exists, indicating the start or stop of an operation, etc. .d.), receiving instructions for performing an operation on an object, etc. In another use case, if the response contains instructions for performing an operation on an object, the processors of the field computer system 13718 may send instructions to the appropriate system of the field system 13702 to cause that system to perform the operation in accordance with the transmitted instructions.

[001139] In one embodiment, it may be useful to use one or more wireless links to provide one or more components of the remote computer system 13704, field computer system 13716, welding system 3001, welding system 5004, cooler system 6500, purge and test system 7001 or 7500 welding systems with the ability to communicate with each other to reduce the number of communication cables in various systems of the 13702 field system to reduce the possible cable entanglement that can delay operations or damage other components of these systems. For example, by reducing the number of communication cables in the 3001 Weld System, 5004 Weld System, 7001 Purge and Test System, or 7500 Weld System, some embodiments can reduce the potential for cable entanglement during rotation of a control device (e.g., reference laser, reference chamber, or other control device), welding torch or other component of these systems.

[001140] In Fig. 137C illustrates communication links between a remote computer system 13730 and components of a field system 13702 without a field computer system 13716, in accordance with one or more embodiments of the invention. In one embodiment, the remote computer system 13704 (or its processors 13730) may communicate with one or more other components of the field system 13702 via one or more wired or wireless links between various systems in the field system 13702 and the remote computer system 13704 (e.g., without the need for a separate 13716 field computer system). By way of example, the processors of the remote computer system 13730 may receive test data, inputs, operation monitoring data, or other data from one or more systems of the field system 13702 (or their respective electronic modules), such as a welding system 3001 (e.g., an internal system 3001 Welding System), 5004 Welding System (for example, 5004 Internal Welding System), 6500 Cooling System (for example, 6500 Internal Cooling System), 7001 Purge and Check System, 7500 Welding System (for example, 7500 External Welding System), or other systems 13724 field system 13702 (for example, internal cooler). In response, the respective systems of the 13702 field system receive one or more responses containing profile data (e.g., pre-weld profile data, on-the-fly profile data, post-weld profile data, etc.), instructions for performing on-site operations. , warnings (eg, indicating a defect in the event that a defect exists, indicating the start or termination of an operation, etc.), or other data from the remote computer system 13704. In one use case, for example, in the case where one of systems field system 13702 receives a response containing instructions to perform an operation on the object, this system can perform the operation in accordance with the transmitted instructions.

[001141] As another example, one or more 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 its processors 13718), remote computer system (or its 13730 processors) or other components of the 5004 welding system via one or more wired or wireless links. In one scenario, for example, one or more electronic modules 5014, 5046, 5064, 5118 may receive data from one or more sensors or controls of the welding system 5004, process sensor data or test data, transmit sensor data or test data to field computer processors. systems 13718 or processors of a remote computer system 13730, generate signals to control one or more motors or other mechanisms of the welding system 5004 to perform one or more operations, etc.

[001142] As another example, one or more 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 its processors 13718), a remote computer system (or its 13730 processors) or other components of the 3001 welding system via one or more wired or wireless links. In one scenario, for example, one or more electronic modules 3126, 13722 may receive data from one or more sensors or controls of the welding system 5004, process sensor data or test data, transmit sensor data or test data to the processors of the field computer system 13718 or to processors of the remote computer system 13730, generate signals to control one or more motors or other mechanisms of the welding system 3001 to perform one or more operations, etc.

[001143] As another example, one or more electronic 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 processors 13718), a remote computer system (or its 13730 processors) or other components of the 6500 chiller system through one or more wired or wireless links. In one scenario, for example, one or more electronic modules 6528, 13722 may receive data from one or more sensors or monitors of the chiller system 6500, process sensor data or test data, transmit sensor data or test data to processors in the field computer system 13718 or to processors of the remote computer system 13730, generate signals to control one or more motors or other mechanisms of the cooler system 6500 to perform one or more operations, etc.

[001144] As another example, one or more electronic modules 7032, 7036, 7040, 7064 or other components of the purge and test system 7001 may include one or more processors configured to communicate with the field computer system 13716 (or its processors 13718), remote computer system (or its 13730 processors) or other components of the 7001 purge and test system via one or more wired or wireless links. In one scenario, for example, one or more electronic modules 7032, 7036, 7040, 7064 may receive data from one or more sensors or monitors of the purge and test system 7001, process sensor data or test data, transmit sensor data or test data to processors. field computer system 13718 or remote computer system processors 13730, generate signals to control one or more motors or other mechanisms of the purge and test system to perform one or more operations, etc.

[001145] As another example, one or more 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 its processors 13718), a remote computer system (or its 13730 processors) or other components of the 3001 welding system via one or more wired or wireless links. In one scenario, for example, one or more electronic modules 3126, 13722 may receive data from one or more sensors or controls of the welding system 5004, process sensor data or test data, transmit sensor data or test data to the processors of the field computer system 13718 or to processors of the remote computer system 13730, generate signals to control one or more motors or other mechanisms of the welding system 3001 to perform one or more operations, etc.

[001146] In one embodiment, the field system (e.g., 5000 field system, 13702 field system, etc.) can operate with one or more remote computer systems (e.g., a 5138 computer system that is located remotely from the 5000 field system, remote computer 13704, etc.) to facilitate field testing or physical operations based on them. The field system may include one or more components that may be communicatively coupled to each other and/or to one or more components of remote computer systems. In one embodiment of the invention, one or more field devices (eg, 13712 field devices) of a field system may be directed to perform one or more operations based on the results of checking one or more objects. By way of example, a control device (eg, control device 13714) of a field system may inspect an object. One or more processors of the field system (eg, processors 13718 of the field computer system 13716) may receive verification data associated with verification of an object from the control device. Based on the verification data, the processors may direct the field device of the field system to perform an operation that physically affects the object. The monitor may include a monitor laser, a monitor camera, an x-ray monitor, a gamma ray monitor, an ultrasonic monitor, a magnetic particle monitor, an eddy current monitor, a temperature monitor, or other monitor. The inspection data may include laser inspection data, inspection chamber 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.

[001147] In one embodiment of the invention, field system processors (e.g., processors 13718 of field computer system 13716) may process verification data to generate data associated with performing an operation that physically affects an object and cause the field device to perform an operation based on the data, associated with the operation. In one embodiment of the invention, the field system processors may transmit (via a transmitter) test data to a remote computer system. In response to the transmission of the verification data, the processors may receive from the remote computer system data associated with the execution of an operation that physically affects the object. As an example, transaction-related data may be generated at a remote computer system based on the verification data. Upon receipt of the data associated with the operation, the processors may direct the field device to perform the operation based on the data associated with the operation. Processors may cause a field device to perform an 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, monitor, and provide on-the-fly updates to perform the operation (for example, by monitoring the object while the operation is in progress), or other methods.

[001148] In one embodiment of the invention, the verification 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 operations, or other information. As an example, in the case where one or more defects are found based on the inspection data, the operation-related data generated may relate to performing an operation to eliminate the detected defects. As another example, in the case where it is determined that the object is ready for the next step of operations, the generated data associated with the operation may be related to the execution of the operation associated with the next step of operations.

[001149] A field device (eg, field device 13712) may include a welding device, a coating device, an alignment device, a heating device, a cooling device, a protective device, a control device, or other device. Operation related data may include welding instructions, coating instructions, change instructions, alignment instructions, or other instructions or data. Instructions related to welding may include instructions related to welding in the area of the contact surface between the first object and the second object (for example, the area of the contact surface between pipes or other objects), instructions related to the wire feed speed, wire consumption, width oscillations, oscillation mode, oscillation amplitude, welding time, gas consumption, welding arc power levels, welding current, welding voltage, welding resistance, welding torch travel speed, position of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip relative to it the plane of rotation, the distance from the welding tip of the welding torch to the inner surfaces of the welded pipes, etc. for welding, or other welding-related instructions. Coating instructions may include instructions for coating an object (eg, coating a pipe or other object), instructions related to preheat temperature, coating thickness, or other instructions related to coating. Instructions associated with changes may include instructions associated with expanding at least a portion of an object, instructions associated with shrinking at least a portion of an object, instructions associated with changing the size of at least a portion of an object (e.g., changing radial dimensions, proportional resizing, etc.), reshaping at least part of the object, or other instructions associated with the changes. 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.

[001150] In one embodiment of the invention, based on the verification data associated with the verification of the area of the contact surface between the first object and the second object, one or more processors of the field system (for example, processors 13718 of the field computer system 13716) can receive data associated with the execution of the operation welding in the area of the contact surface. As an example, the processors may transmit (via a transmitter) test data to a remote computer system (eg, remote computer system 13704), and in response, the processors may receive instructions related to tack welding from the remote computer system. The processors may direct the field device to perform welding in the area of the contact surface based on instructions associated with welding.

[001151] In one use case, in the case where it is determined based on the inspection data that the first layer of the weld pass is defective (but can still be changed due to the second weld pass), the welding instructions may include instructions for making the second weld pass so that the second weld pass eliminates the layer defect of the first weld pass. As an example, in the case where it is determined that the layer of the first weld pass is not thick enough, the welding instructions may include instructions to allocate more welding time or use a welding wire (in the case where it has been determined that the layer of the first welding pass is thick enough) for the second welding pass. Thus, the resulting layer of the second welding pass can be thicker (than it would otherwise be) to compensate for the insufficiently thick layer of the first welding pass. As another example, in the case where it is determined that the layer of the first weld pass is too thick, the welding instructions may include instructions to allocate less welding time or use a welding wire (if it has been determined that the layer of the first weld pass was thick enough) for the second weld pass. Thus, the resulting layer of the second welding pass may be thinner (than it would otherwise be) to compensate for the extra layer thickness of the first welding pass.

[001152] In another use case, in the case where a defect is detected in the layer of the first welding pass, the instructions associated with welding need not include instructions for repairing or eliminating the detected defect. As an example, a repair may not be recommended in the event of a defect based on a defect size that does not meet a predetermined defect size threshold (eg, the size of the defect to be repaired is too small to recommend repair). The predetermined defect size threshold may, for example, correspond to a defect size that will not significantly adversely affect the quality of the weld. Thus, in this use case, if the defect size in the layer of the first welding pass is smaller than the predetermined defect size threshold, the welding-related instructions may simply include instructions for the layer of the next welding pass, as if the defect had not been detected. .

[001153] In one embodiment of the invention, based on the verification data associated with the verification of the object, one or more processors of the field system (eg, processors 13718 of the field computer system 13716) can receive data associated with the coverage of the object. As an example, the processors may transmit (via a transmitter) test data to a remote computer system (eg, the remote computer system 13704) and in response, the processors may receive instructions from the remote computer system related to object coverage. The processors may direct the field device to apply one or more layers of a coating to an object based on instructions associated with the coating. In one instance, when it is determined from the test data that the weld on the object is complete and that the completed weld is within specification, the remote computer system may send instructions to the processors in the field system to begin coating the object.

[001154] In one embodiment of the invention, based on the verification data associated with the verification of an object, one or more processors of the field system (for example, processors 13718 of the field computer system 13716) can receive data associated with a change in the size, shape, or other aspect of the object. By way of example, the processors may transmit (via a transmitter) test data to a remote computer system (eg, the remote computer system 13704), and in response, the processors may receive instructions from the remote computer system to change an object. Processors may cause the field device to enlarge at least part of the object, shrink at least part of the object, radially resize at least part of the object, reshape at least part of the object (eg, machine a new bevel on the end of a pipe or perform shape changes), or performing other changes to the object based on the instructions associated with the changes.

[001155] In one embodiment, based on the validation data associated with the validation of the object, one or more processors of the field system (eg, processors 13718 of the field computer system 13716) can obtain data associated with the alignment of the object. As an example, the processors may transmit (via a transmitter) test data to a remote computer system (eg, remote computer system 13704) and in response, the processors may receive instructions from the remote computer system related to object alignment. The processors may cause the field device to perform alignment of at least a portion of an object with at least a portion of another object based on alignment-related instructions. In one use case, such as when the objects are pipes and analysis of the remote computer system check data indicates an alignment error, the alignment related instructions received from the remote computer system may include instructions to change the position of at least one of the pipes for which an alignment error has been detected (for example, an angular error resulting in a gap between the pipes, a positioning error resulting in difficulty with a step transition, etc.).

[001156] In one embodiment of the invention, one or more operations can be performed on one or more objects based on the results of checks on several objects. Thus, for example, validation data resulting from the validation of multiple objects can be used to analyze the objects as a whole. In some scenarios, such an analysis may otherwise be incomplete if reduced to looking at the validation data of only one object. By way of example, while each of the individual pipes of a conduit may be within specification, the conduit or section thereof (comprising a plurality of individual pipes) as a whole may be outside of specification. As another example, while individual pipes of a pipeline may be ready for the next stage of operations, the pipeline or pipeline section as a whole may not be ready for the next stage of operations. Using the inspection data obtained from the inspection of each of the pipeline pipes or pipeline section, a more complete analysis of the pipe or pipeline section as a whole can be performed.

[001157] In one embodiment, one or more field system processors (e.g., processors 13718 of the 13716 field computer system) may receive (via a receiver) first test data associated with a test of a first object and second test data associated with a test of a second object. . Based on the first test data and the second test data, the processors may cause the field device of the field system to perform an operation that physically affects one or more objects. Both the first inspection data and the second inspection data may include at least one of laser inspection data, camera inspection data, radiographic inspection data, gamma ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, inspection data. temperature or other test data. The test of the first object and the test of the second object may be performed by the same control device or by different control devices.

[001158] In one embodiment, field system processors (e.g., processors 13718 of field computer system 13716) may process first test data and second test data to generate data associated with performing an operation that physically affects an object and cause the field device to perform transactions based on transaction-related data. In one embodiment, the processors in the field system may transmit the first test data and the second test data to a remote computer system (eg, remote computer system 13704). In response to the transmission of the first test data and the second test data, the processors may receive from the remote computer system data associated with performing an operation that physically affects the object. As an example, transaction-related data may be generated at a remote computer system based on the first check data and the second check data. Upon receipt of the data associated with the operation, the processors of the field system may direct the field device to perform the operation based on the data associated with the operation.

[001159] In one embodiment of the invention, the data associated with the operation (on which the execution of the operation on the object is based), as an additional or alternative option, can be based on one or more input parameters of one or more operations performed on one or more objects (for example, an object, another object, etc.). By way of example, a field device of a field system may perform operations prior to checking an object. Input parameters of previously performed operations, validation data associated with validation of an object, or other data may be transmitted to a remote computer system. Upon receiving the transmitted data, the remote computer system may generate transaction-related data based on input parameters, validation data, or other data. In the case where, for example, a defect is detected based on inspection data, the inputs can be analyzed in relation to the detected defect to determine the cause of the defect (e.g., the actual outputs do not match the theoretical outputs of the inputs), and the operation-related data can be generated in such a way that the data associated with the operation can be used to perform an operation that is intended to repair or eliminate the detected defect or the cause of the defect.

[001160] In one use case, when it is determined that the layer of the first weld pass resulting from the welding operation is not thick enough (based on the test data associated with the test of the layer of the first weld pass), the input parameters for the weld operation may be taken into account to determine the cause of the insufficient layer thickness of the first welding pass. For example, if insufficient thickness is determined to be caused by insufficient welding time or filler wire, welding-related instructions for the second welding pass can be generated containing input parameters calibrated to compensate for the insufficient thickness of the first pass. weld pass or the established reason for such insufficiency (for example, more welding time, more wire used, etc.).

[001161] Processing data received from the field system

[001162] In one embodiment, a computer system (e.g., 5138 computer system, 13704 remote computer system, 13716 field computer system, etc.) can work with one or more field systems (e.g., 5000 field system, 13702 field system ) to facilitate the conduct of field tests or physical operations based on them. The computer system may include one or more processors or other components that may be in communication with each other and/or with 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 of the invention, the processors of the computer system may receive verification data associated with verification of an object from the field system. The processors may process the verification data to generate data associated with the execution of an operation that physically affects the object. The processors may send operation-related data to the field system to direct the field system to perform an operation that will physically affect the object. As an example, a field system may perform an operation based on data associated with the operation. As described herein, data associated with an operation may include instructions associated with welding, instructions associated with coating, instructions associated with changes, instructions associated with alignment, or other instructions or data.

[001163] In one embodiment, the processors of the computer system may receive (via a receiver) verification data associated with verification of multiple objects from one or more field systems and generate, based on the verification data, data associated with performing an operation that physically affects an object of at least one of the field systems. The processors may send operation-related data to the field system to direct the field system to perform an operation that physically affects the object. The inspection data associated with inspections of each object may include at least one of laser inspection data, camera inspection data, X-ray inspection data, gamma radiation inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data, temperature control data or other test data. Multiple object checks can be performed by the same control device or by different control devices.

[001164] In one embodiment of the invention, the data associated with the operation (on which the operation is based on the object), as an additional or alternative option, can be based on one or more input parameters of one or more operations performed on the object. By way of example, a field device (eg, 13712 field device) of a field system may perform operations prior to checking an object. The processors of the computer system may receive from the field system or other sources inputs to previously performed operations, verification data associated with verification of an object, or other data. The processors of the computer system may generate transaction-related data based on the received data. For example, if a defect is found based on the verification data, the inputs can be analyzed in relation to the detected defect to determine the cause of the defect (e.g., the actual output does not match the theoretical output of the inputs) and transaction-related data can be generated such that the associated with the operation, the data could be used to perform an operation that is intended to repair or eliminate the detected defect or the cause of the defect.

[001165] In one embodiment of the invention, the data associated with the operation (based on which the operation is performed on the object), as an additional or alternative option, based on observations of one or more operations performed on one or more other objects. In one embodiment of the invention, the processors of the computer system may control one or more operations on one or more objects. By way of example, the processors may monitor the execution of operations through one or more control devices, such as one or any combination of a control laser, a control camera, an X-ray control device, a gamma ray control device, an ultrasonic control device, a magnetic particle control device, a vortex control device. currents, temperature monitor or other control device. During such monitoring, the processors may receive data associated with observations of operations, such as observations of one or more field devices during operations, observations of objects during operations, observations of environmental conditions during operations, or other observations. Processors may compare observations to determine the circumstances that are likely causes of defects and may generate transaction-related data for subsequent operations to avoid or mitigate such defects. In one embodiment of the invention, the processors of a computer system may compare one or more sets of observations of an operation performed on one or more objects on which a defect is found (after the operation is performed) with one or more other sets of observations of the same operation performed on one or more other non-defective items to determine the circumstances that likely caused the defect (as described in more detail elsewhere in this document). In one embodiment of the invention, the definition of such circumstances can be stored and used (for example, in combination with the definition of such circumstances that occur in other field systems) to (i) generate and select one or more operation protocols for subsequent operations (as described in this document) to prevent or reduce defects, (ii) enable defects to be detected early in the process (for example, as described in this document through active monitoring of operation progress, on-the-fly inspection during operation, etc.) or ( iii) provide other benefits to create better products for current and future customers.

[001166] As an example, analysis of inspection data for multiple welds and observational data from the operation of making those welds may reveal that the absence of welding defects is significantly more likely in the case where the welding voltage drops more than 0.5 V below the input parameter welding voltage while the torch is welding between the 2 o'clock and 4 o'clock positions on the pipe. Conversely, the welding voltage may drop as much as 1.2 V below the welding voltage input at other locations on the pipe without resulting in a deposition defect. Based on these observations, the computer system processors can generate and send new welding inputs that tell the welding devices to increase the welding voltage by 0.7 V when the torch is between the 2 o'clock and 4 o'clock positions. As another example, if the analysis shows that the case of a drop in welding voltage leads to a disadvantage in the form of welding defects while the torch is welding downhill (but not during welding uphill), the generated new welding input parameters can give a prescription to welding devices to increase the welding voltage only when the torch is welding downhill. As another example, in the case where the analysis shows that the occurrence of a drop in welding voltage is the cause of the absence of welding defects for external welds (but not for internal welds), the generated new welding inputs can instruct external welding devices to increase the welding voltage. .

[001167] In one embodiment of the invention, the processors of the computer system may receive audit data associated with checks on one or more objects and compare the check data against a predetermined quality profile for those objects. Based on the comparison, the processors can determine whether the object has one or more defects, whether the object is ready for the next stage of operations, or provide other information. As an example, in the case where one or more defects are detected based on the inspection data, the operation-related data that is generated may relate to performing an operation to eliminate the detected defects. As another example, in the case where it is determined that the object is ready for the next stage of operations, the operation-related data that is generated may relate to the execution of the operation associated with the next stage of operations.

[001168] As an example, a predefined quality profile may contain one or more size criteria, shape criteria, consistency criteria, alignment criteria, temperature criteria, color criteria, or other criteria. In one embodiment of the invention, a predetermined quality profile for a pipeline pipe may contain one or more allowable ranges for pipe inner diameter, pipe outer diameter, pipe thickness, size of the area of contact surface between one pipe and another pipe to which the pipe is or is to be welded. , the height of the weld inside the pipe, the height of the weld on the outside of the pipe, the temperature of the weld or pipe metal (for example, during the welding operation), the color of the weld or pipe metal during the welding operation (which, for example, may indicate the temperature of the metal weld or pipe) or other criteria. The predetermined quality profile may correspond to a certain quality level, such as a gold quality standard (eg, high quality level), a minimum required quality level, and so on.

[001169] In one embodiment, the processors of the computer system may provide inspection data associated with inspections of one or more entities, one or more analysis results of inspection data, or other data for presentation to a user (e.g., an operator, inspector, manager, or other user) . In one embodiment, the processors may receive user input from a user indicative of a defect associated with at least one of the objects. As an example, the user can indicate where a defect is found on an object and what kind of defect it is. Based on the specified defect, the processors may generate operation-related data that may be used to instruct the field system to perform an operation to repair or repair the defect associated with the item.

[001170] In one embodiment of the invention, one or more operation triggers may be provided to eliminate circumstances that lead to one or more defects (eg, in an object, a group of objects, a project, etc.). As an example, despite using the same inputs for a particular operation, field devices that use those inputs to perform an operation may perform the operation differently, which could result in an object (controlled by one field device) being have a defect, and another object (managed by another field device) may not have defects. These differences in results may be caused by one or more actual inputs to field devices that differ from expected inputs, one or more actual outputs to field devices that differ from expected outputs, one or more deviations in sites on which field devices operating, one or more actual operating conditions that differ from acceptable operating conditions (eg, environmental conditions, object misalignment or mispositioning, etc.) or other circumstances.

[001171] In one embodiment of the invention, the processors of the computer system may control one or more operations on one or more objects. During such monitoring, the processors may receive data associated with observations of operations, such as observations of one or more field devices during operations, observations of objects during operations, observations of environmental conditions during operations, or other observations. Processors may compare observations with each other to generate one or more operation triggers. Once such triggers are applied, one or more field systems may direct one or more operations to be performed in response to one or more subsequent observations that satisfy the respective triggers. Triggers may include one or more triggers that trigger defect prevention or mitigation operations, or other triggers.

[001172] In one embodiment of the invention, based on data related to the observations of the operations, the processors of the computer system can compare the first set of observations of the operation performed on the object on which the defect is detected (after the operation is performed), with one or more other sets of observations for the same operation performed on one or more other objects without a defect. After the comparison, the processors may determine one or more differences between the first set of observations and other sets of observations. Based on the differences, the processors may generate one or more triggers associated with one or more operations (eg, defect prevention operations or other operations). As an example, in the case where there are general differences between the first set of observations and each of the other sets of observations, it is likely that the observed circumstances corresponding to the general differences caused the defect. Thus, in the event that these circumstances are observed during a subsequent operation, one or more operations can be performed to eliminate these circumstances in order to prevent the occurrence of a defect (for example, by terminating the subsequent operation until the circumstances no longer occur, by changing input parameters for a subsequent operation in order to level the circumstances, by generating an alert indicating the circumstances, etc.).

[001173] In one embodiment of the invention, based on data related to the observations of the operations, the processors of the computer system can compare the second set of observations of the same operation performed on another object on which the defect is detected (after the operation is performed) with other sets of observations (for the same operation performed on other objects without a defect). After the comparison, the processors may determine one or more differences between the second set of observations and other sets of observations. As an example, processors may then compare (i) the overall differences between the first set of observations and each of the other sets of observations with (ii) the overall differences between the second set of observations and each of the other sets of observations to determine the differences common to the first and second sets of observations ( for example, similarities that both the first and second set of observations have and which are general differences compared to other sets of observations of other objects without a defect). Based on the differences common to both the first and second set, the processors may generate one or more triggers associated with one or more operations (eg, defect prevention operations or another operation).

[001174] In one embodiment of the invention, by comparing one or more sets of observations of the welding operation for the root pass (for one or more areas of the contact surface between the pipes), the processors of the computer system can determine the overall differences that at least one set of observations has of a weld operation (which resulted in a defect in its root pass) compared to other sets of observations of a weld operation during which a root pass was performed without a defect. As an example, in the case where the overall differences include a certain deviation between one or more measured inputs and the inputs used for the welding operation, the processors may generate one or more triggers that initiate one or more actions to correct the deviation when such deviation is detected. . For example, subsequent welding operations for the root pass can be monitored and if there is a deviation from the input parameters used by the welding device to perform the root pass welding operation, the generated triggers can cause the associated operations to be performed to correct the deviation (for example, changing the input parameters to ensure that so that the actual inputs for the welding operation are within the expected input ranges associated with the unchanged inputs, generating an alert that is provided to the operator or another person or system, aborting the welding operation, etc.). In other use cases, one or more of these types of triggers may be generated to deal with circumstances during a coating operation, a preheat operation, a cooling operation, an alignment operation, a shielding operation, an inspection operation, or another operation, respectively.

[001175] In another use case, when monitoring a subsequent operation on an object, a circumstance corresponding to observations common to objects with defects can be detected. In response, an operation trigger for this circumstance can cause the operation associated with the operation trigger to be executed on the object. For example, the processors of the computer system may change one or more input parameters for a subsequent operation or another operation to be performed after the subsequent operation. Processors may, for example, change inputs to a subsequent operation during a subsequent operation, change inputs to another next operation before another subsequent operation, or perform other modification operations associated with an operation trigger. The changed input parameters may include one or more welding parameters, coating parameters, alignment parameters, change parameters, or other parameters. As another example, processors may halt a subsequent operation (e.g., halt a subsequent operation until further notice), generate an alert during a subsequent operation indicating circumstances (e.g., generating and transmitting an alert to a field system performing a subsequent operation, providing an alert to a manager, field operator or other personnel, etc.) or perform other operations related to the operation trigger. Thus, for example, the above operation triggers and/or active controls can help detect defects early in the process and prevent or reduce defects to enable more efficient and productive operations and provide better products to present and future customers.

[001176] Protocols of transactions and transactions based on them

[001177] In one embodiment of the invention, one or more operation protocols for performing one or more operations may be generated based on checks on one or more objects. As an example, the processors of a computer system (e.g., 5138 computer system, 13704 remote computer system, 13716 field computer system, etc.) can receive data from a field system (e.g., 5000 field system, 13702 field system, etc.) checks associated with checking an object (for example, checking before performing one or more operations that physically affect the object, checking during the execution of operations, checking after performing operations, etc.). The processors may generate an operation protocol (associated with at least one operation type of operations) based on the verification data and one or more input parameters used to perform the operations. The operation protocol may, for example, include a weld protocol, a coating protocol, an alignment protocol, a change protocol, or another protocol. One or more operation protocol parameters may contain one or more welding parameters, coating parameters, alignment parameters, modification parameters, or other parameters.

[001178] In one embodiment of the invention, the processors of the computer system may select an operation protocol to perform a subsequent operation similar to at least one of the operations (that physically affect the object). The processors may generate, based on at least one operation protocol input, data associated with the execution of a subsequent operation. The processors may transmit operation-related data to the field system to direct the field system to perform a subsequent operation. As an example, the field system may perform a subsequent operation based on data associated with the operation.

[001179] In one embodiment of the invention, based on the inspection data, the processors of the computer system may detect a defect associated with an object. In response to detection of a defect, the processors may generate an operation log such that the operation log contains a set of input parameters having at least one input parameter different from the set of input parameters used to perform the operations. As an example, a predefined operation protocol can be used to perform an operation on an object. In the event that a defect is found on an object based on an inspection of the object, the predetermined operation protocol may be modified to avoid similar defects when the predetermined operation protocol is used for one or more subsequent operations, similar to the operation that likely led to the detected object to a defect. The modified operation protocol can be saved as a new predefined operation protocol that will replace the previous version of the predefined operation protocol, and so on.

[001180] In one embodiment of the invention, 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 contain input parameters related to wire feed speed, wire consumption, width vibrations, amplitude of vibrations, welding time, gas flow rate, welding arc power levels, welding current, welding voltage, welding resistance, welding torch travel speed, position of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip relative to its plane of rotation , the distance from the welding tip of the welding torch to the inner surfaces of the welded pipes, or other parameters. In the event that, for example, it is determined that a welding pass layer of insufficient thickness has been formed during a welding operation, the predetermined welding operation protocol may be modified to allow more welding time, more wire to be used (e.g., increased wire feed speed), or other changes to the input parameters of a predefined welding operation protocol. Thus, when a modified operation protocol is subsequently used to perform a similar operation on two similar pipes, changing the input parameters can prevent the problem of insufficient thickness.

[001181] In one embodiment of the invention, based on the verification data, the processors of the computer system can determine whether the quality of one or more aspects of an object resulting from operations (that physically affect the object) meets or exceeds a specified quality standard against a predefined quality profile. As an example, processors may generate an operation protocol such that the operation protocol contains one or more input parameters (used to perform operations) corresponding to the quality of aspects of the object that meet or exceed a quality standard indicated by a predefined quality profile. The predefined quality profile may correspond to a certain quality level, such as a gold quality standard (eg, high quality level), a minimum required quality level, and so on. In the event that the quality of aspects of an object meets or exceeds the quality standard specified in the predefined quality profile, the input parameters (used to perform operations that lead to such results) may be used to generate an operation log (for example, such that the operation log contains some or all of the inputs). Thus, for example, an operation log may be used to perform one or more subsequent operations similar to the operation that produced results such that subsequent operations provide similar quality.

[001182] As another example, if the quality of aspects of an object does not meet a quality standard (denoted by a predefined quality profile), processors may generate an operation log such that the operation log does not contain one or more input parameters (used to perform the operations that resulted in to the verified state of the object). In one use case, if a predefined operation protocol (containing input parameters used to perform the operations) was selected to perform at least one of the operations, and the quality of aspects of the resulting object did not meet the minimum required quality level, then one or more of the input parameters are preliminarily of a defined operation protocol can be modified to avoid subsequent unsatisfactory results when a predefined operation protocol is used to perform subsequent operations.

[001183] In one embodiment, the computer system processors may receive inspection data associated with inspections of one or more objects and compare the inspection data with a predefined quality profile for the objects to determine if the quality of one or more aspects of the objects meets or exceeds the quality. the quality standard specified in the predefined quality profile. As an example, based on the comparison, the processors may determine whether the object has one or more defects, whether the object is ready for the next stage of operations, or generate other information. As another example, in response to the quality of aspects of an object exceeding a quality standard indicated by a predefined quality profile, the processors may generate a new quality profile based on the inspection data, wherein the new quality profile will point to a new quality standard that is based on the inspection data. . The new quality profile, for example, may be stored in a database for use in the analysis of one or more aspects resulting from one or more subsequent operations.

[001184] In one embodiment, the processors of the computer system may provide inspection data associated with inspections of one or more entities, one or more analysis results of inspection data, or other data for presentation to a user (e.g., operator, inspector, manager, or other user) . In one embodiment, the processors may receive user input indicative of the quality level of one or more aspects of an object as a result of one or more operations (eg, low quality level, high quality level, etc.). In response to user input, the processors may generate a new quality profile associated with the specified quality level, wherein the new quality profile points to a new quality standard based on the validation data. The new quality profile may, for example, be stored in a database for use in analyzing one or more aspects resulting from one or more subsequent operations.

[001185] In one embodiment of the invention, the processors of a computer system may generate one or more operation protocols based on data associated with input parameters used to perform one or more operations, data associated with monitoring operations, verification data associated with checking objects on which operations are performed (for example, before, during, or after an operation), or other data. As an example, processors may analyze inspection data to determine if any object has defects. The processors can then compare one or more sets of observations of an operation performed on one or more objects that have a defect (after the operation has been performed) with one or more other sets of observations of the same operation performed on one or more other objects without a defect. to determine the circumstances that likely led to the defect (as described in more detail elsewhere in this document). Based on the comparison, processors may generate activity logs such that the activity logs preclude or otherwise preclude circumstances (that likely caused the defect) when the activity logs are used for one or more downstream operations (e.g., downstream operations that are the same or similar to the operation being performed and observed).

[001186] As another example, if the inputs used to perform an operation on one or more objects are observed to be different from the inputs used to perform an operation on one or more other objects, then the processors may compare these observations to each other. another to determine whether differences in input parameters could lead to a defect. For example, observations can be compared to determine the overall differences between the inputs used to perform an operation on an object with a received defect and the inputs used to perform operations on objects without a defect. Based on the general differences, processors may generate operation logs such that the operation logs do not include the input parameters that likely caused the defect. The generated transaction logs may be stored such that the transaction logs can be used in one or more subsequent transactions (eg, subsequent transactions that are the same or similar to the performed and observed transaction). For example, in one use of welding protocols, analysis of test data from multiple welds and observational data from those welds may reveal that the absence of weld defects is significantly more likely when the weld voltage drops more than 0.5 V below the weld input. voltage while the torch welds between the 2 o'clock and 4 o'clock positions on the pipe. Conversely, the welding voltage may drop as much as 1.2 V below the welding voltage input at other locations on the pipe without resulting in a deposition defect. Based on these observations, the computer system processors can generate weld protocols containing new weld inputs that indicate the need for a 0.7 volt increase in weld voltage when the torch is between the 2 o'clock and 4 o'clock positions.

[001187] Additional exemplary block diagrams

[001188] In Fig. 138 illustrates a flow diagram of a method 13800 for facilitating, through a field system (eg, one of the field systems 13702), field testing and physical operations based thereon, in accordance with one or more embodiments of the invention. The processing operations according to the method described below are illustrative and not restrictive. In some embodiments of the invention, for example, the method may be performed with one or more additional steps not described and/or without one or more steps described. In addition, the order in which the processing operations according to the method are illustrated (and described below) is not restrictive. In some embodiments, the method may be performed by at least one or more processing devices (e.g., a digital processor, an analog processor, a digital information processing circuit, an analog information processing circuit, a state machine, and/or other mechanisms for electronic information processing). The processing devices may include one or more devices that perform some or all of the operations according to the methods in response to instructions electronically stored on an electronic storage medium. Processing devices may include one or more hardware, firmware, and/or software devices specifically designed to perform one or more operations according to the method.

[001189] In one embodiment of the invention, the object can be scanned (13802). As an example, an object may be scanned before, during, or after an operation that physically affects the object and is performed on the object to obtain verification data. Operation 13802 may be performed by a control device that is the same or similar to control device 13714 in accordance with one or more embodiments of the invention. By way of example, the monitor may include a monitor laser, a monitor camera, an X-ray monitor, a gamma ray monitor, an ultrasonic monitor, a magnetic particle monitor, an eddy current monitor, a temperature monitor, or other monitor. 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.

[001190] In one embodiment of the invention, verification data associated with object verification can be obtained (13804). Operation 13804 may be performed by a field computer system that is the same or similar to field computer system 13716 in accordance with one or more embodiments of the invention.

[001191] In one embodiment, the verification data may be transmitted to a remote computer system (eg, remote computer system 13720) (13806). Operation 13806 may be performed using a field computer system that is the same or similar to field computer system 13716 in accordance with one or more embodiments of the invention.

[001192] In one embodiment of the invention, data related to the execution of an operation that physically affects an object may come from a remote computer system responding to the verification data transmission (13808). As an example, the data associated with the operation may be obtained based on the verification data. As another example, data associated with an operation may be obtained by a remote computer system based on inspection data, other inspection data associated with scanning another object, input parameters used to perform operations on respective objects prior to scanning, or other data. Operation 13808 may be performed by a field computer system that is the same or similar to field computer system 13716 in accordance with one or more embodiments of the invention.

[001193] In one embodiment of the invention, based on the data related to the operation, the field device of the field system can be directed to perform an operation that physically affects the object (13810). Operation 13810 may be performed by a field computer system that is the same or similar to field computer system 13716, in accordance with one or more embodiments of the invention.

[001194] In one embodiment of the invention, with reference to FIG. 138 Operation-related data may contain welding-related instructions such as instructions regarding wire feed speed, wire consumption, wave width, wave shape, wave amplitude, welding time, gas flow rate, welding arc power levels, welding current, welding voltage. , welding resistance, welding torch travel speed, position of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip relative to its plane of rotation, distance from the welding torch welding tip to the inner surfaces of the pipes to be welded, or other instructions. Based on the instructions associated with welding, the field device of the field system may be directed to perform a welding operation on the first object and the second object (eg, welding two pipes to each other, welding two other objects to each other, etc.).

[001195] In one embodiment of the invention, with reference to FIG. 138, the operation-related data may contain coating-related instructions, such as instructions regarding preheat temperature, coating thickness, or other instructions. Based on coating instructions, a field device of a field system may be directed to apply one or more coats of a coating to an object.

[001196] In one embodiment of the invention, with reference to FIG. 138, the data associated with the operation may contain instructions related to alignment. Based on alignment instructions, a field device of the field system may be directed to perform alignment of an object (eg, align two pipes for welding, align other objects with each other, etc.).

[001197] In one embodiment of the invention, with reference to FIG. 138, the data associated with the operation may contain instructions associated with the change. Based on the instructions associated with the change, the field device of the field system may be instructed to change the object, for example, increase at least part of the object, reduce at least part of the object, change the size of at least part of the object, change the shape of at least part of the object, or other changes.

[001198] In Fig. 139 illustrates a flow diagram of a method 13900 for facilitating field testing and physical operations based thereon by a computer system, in accordance with one or more embodiments of the invention. The processing operations according to the method described below are illustrative and not restrictive. In some embodiments of the invention, for example, the method may be performed with one or more additional steps not described and/or without one or more steps described. In addition, the order in which the processing operations according to the methods are illustrated (and described below) is not restrictive. In some embodiments, the method may be performed by at least one or more processing devices (e.g., a digital processor, an analog processor, a digital information processing circuit, an analog information processing circuit, a state machine, and/or other mechanisms for electronic information processing). The processing devices may include one or more devices that perform some or all of the operations according to the methods in response to instructions electronically stored on an electronic storage medium. Processing devices may include one or more hardware, firmware, and/or software devices specifically designed to perform one or more operations according to the method.

[001199] In one embodiment of the invention, verification data associated with scanning an object may be received from the field system (13902). Operation 13902 may be performed by an object profile subsystem that is the same or similar to object profile subsystem 13732 in accordance with one or more embodiments of the invention. As an 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.

[001200] In one embodiment of the invention, one or more input parameters of one or more operations performed on the object (13904) can be obtained. As an example, operations performed on an object may be operations that physically affected the object and were performed on the object before the object was scanned (on which the scan data is based). Input parameters can be input parameters used to perform operations on the object (for example, welding parameters, coating parameters, or other input parameters). Operation 13904 may be performed by an operations control subsystem that is the same or similar to operations control subsystem 13738 in accordance with one or more embodiments of the invention.

[001201] In one embodiment of the invention, validation data and input parameters may be processed to generate data associated with performing an operation that physically affects the object (13906). By way of example, transaction-related data may include one or more of the transaction-related data types described above with respect to FIG. 138 (eg welding instructions, coating instructions, etc.). Operation 13906 may be performed by an operations manager subsystem that is the same or similar to operations manager subsystem 13734 in accordance with one or more embodiments of the invention.

[001202] In one embodiment of the invention, data associated with the operation may be transmitted to the field system to cause the field system to perform an operation when the operation is performed based on the data associated with the operation (13908). By way of example, the operations that may be instructed by the field system to perform may include one or more of the types of operations (which are instructed to be performed by a field device of the field system) described above with reference to FIG. 138. Operation 13908 may be performed by an operations manager subsystem that is the same or similar to operations manager subsystem 13734 in accordance with one or more embodiments of the invention.

[001203] In Fig. 140 illustrates a flowchart of a method 14000 for facilitating, through a computer system, field testing and physical operations based thereon, in accordance with one or more embodiments of the invention. The processing operations according to the method described below are illustrative and not restrictive. In some embodiments of the invention, for example, the method may be performed with one or more additional steps not described and/or without one or more of the steps described. In addition, the order in which the processing operations according to the methods are illustrated (and described below) is not restrictive. In some embodiments, the method may be performed by at least one or more processing devices (e.g., a digital processor, an analog processor, a digital information processing circuit, an analog information processing circuit, a state machine, and/or other mechanisms for electronic information processing). The processing devices may include one or more devices that perform some or all of the operations according to the methods in response to instructions electronically stored on an electronic storage medium. Processing devices may include one or more hardware, firmware, and/or software devices specifically designed to perform one or more operations according to the method.

[001204] In one embodiment of the invention, a defect associated with an object may be detected based on the data obtained from the inspection associated with the analysis of the object (14002). As an example, the analysis may be performed after a manufacturing operation that has been performed on a site using a first set of input parameters (eg, welding parameters, coating parameters, or other input parameters). Inspection data can be provided by the field system, where inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray test, ultrasonic test data, magnetic particle test data, eddy current test data, temperature test data, or other test data . Process operation 14002 may be performed by an object profile subsystem that is the same or similar to object profile subsystem 13732, in accordance with one or more embodiments of the invention.

[001205] In one embodiment of the invention, a process protocol can be generated (14004) associated with the type of process operation (which was performed at the facility using the first set of input parameters). As an example, a process protocol may be generated such that the process protocol contains a second set of inputs that is different from the first set of inputs (eg, the one used to perform the process that likely caused the defect). In one use case, for example, the first set of input parameters and the data resulting from the test can be analyzed to determine which of the parameters likely caused the defect, and those parameters (which likely caused the defect) could be changed to creating a second set of input parameters for the protocol of the technological operation. Once generated, the process operation profile may be stored in a database (eg, a process protocol database or other database) for use with subsequent process operations. The workflow 14004 may be performed by a workflow protocol subsystem that is the same or similar to the workflow protocol subsystem 13736, in accordance with one or more embodiments of the invention.

[001206] In one embodiment of the invention, a process operation protocol may be selected to perform a subsequent process operation similar to the process operation (performed at the facility using the first set of input parameters) (14006). As an example, if the previous process step was a root welding process, the subsequent process step may also be a root welding process. As another example, if the previous process step was a hot pass weld process step, the subsequent process step may also be a hot pass weld process step. The process step 14006 may be performed by a process flow protocol subsystem that is the same or similar to the process flow protocol subsystem 13736, in accordance with one or more embodiments of the invention.

[001207] In one embodiment of the invention, data associated with the execution of a subsequent process step may be generated based on at least one process protocol parameter (14008). The process operation 14008 may be performed by a process operation control subsystem that is the same or similar to the process operation control subsystem 13734 in accordance with one or more embodiments of the invention.

[001208] In one embodiment of the invention, process related data can be transmitted to the field system and cause the field system to perform a subsequent process step, where the subsequent process step is performed based on the process related data (14010). The process operation 14010 may be performed by a process operation control subsystem that is the same or similar to the process operation control subsystem 13734 in accordance with one or more embodiments of the invention.

[001209] In Fig. 141 is a flow diagram of a method 14100 for facilitating, by means of a computer system, field trials and physical processing operations based thereon, in accordance with one or more embodiments of the invention. The steps of the method described below are intended to be illustrative and not limiting. For example, in some embodiments of the invention, the method may be performed with one or more additional process steps not described and/or without one or more process steps discussed. In addition, the order in which the process steps of the methods are illustrated (and described below) is not limited. In some embodiments, the method may be implemented by at least one or more processing devices (e.g., a digital processor, an analog processor, a digital information processing circuit, an analog information processing circuit, an internal state machine, and/or other mechanisms for electronic information processing). The processing devices may comprise one or more devices that perform some or all of the process steps of the methods in response to instructions stored electronically on an electronic storage medium. Processing devices may include one or more devices configured with hardware, firmware and/or software specifically designed to perform one or more process steps of the method.

[001210] In one embodiment of the invention, the quality of one or more aspects of an object can be determined based on the data obtained from the inspection associated with the analysis of the object (14102). As an example, the analysis may be performed after a manufacturing operation that has been performed on a site using a set of input parameters (eg, welding parameters, coating parameters, or other input parameters). Inspection data can be provided by the field system, where inspection data may include laser inspection data, camera inspection data, x-ray inspection data, gamma ray test, ultrasonic test data, magnetic particle test data, eddy current test data, temperature test data, or other test data . Technological operation 14102 may be performed by an object profile subsystem that is the same or similar to object profile subsystem 13732, in accordance with one or more embodiments of the invention.

[001211] In one embodiment of the invention, meeting a quality that exceeds a quality standard (indicated by a predefined quality profile), a process protocol can be generated (14104) associated with the type of process operation (which was performed at the facility using a set of input parameters) . As an example, a process protocol may be generated such that the process protocol contains one or more parameters of a set of input parameters (used to perform the process operation). As another example, a process protocol may be generated such that the process protocol contains all of the parameters of a set of input parameters. Once generated, the process operation profile may be stored in a database (eg, a process protocol database or other database) for use with subsequent process operations. The process step 14104 may be performed by a process flow protocol subsystem that is the same or similar to the process flow protocol subsystem 13736, in accordance with one or more embodiments of the invention.

[001212] In one embodiment of the invention, a process operation protocol may be selected to perform a subsequent process operation similar to the process operation (performed at the facility using the first set of input parameters) (14106). The process step 14106 may be performed by a process flow protocol subsystem that is the same or similar to the process flow protocol subsystem 13736, in accordance with one or more embodiments of the invention.

[001213] In one embodiment of the invention, data associated with the execution of a subsequent process step may be generated based on at least one process protocol parameter (14108). The process operation 14108 may be performed by a process operation control subsystem that is the same or similar to the process operation control subsystem 13734 in accordance with one or more embodiments of the invention.

[001214] In one embodiment of the invention, process related data can be transmitted to the field system and cause the field system to perform a subsequent process step, where the subsequent process step is performed based on the process related data (14110). Process operation 14110 may be performed by a process operation control subsystem that is the same or similar to process operation control subsystem 13734 in accordance with one or more embodiments of the invention.

[001215] In Fig. 142 is a flow diagram of a method 14200 for facilitating, via a computer system, field trials and physical processing steps thereon, in accordance with one or more embodiments of the invention. The steps of the method described below are intended to be illustrative and not limiting. For example, in some embodiments of the invention, the method may be performed with one or more additional process steps not described and/or without one or more process steps discussed. In addition, the order in which the process steps of the methods are illustrated (and described below) is not limited. In some embodiments, the method may be implemented by at least one or more processing devices (e.g., a digital processor, an analog processor, a digital information processing circuit, an analog information processing circuit, an internal state machine, and/or other mechanisms for electronic information processing). The processing devices may comprise one or more devices that perform some or all of the process steps of the methods in response to instructions stored electronically on an electronic storage medium. Processing devices may include one or more devices configured with hardware, firmware and/or software specifically designed to perform one or more process steps of the method.

[001216] In one embodiment of the invention, one or more technological operations performed at one or more objects can be monitored (14202). The process operation 14202 may be performed by a process control subsystem that is the same or similar to the process control subsystem 13738 in accordance with one or more embodiments of the invention.

[001217] In one embodiment of the invention, data related to observations of process operations may be obtained based on operational control (14204). As an example, observation-related data may include data relating to observations of one or more field devices during a process operation, observations of objects during a process operation, environmental observations during a process operation, or other observations. The process operation 14204 may be performed by a process control subsystem that is the same or similar to the process control subsystem 13738 in accordance with one or more embodiments of the invention.

[001218] In one embodiment of the invention, one or more sets of process operation observations (performed on one or more objects identified as having a defect) can be compared with one or more other sets of process operation observations (performed on one or more other process operations). in the absence of a defect) (14206). The workflow 14206 may be performed by a workflow protocol subsystem that is the same or similar to the workflow protocol subsystem 13736, in accordance with one or more embodiments of the invention.

[001219] In one embodiment of the invention, one or more overall differences of sets of observations (corresponding to defective objects) with other sets of observations (corresponding to objects without a defect) can be determined based on comparison (14208). The workflow 14208 may be performed by a workflow protocol subsystem that is the same or similar to the workflow protocol subsystem 13736, in accordance with one or more embodiments of the invention.

[001220] In one embodiment, one or more process triggers may be implemented based on common differences (14210). As an example, when implementing a process step trigger based on one of the common differences, the process step trigger may cause the associated process step to be executed when a condition corresponding to the common difference occurs in a subsequent process step. The workflow 14210 may be performed by a workflow protocol subsystem that is the same or similar to the workflow protocol subsystem 13740, in accordance with one or more embodiments of the invention.

[001221] In one embodiment of the invention, a universal cloud logging system (herein also referred to as "uLog", or "uLog system", or "uCloud") is a system of software, hardware, equipment and telecommunications networks that Easily collect welding data for quality control and quality management, welding data logging, task and project management, safety control and management and supervision, real-time welding performance monitoring, and data presentation and visualization. The uLog system may use wired systems and devices and/or wireless systems and devices and/or Bluetooth systems and devices and/or cloud systems and devices. The uLog system can use software technologies, mobile and desktop device technologies, telecommunication technologies and other technologies in products, devices, systems, processes and methods that achieve high quality welding, supervision, control, management and safety. The uLog system can be used in land, sea, ship-based, platform-based, structure-based, or other installation environments. In one embodiment of the invention, the uLog may handle Bluetooth communication and the data may be transferred to the uLog for processing by Bluetooth technology or any other wireless means.

[001222] In one embodiment, uLog has tools that easily collect welding condition data and/or logs of records of welding condition data. In its many and varied variations, the uLog system can use welding condition data and other pipeline design and associated data to produce one or more of the following: analytical results, field reports, management data, quality control data, automatic generated administrative reports, daily summaries, data archives, welding records, material usage data, quality control records, and project management records.

[001223] In one embodiment, uLog may be used to maintain and/or generate welding method qualification test ("PQR") reports and associated data. The uLog functionality can also be used to record, develop, maintain and manage welding procedure specifications ("WPS").

[001224] uLog may allow a user to view, record, monitor, measure, and analyze log data for one or more welds and/or welding and/or inspection and/or control activities. Using uLog and its analytical functionality, the user can achieve improved welding quality and quantify welding results. In its many and varied embodiments of the invention, uLog may have real-time or historical data processing functionality. This allows the user to make decisions in real time and/or based on historical data. In one embodiment of the invention, uLog can provide real-time user data on any aspect of current welding, coating, supervision, pipe processing, project management, piping design and/or installation work, and provides weld quality control and/or welding work in the mode real time and/or other pipeline construction activities. In another embodiment of the invention, uLog may also provide functionality for facility management, project management, accounting, inventory and material management, and financial control and audit of both financial and material resources. uLog can also provide functionality in the areas of HR and time management, as well as payroll and support.

[001225] Without limitation, various embodiments of the present invention may, for example, be implemented as a computer system, method, cloud service, or computer program product. Accordingly, various embodiments of the invention may take the form of an all-hardware embodiment of the invention, an all-software embodiment of the invention (e.g., one or more computer applications such as an “Application” (or “App”) to be implemented on a mobile device and/or or an application for installation on a desktop computer) or an embodiment of the invention that combines software and hardware aspects. In addition, embodiments of the invention may take the form of a computer program product stored on a computer-readable storage medium having computer-readable instructions (eg, software) embodied in the storage medium. Various embodiments of the invention may take the form of software implemented on a network. Any suitable computer-readable storage medium may be used, including, for example, hard drives, CDs, DVDs, optical storage devices, solid state storage devices, and/or magnetic storage devices.

[001226] Various embodiments of the invention are described below with reference to illustrations in the form of schematic images, block diagrams, pictures, and flowcharts of process sequences of methods, apparatuses (eg, systems), and computer program products. It should be understood that the illustrations of each block of flowcharts and flowcharts and the illustrations of combinations of flowcharts and flowcharts, respectively, may be implemented by a computer executing computer program instructions. These computer program instructions can be downloaded to a general purpose computer, special purpose computer, or other programmable data processing device to create a machine, so that the instructions executed on the computer or other programmable data processing device create the means to implement the functions specified in the block or blocks. technological operation sequence diagrams.

[001227] These computer program instructions can also be stored in a computer-readable storage device that can direct a computer or other programmable data processing device to function such that the instructions stored in the computer-readable storage device produce a finished product that can be configured to implementation of the function specified in the block or blocks of the sequence diagram of the technological operation. Computer program instructions may also be downloaded to a computer or other programmable processing device to cause a series of operational steps to be performed on the computer or other programmable device to create a computer-implemented process such that the instructions executed on the computer or other programmable device provide steps for implementing the functions specified in the block or blocks of the workflow diagram.

[001228] Accordingly, block diagram and flowchart illustrations support combinations of mechanisms to perform said functions, combinations of steps to perform said functions, and program instructions to perform said functions. It should also be understood that illustrations of each block of block diagrams and flowcharts, and illustrations of combinations of blocks in the block diagrams and flowcharts, may be implemented using special hardware computer systems that perform the indicated functions or steps, or combinations of special equipment and other equipment that executes appropriate computer commands. Implementation can also be done with custom software and hardware using custom software and/or applications. The system as a whole can be accessed from various computer platforms, including mobile devices.

[001229] In Fig. 143 shows images of land pipelines. uLog can be used in any piping fabrication in any structural environment. Structural environments may include those present on land, offshore, both onshore and offshore, underwater, from sea level, on site, on a ship, on a barge, on a platform, on a structure, in space or any other structural external conditions. For example, uLog can be used to control pipeline welding.

[001230] In Fig. shows a welding station 14410 according to an embodiment of the present invention. uLog can be used in conjunction with a 14410 welding station. uLog can process data received from a 14410 welding station. A welding station can contain a 14412 welding machine or welding system, a 14414 welder, or an automatic or robotic welding system. In one 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 US Pat. To control the welding process, as well as to obtain data on the welding process, the welding station 14410 can be controlled by the computer system 14416. uLog, implemented in the computer system 14416, can control the welding station 14410, including the welding machine 14412, and can also process data received from product 14418, such as a pipe and/or work or welding data that affects the workpiece (e.g. pipe) 14418.

[001231] In Fig. 145 shows a plurality of pipeline welding stations 14410 (pipe welding extent 14420) in accordance with an embodiment of the present invention. uLog can be used for 14420 pipeline welds. uLog can process data received from one or more welding stations 14410 along the length 14420 of pipeline welding. In one embodiment of the invention, uLog can process data received from multiple stations or from many welding stations 14410. There are no restrictions on the location of welding stations 14410. Pipelines 14418 can be very long, and one or more stations can be located anywhere without restrictions . In addition, uLog supports the processing of data received simultaneously from several projects and/or activities and/or tasks and/or people. Expert evaluation of the uLog user can be carried out both on projects and within projects. uLog allows the user to work with data received from one or more projects simultaneously or sequentially, in real time or based on archived data.

[001232] FIG. 146 is a schematic diagram of a system with multiple welding stations 14410 communicating with multiple control stations (computer systems) 14416 and collecting logs, in accordance with an embodiment of the present invention. In one embodiment of the invention, data on welding conditions may be collected at a log collection station 14416 associated with the welding station 14410. Control and log collection stations 14416 may process data for one or more weld and/or welding stations 14410. Data collection and /or processing may originate from pipeline design, welding station equipment, operator, welder, or other data entry means. In a non-limiting example, equipment processors, embedded processors, computers, sensors, processing controllers, wired or wireless analog and digital devices, and portable data processors can be used to acquire, communicate, and/or process data from a welding station and/or welding system. In one embodiment of the invention, one or more technicians can manage the welding station (station) 14410 and station (station) 14416 management and collection of logs. There is no limit to the number of 14416 log collection stations that can be used with uLog. Record Log Collection Station 14416 with Welding Station 14410 for Welding System 14422.

[001233] FIG. 147 is a schematic diagram of a system with multiple welding stations 14410 communicating with multiple control and log collection stations 14416, in accordance with another embodiment of the present invention. In one embodiment, welding condition data may be collected from each 14410 welding station or 14422 welding system. In another embodiment, welding condition data may be collected from a number of stations or 14410 welding systems. There is no limit to the number of welding stations 14410 and/or 14422 welding systems.

[001234] FIG. 148 is a schematic representation of a welding station 14410 communicating with a wireless network 14424 via a wireless connection (eg, Wi-Fi connection) 14426, according to an embodiment of the present invention. For example, the welding station 14410 may be equipped with wireless capabilities such as Bluetooth, Wi-Fi, cellular, satellite phone, or other wireless means. For a non-limiting example, the welding station 14410 may have one or more computers, servers, or welding process data processors 14416 that can collect and process welding system data. As shown in FIG. 148, welding station 14410 includes two welding machines or welding systems 14412. In one embodiment, welding systems 14412 comprise an orbital welding system. One of the 14412 welding machines is a clockwise rotation (CW) welding machine or system, and the other 14412 welding machine is a counterclockwise rotation (CCW) welding machine or system.

[001235] FIG. 149 is a schematic representation of a plurality of workstations 14430 communicating with a cloud server 14432 via the World Wide Web (Internet) in accordance with an embodiment of the present invention. uLog can be configured at the local, regional, project, or global level. The implementation of uLog is not limited by geographic restrictions. One or more 14430 workstations can be networked with uLog. In one embodiment of the invention, users, staff, managers, engineers, departments, companies, professionals, workers, customers, and a variety of other parties can be connected to uLog over a network. Each workstation 14430 includes a welding station 14410 controlled by a welder 14414 (as shown in Fig. 144), a lead technician 14434 and a welding engineer 14436, and so on. Each workstation 14430 is configured to communicate with a cloud server 14432 via a dedicated communication line or channel 14440 or over the Internet 14442. The cloud server 14432 can be accessed by the system manager 14438 and the design engineer 14439. To store data about the conditions of the welding can be a storage device 14433 is provided that communicates with the cloud server.

[001236] FIG. 150 is a schematic representation of a plurality of welding stations 14410 communicating with intermediate computing devices 14450 controlled by technical managers (leading technicians 14452, inspectors 14454, engineers 14456, etc.) via channels or lines 14458, according to an embodiment of the present inventions. For example, each welding station 14410 may communicate with one or more intermediate computing devices 14450. Similarly, each intermediate computing device 14450 is configured to communicate with one or more welding stations 14410. In turn, intermediate computing devices 14450 are configured to communicate with cloud server 14432 over the Internet 14442. Parts of the uLog program are configured to run on the cloud server 14432, other parts of uLog are configured to run on intermediate computing devices 14450, and other parts are configured to run on the computer/server 14416 of the welding station. Each part or component of uLog works in cooperation with other parts or components to provide end-to-end control of the entire system. In one embodiment of the invention, uLog may optionally have differentiated WAN capabilities and propagate network capabilities. In another embodiment of the invention, all features are fully integrated; and in another embodiment of the invention, the possibilities may be without differentiation.

[001237] FIG. 151 is a schematic representation of a plurality of welding stations 14412 communicating with an intermediate computer system 14450 (controlled by terminals for Engineers, Technicians and Quality Specialists) via a wireless (e.g. Wi-Fi) link 14426 to a wireless communication network 14424 in accordance with embodiment of the present invention. The intermediate computer system may be any type of computing device, including a tablet, telephone, smart phone, PDA, and/or other wireless device(s) for data entry, data processing, data exchange, input, output, and other functions. The staging computer runs the uLog program and can be controlled by design engineers, quality control specialists, users, supervisory technicians, and others. In one embodiment, uLog running on the intermediate computer 14450 provides data, processes data, and communicates data or information with the welding station computer 14416 located at each of the welding stations 14410.

[001238] FIG. 152 is a schematic representation of a plurality of welding stations 14410 communicating with an intermediate computer system 14450 via a wireless (eg, Wi-Fi) link 14426 to a wireless communications network 14424 in accordance with an embodiment of the present invention. On FIG. 152 shows an extensive network configuration. The 14450 Intermediate Computer System has wireless capabilities such as Wi-Fi or cellular (3G, 4G, etc.) that allows it to wirelessly communicate with any of the 14410 Welding Stations. The 14450 Intermediate Computer can be a mobile wireless device of any type, such as a smartphone, tablet, or PDA, that can connect anywhere in the wireless network 14424. In one embodiment, the uLog program or system can use mesh processing over the wireless (e.g., Wi-Fi) mesh network 14424. For example, the server 14416 of the welding station 14410 can communicate with the uLog device 14450 via the wireless mesh network 14424 and can connect anywhere within the mesh network 14424. In one embodiment, the mesh network technology can be used in an extensive network configuration.

[001239] FIG. 153 is a schematic representation of a plurality of welding stations 14410 communicating with a plurality of intermediate computing systems 14450 (controlled by an engineer 14456, inspectors 14454, lead technician 14452, etc.), which in turn communicate with a cloud server 14432, in in accordance with an embodiment of the present invention. On FIG. 153 shows a data flow diagram for a general network configuration. In one embodiment of the invention, the general network configuration may be a global network configuration. The overall network configuration can be used by managers, engineers, inspectors, technicians, lead technicians, welding engineers, welders and welding stations, among others. In one embodiment of the invention, the overall uLog network configuration may optionally have a data stream differentiated by worldwide network capabilities and enhance the network capabilities. In another embodiment of the invention, all capabilities are fully integrated without differentiation. Similar to the configuration shown in FIG. 150, for example, each welding station 14410 may communicate with one or more intermediate computing devices 14450. Each intermediate computing device 14450 is configured to communicate with one or more welding stations 14410. In turn, intermediate computing devices 14450 are configured to communicate with the cloud. server 14432 over the internet 14442. Parts of the uLog program are configured to run on the 14432 cloud server, other parts of uLog are configured to run on the 14450 intermediate computing devices, and other parts are configured to run on the welding station computer/server 14416. Each part or component of a program or uLog system works in cooperation with other parts or components to provide integrated control of the entire system. In one embodiment of the invention, uLog may optionally have differentiated WAN capabilities and propagate network capabilities. In another embodiment of the invention, all features are fully integrated; and in another embodiment of the invention, the possibilities may be without differentiation.

[001240] In Fig. 154 shows an example of a graphical user interface ("GUI") for a "Main Screen" 14460 of a cloud-based universal data logging (uLog) application implemented by a computer system in a welding station 14410, in an intermediate computer system 14450, or in a cloud server 14432, according to an embodiment of the present inventions. In one embodiment of the invention, uLog provides a variety of functions for data extraction, data analysis, data analytics, data mining, data logging, and reporting. GUI 14460 includes a number of icons 14461-14468. Each icon, when activated (for example, by mouse click or finger touch), opens the application. For example, icon 14461 is associated with an "Admin" application configured to be managed by an administrator to set up uLog administrative functions. Welding parameters icon 14462 is configured to enter welding parameters. Icon 14463 is associated with the "Log" function. Icon 14464 is associated with the Report application. Icon 14465 is associated with the Job Setup application. Icon 14466 is associated with the Analytics app. Icon 14468 is associated with downloading and saving data in the Cloud (i.e. storing data on a cloud server 14432 or storage device 14433). Therefore, as can be understood, the functionality of the uLog universal logging system may include, but is not limited to, the processing of data and information regarding: administration, welding parameters, logs, records, reports, job setup, supervision, quality control, coating, pipe processing, user and/or administrative diagnostics, analytics and data for processing by local and/or cloud means.

[001241] The scope of this invention includes methods and means for achieving the described technical support of welding and pipeline construction, and also covers any article, product, means and methods for creating and using any software, application, computer executable code, software tools, logical sequences or other forms of electronic or automated means to achieve and/or use the methods herein. Such products, articles, and tools include, for example, but are not limited to, a software product delivered on a fixed medium such as a disk, or on a physical storage device, or on a flash drive, or as a software product, or as application provided by digital download or provided in other ways. This application expressly covers installed, removed, compiled, and uncompiled versions of any software product or equivalent product that may be used, implemented, installed, or otherwise activated in order to use, achieve, and/or practice the methods described in this document. In addition to its normal and generally accepted meanings, the description of "machine-readable program code facility" is intended to be interpreted broadly to cover any kind and type of computer-readable program code, executable code, software as a service, web service, cloud service, or process with using cloud computing, an embedded application, a software product provided on a fixed medium such as a disk, or a physical storage device, or a flash memory, or a memory card, or as a software application product, or as an application provided by a digital download or coded into firmware, or made available in other ways that can be used to make, use, sell, practice, achieve, participate in, produce, operate, or control in the ways described herein. In this regard, the application is construed broadly and is not limited to any means of delivery or any form of product to provide or use, achieve and/or practice the computer-readable program code products, tools and/or methods described herein. In embodiments of the invention, all methods herein may be obtained and provided to the user in the form of software product(s), software application(s), machine-readable program code tool(s), or any other product(s) or device(s), which may be used to achieve any, some, or all of the results, calculations, and/or numerical methods described herein.

[001242] In one embodiment of the invention, the user can set up work locally or in the cloud. In a cloud example, a user may use and/or inherit work related information from the cloud to be retrieved from or placed on the user's device and/or machine (eg, a 14416 computer associated with a 14412 welding machine). By setting a job on a device or using the Cloud, the 14416 device can be enabled to inherit work-related information from the cloud to be placed on the 14416 device and/or machine. In another embodiment of the invention, uLog provides a single point data integrity service. In addition, uCloud features also provide storage and retrieval of machine-to-cloud (M2O) and cloud-to-machine (O2M) data.

[001243] In one embodiment of the invention, a centralized location can be used where detailed job client data can be entered, processed and stored, or automatically retrieved using uLog. uLog can also take a distributed approach to managing and processing data. uLog can create and attach job-specific parameter files to be applied to the running job by authorized representatives with assigned user privilege levels. This job-related information can be inherited by a designated user and placed on 14416 computers associated with 14412 welding machines (cloud to machine, "O2M"). Changes made to job-related information are collected from the 14416 computers associated with the 14412 welding machines and synced back to the (machine-to-cloud, "M2O") cloud (i.e., 14432 cloud server). The 14432 cloud server provides a single point where some or all of the data is processed by uLog.

[001244] uLog can process, record, analyze and use data from one, more or all of the following types of equipment: welding machines, pipe bending equipment, pipe handling equipment, end preparation equipment, clamps, filling equipment and/or crushing equipment and/or systems of double connection, weighing equipment and/or systems, conveying equipment and/or systems, vessel equipment for laying pipelines and construction/control systems. uLog can also be an enterprise resource planning (ERP) system or work with an ERP system.

[001245] uLog may use and/or process data received from one or more of the following types of welding equipment. For example, such welding equipment may include, but is not limited to: manual welding equipment, automatic welding equipment, external welding machine, internal welding machine, single welding head welding machine, dual welding head welding machine, multiple welding head welding machine, high-performance welding systems, supervision system, internal supervision system, external supervision system.

[001246] uLog may use and/or process data obtained from one or more of the following types of pipe bending equipment: tube benders, wedges, hydraulic wedges, dowel mandrels, hydraulic plug mandrels, pneumatic mandrels, pneumatic wedge mandrels. uLog may use and/or process data from one or more of the following types of pipe handling equipment: DECKHAND® equipment (CRC-Evans, Houston, TX), vehicles, construction machinery and equipment adapted to produce data for use or processing. uLog may use and/or process data obtained from one or more of the following types of equipment: bending sets and dies, angle measuring equipment and devices, compressors, cradles, booms and/or supports, degaussing equipment, tires, wheels and rims.

[001247] uLog may use and/or process data received from one or more of the following types of equipment: final preparation station for increasing the area at the pipe bevel, line station for aligning the pipe and external weld, station for applying the last layer of filling for processing external welds, internal welding station for internal welding, power trailer or containers with diesel generator and welding rectifiers, pipe skids and supports for pipe transfer from station to station, internal pneumatic line clamps and pipe lining machines, arc welding machines and technological equipment.

[001248] uLog may also use and/or process data obtained from one or more of the following types of equipment: Vessel laying equipment, pipe handling equipment, dual connection equipment, co-coating equipment, coating equipment, surface equipment , marine equipment, deep water equipment, shallow water equipment, roller units, conveyors, pipe transport equipment, support frames, support blocks, roller modules, roller modules of the longitudinal conveyor, pipe elevators, pipe supports, roller type pipe supports ( PSA and PSF), Pipe Carts, PTC-V Pipe Carts, Pipe Back Supports, Adjustable Pipe Supports, SPSA Roller Type Back Pipe Supports, TPSA Track Type Pipe Supports, Cross Conveyors, Conveyors with step conveyor and cross conveyors TV-CW.

[001249] uLog may use and/or process data obtained from any one or more of the following types of processes and methods: welding, pipe welding, pipeline welding, coating, co-coating, pipeline site weld isolation, supervision, quality control , non-destructive testing, heat treatment, management, offshore management, onshore management, managed services, welding engineering, onshore pipe depot management and microalloying.

[001250] In one embodiment of the invention, uLog can be used to deploy daily job statistics from the cloud and from a mobile device. The creation of PQR and/or WPS and/or daily reports may be done from a mobile platform and/or in the cloud or by other means. Analytics collected cloud and mobile device data provide feedback to the management system to improve quality and predict defects. In one embodiment of the invention, uLog provides integrated pipe joint marking synchronized with data logs. uLog can also use single point acquisition of data logs, provide information about machine setup and software versions.

[001251] uLog can also automatically report machine status errors, automatically stamp the job location in job records, and perform synchronized retrieval of job-related parameter change records from all users for a given project. In addition, uLog can also generate a project-related consolidated report for clients from a single point.

[001252] In Fig. 155 shows an example GUI for the Real-time Log screen of a cloud-based universal data logging (uLog) application showing voltages versus time at a single welding station in accordance with an embodiment of the present invention. In one embodiment of the invention, uLog performs a centralized collection of data from all welding pipe handling machines, coating machines, and all types of data related to such machines and activities. A current summary of welding, coating and inspection activities in real time can be created. The table lists various parameters, including: event number, time stamp, zone identification, inclination of the welder or welding system in degrees, welding machine travel speed, applied voltage or voltage applied to the welding wire, applied current (A) or current applied to the welding wire, wire feed speed or welding wire speed, etc. For example, various parameters including welding wire feed speed (ie, welding wire speed) and welding device speed (travel speed) and other parameters may be presented in the form of tables and/or graphs. In addition, the voltage applied to the welding wire may also be displayed in a table and/or as a graph as a function of time.

[001253] Optionally, uLog may support electronic signatures for PQR/WPS documents. Optionally, uLog can version and rollback system settings. In one embodiment of the invention, uLog also has functionality to deploy daily job statistics from cloud and/or mobile devices. For a non-limiting example, uLog may perform data management and may provide user reports on the number of welds completed in a given period of time (e.g., per hour, in one day, in a week, etc.) and may report the amount of material consumed (e.g., welding consumable) used for a certain period of time (e.g. per hour, for one day...) or other period of time. Job and error reports can also be generated using uLog.

[001254] In one embodiment of the invention, uLog may send an email and/or SMS (text message) or other notification to the appropriate authorities. uLog can also be used for financial functions, accounting auditing, time tracking, and other management tasks. For example, uLog can bill a customer on time. In one embodiment of the invention, the invoice may be created based on the number of welds, or based on the consumables that have been used and/or the amount of waste. uLog provides a scoring system and supports efficient invoicing and accounting for pipeline welding projects.

[001255] uLog can also be used to automatically replenish materials and/or equipment and/or other resources or inventory during the course of a project. The many and varied features of uLog described in this document can reduce job disruption, downtime, waste, and other negative impacts during construction.

[001256] In Fig. Figure 156 shows an example GUI for the Get Log screen of the cloud-based Universal Data Logging (uLog) application showing welding data parameters including weld event type, time, zone, seam movement speed (welding system movement speed), wire feed movement speed (welding speed). wire) in accordance with an embodiment of the present invention. On FIG. 156 shows the various parameters that are reported in the table, including: weld identification or type number, event number, timestamp, zone identification, inclination of the welder or welding system in degrees, travel speed of the welder, applied voltage or voltage applied to the welding wire, applied current (A) or current applied to the welding wire and wire feed speed (welding wire speed). In one embodiment of the invention, uLog can automatically stamp the location of a job in job records. In other examples, data logs may be time-stamped and time zones may be displayed, as shown in the table shown in FIG. 156. Timestamps may be synchronized with GPS and/or based on data available and/or entered into uLog so that the logs reflect the time zone in which they were recorded.

[001257] In Fig. 157 shows an example GUI for a cloud-based universal data logging (uLog) application summary report screen displaying various welding parameters, including welding time, welding station ID, welding arc voltage, and so on. according to an embodiment of the present invention. In one embodiment of the invention, uLog can create and/or generate PQR and/or WPS and/or summary reports and/or daily reports, all performed on a mobile platform and in the cloud. PQR, WPS, summary and daily reports can be created manually or generated automatically. uLog can generate one, several, or all of these types of reports on a schedule, on a given occasion, or at the same time. uLog provides the benefit of handling shared and consistent data. Collected identical data can be used to create reports in the same or different locations and/or output devices.

[001258] Reporting rules may be set on uLog, which may be configurable. In one embodiment of the invention, critical data for a given project may be synchronized to the cloud. uLog provides for the creation of a qualifying project linker to be sent to the user and/or the user's client and/or other recipient at the end of the qualification process with electronic signatures for approval. uLog reduces the time and expense of creating these reports and approved documents.

[001259] FIG. 158 shows an example of a GUI for the Save Data to Log screen of a cloud-based universal data logging (uLog) application displaying various icons according to an embodiment of the present invention. uLog provides unlimited data storage services. The pipeline construction industry is widespread throughout the world and its projects can be geographically dispersed. In addition, the construction of the pipeline can take place in adverse environmental conditions and in harsh climates. uLog allows you to store and protect data anywhere the user and/or equipment may be. The data may also be synchronized or otherwise processed. For example, data from a job, logbook, welding station, welding parameter, reports, and job locations can be stored in the cloud. In one embodiment of the invention, location data may be stored in addition to technical and/or control data.

[001260] In Fig. 159 shows an example GUI for the Analytics screen of a cloud-based universal data logging (uLog) application showing two icons for selecting the type of analysis to be performed (eg, trend, moving average) in accordance with an embodiment of the present invention. In one embodiment of the invention, uLog analytics can process and provide data trends, moving averages, and/or any type of data processing required by the user. In one embodiment, uLog may have cloud data logging, reporting, and analytics systems. For example, analytics can be performed based on the collected data to provide feedback to the control system to improve the quality and prediction of defects in welds and/or construction equipment, activities and manufacturing operations. In one embodiment of the invention, data may be collected using the cloud and/or one or more mobile devices. In one embodiment of the invention, uLog supports synchronized retrieval of job related parameter change notes from all users on a given project. In another embodiment of the invention, uLog can monitor, analyze and report on ongoing activity in real time and provide current summary data and summary report(s) for welding, coating and supervision operations. The uLog system can version and rollback system settings. The uLog system also provides one-stop access to data logs, machine setup information, and software version information. In yet another embodiment of the invention, an integrated pipe joint marking can be obtained and synchronized with the data logs.

[001261] In Fig. Figure 160 shows an example GUI for the Weld Parameters screen of a cloud-based universal data logging (uLog) application, showing two different mechanisms for selecting the type of function to perform (e.g., Get Weld Parameters (WT), Set Weld Parameters (WL), View WL Weld Parameters ...) in accordance with an embodiment of the present invention. In one embodiment of the invention, the uLog cloud logging system can perform any of the following actions and/or processes: get welding parameters, set welding parameters, view and process welding parameter notes, view and process welding parameters passing, and roll back welding parameters. In one embodiment, the uLog may contain any, several, or all of the following: Pipeline miles reward(s) functionality, pipeline miles functionality, uLog functionality, M2O functionality, and O2M functionality.

[001262] The welder or welding technician may waste welding wire if the welder changes the spool too soon before most of the wire is used up. In addition, the welding process can be interrupted if the spool runs out of wire during the welding process, resulting in downtime and the need to repair the defect. One way to solve these problems in the present embodiment is to use the speed of the wire feed motor to determine the wire feed speed and therefore determine the length of the welding wire that is consumed over a certain period of time. However, this method may contain errors due to wire slippage on the wire feed motor wheel or an incorrect starting weight. As a result, determining wire length based on motor speed may be inaccurate. In addition, an incorrect initial weight may cause the user to believe that there is enough wire in the spool to complete the weld (if the initial or initial weight exceeds, for example, the estimate), when in fact there is not enough wire left in the spool to complete the weld. welding. To overcome this shortcoming, a device is used to measure the mass of a coil of wire in real time, while the motor is pulling the welding wire. By measuring the weight of the spool, the user or welder can determine before welding if there is enough wire left in the spool to complete the weld. As a result, the weight of the wire can be determined at any time, which greatly eliminates uncertainty due to slippage or an unknown initial mass of the spool. In addition, the weight can be compared to the wire feed speed to determine if the wire is being fed at a given speed.

[001263] In Fig. 161A schematically depicts an example of a spool 14480 that is configured to hold a welding wire in accordance with an embodiment of the present invention. On FIG. 161B is a schematic side view of the hub sensor 14482, which is configured to measure the mass of the coil 14480 according to an embodiment of the present invention. On FIG. 161C is another side view of the hub sensor showing the location of the sensor elements or strain gauges/gauges 14484 for measuring strain under load when the coil 14480 is mounted on the hub 14482 in accordance with an embodiment of the present invention. As shown in FIG. 161B, when the coil is mounted on the hub 14482, the weight of the coil will exert a force on the axle 14482A of the hub 14482, which in turn will deform the side portion of the hub 14482B. Strain sensors 14484 are provided on the side of the hub 14482B to detect strain due to the weight of the spool. Examples of strain gauges that can be used to measure strain are piezoelectric elements. Strain sensors 14484 convert the strain force into a measurable stress. Therefore, by measuring the voltage, the weight of the coil 14482 can be determined. In one embodiment, a temperature sensor (not shown) can be provided in the hub, positioned to obtain hub temperature data to apply corrections to strain sensor measurements over a wide range of temperatures.

[001264] In Fig. 162 is a schematic diagram in which the welding wire 14486 in the spool 14480 mounted on the hub 14482 is pulled by the wire propulsion system 14490 14482 to a welding device (not shown) in accordance with an embodiment of the present invention. The welding wire 14486 is drawn by the propulsion system 14490. In one embodiment, the speed of rotation of the propulsion system (used to determine the wire feed speed) can be measured by the sensor 14492. minute or RPM, as measured by the 14492 gauge) to achieve the desired wire feed speed to the welder. In another embodiment of the invention, the rotation of the propulsion system can be changed in accordance with the desired wire delivery speed (wire feed speed) measured by the sensor 14492. The propulsion system 14490 is configured to feed or supply the welding wire 14486 to the welding device 14500 to weld the workpiece 144101 ( e.g. pipes, etc.). The speed of the welding device 14500 is measured by the speed sensor 14502. The 14502 speed sensor is also configured to measure various welding parameters or welding data.

[001265] In Fig. 164A and 164B show enlarged cross sections of a propulsion system 14490 according to an embodiment of the present invention. As shown, the propulsion system includes a motor 14491 and a feed wheel 14493. The motor 14491 engages the feed wheel 14493 so as to rotate the feed wheel 14493. The propulsion system 14490 further includes a pressure roller 14495 that engages the feed wheel 14493. A tension spring 14497 is provided to bias the pinch roller 14495 against the feed wheel 14493. The welding wire 14486 is located between the feed wheel 14493 and the pinch roller 14495. Therefore, the pinch roller 14495 presses on the wire 14486 to bring the wire 14486 into contact with the feed wheel 14493. As a result, the rotation of the feed wheel 14493 and pinch roller 14495, as shown by the arrows in FIG. 164B will translate, in theory, to the linear movement of wire 14486, as indicated by the arrow. In one embodiment, the feed wheel 14493 is provided with teeth so as to grip the wire 14486 by friction and cause the wire 14486 to move. However, there may be situations where the wire 14486 is not completely captured by the feed wheel 14493. In this case, the wire 14486 may slip because although the feed wheel 14493 rotates, this rotation of the feed wheel 14493 does not translate into an accurate linear movement of the wire 14486. For example, this can occur when the teeth on the 14493 feed wheel are worn (thus not providing enough friction to grip the 14486 wire), or when the 14495 pinch roller is worn (while not applying enough pressure or force on the 14486 wire to force the 14486 wire to the feed wheel 14493), or when the tension spring 14497 loses its original tension (thus causing pinch roller 14495 to not apply enough pressure or force to wire 14486) or when the nut 14499 holding feed wheel 14493 loosens (thus causing that the feed wheel is not grasping wire 14486), or any combination of spoken. As shown in FIG. 164A, the propulsion system 14490 includes a rotation speed sensor 14492 that is configured and arranged to sense the rotation speed of the engine 14491. An output device 14498 is provided for input and output of data to and from the propulsion system 14490, data includes the speed of the motor 14491. The data received from the output device 14498 is sent to the computer 14416 associated with the welding station 14410.

[001266] FIG. 165 is a welding system configuration diagram showing the relationships of various system components, in accordance with an embodiment of the present invention. As shown in FIG. 165, the rotational speed of the propulsion system 14490 is measured by the rotation speed sensor (RPM sensor) 14492. In addition, the weight of the welding wire spool 14480 is measured by the weight sensor(s) 14484 in the hub sensor 14482. The speed of the welding device 14500 is measured by the speed sensor 14502. All parameters or data measured by rotation speed sensor 14492, weight sensor 14483, and speed sensor 14502 are entered into computer 14416 at welding station 14410. In one embodiment, computer 14416 may be controlled by intermediate computer 14450. Intermediate computer 14450 may be a wireless device, such like tablet, mobile device, smartphone, laptop, etc. Therefore, intermediate computer 14450 can access data on computer 14416, including data from RPM sensor 14492, weight sensor 14484, and speed sensor 14502. Intermediate computer 14450 further communicates (eg, wirelessly) with cloud server 14432 where data from computer 14416 can be stored and/or further processed. In one embodiment of the present invention, no intermediate computer is used. In this case, the computer 14416 is directly connected (for example, using wireless technology) to the cloud server 14432.

[001267] As noted in the above paragraphs, due to potential slippage, measuring the speed of the propulsion system (for example, the speed of the feed wheel 14493) in some embodiments may not be sufficient to provide an accurate amount of welding wire that is used or consumed by the welding machine or system. Indeed, even if the rotation of the feed wheel 14493 is accurately measured, the rotation of the wheel will be translated, theoretically, into a displacement and therefore into a certain length. However, due to slippage, the wire does not move, and therefore the length determined based on the rotation or rotation speed of the wheel does not correspond to the actual length of the wire. As a result, the weight of the welding wire spool can also be measured. In one embodiment of the invention, the weight of a new and unused spool of wire is about 15 kg (15,000 g). In one embodiment of the invention, the weight of the coil of wire is measured with an accuracy of about 100 g per 15,000 g, that is, with an accuracy of about 0.7%. Therefore, weight provides a relatively good measurement for determining the amount of welding wire left in the spool. In one embodiment of the invention, the weight of the coil is obtained or measured periodically and recorded with a time stamp and reported to uLog each time the rotation of the coil stops. An indicator, such as a buzzer or flashing light or the like, may indicate to the welder that it is time to reload another spool. In addition, in one embodiment of the invention, the welding machine cannot start the welding process in such a situation. The indicator may indicate a weight threshold at which a complete weld cannot be completed.

[001268] In one embodiment, RF modules are further provided to read the serial number of the coil, the mass of the coil from the manufacturer, the type of coil, the name of the project, and any details that are placed on the RF tag mounted on the coil. This data can be transferred to the cloud via uLog with any additional details. If an old spool is reused, the system compares the serial number to a database of used spools and retrieves the last available weight from the cloud, comparing it to the new pre-work weight reading. A buzzer or indicator light may be present on the system to indicate to the operator that detailed RF tag data has been read and transmitted via CAN. Using the RF system will eliminate any manual accounting work required to keep track of the number of spools in use, their serial numbers, and further identify the workstations on which they are used. In the event that a welding wire with the wrong composition/diameter is shipped, the system can identify this by the properties of the RF tag, alerting the operator to this deviation. This might go unnoticed if the system were completely manual.

[001269] In one embodiment of the invention, the difference DW between the mass W1 measured at time T1 and the mass W2 measured at a later time T2 can be calculated. The difference in weight DW (where DW=W1-W2) corresponds to the weight of the wire that is consumed in the welding process. This difference in weight DW can be compared to the theoretical weight of TW. The theoretical weight TW can be obtained using the motor rotation speed R or the wire linear speed S (the linear speed S depends on the rotation speed R). The theoretical weight TW can be calculated using the following equation (1).

TW=(T2-T1) x S x (Wire diameter) 2 x (Wire material density) x π/4 (1)

[001270] Assuming no slippage, the theoretical weight TW should be equal to the measured weight DW. On the other hand, if slip occurred during the process between time T1 and time T2, the theoretical mass TW will be larger than the measured mass DW. In this case, the ratio R between the theoretical mass TW and the measured mass DW is greater than 1 (R=TW/DW> 1) and/or the difference Δ between the theoretical mass TW and the measured mass DW is greater than zero (Δ=TW - DW> 0) . As a result, if after a certain period of time or number of measurements it is noted that the difference between the measured mass and the theoretical/calculated mass persists, the speed of the propulsion system 14490 can be adjusted or compensated to have a calculated/theoretical mass substantially equal to the measured mass. Therefore, the measured mass is compared with the theoretical mass (determined from the wire feed speed) to determine if the wire is being fed at the expected wire feed speed. In one embodiment of the invention, this determination can be done locally on the side of the welder or using the uLog system on the cloud server 14432.

[001271] FIG. 163 is a flowchart showing the process of comparing the measured mass and the theoretical mass determined based on the wire feed speed, according to an embodiment of the present invention. As can be understood from the above points, the process starts by measuring the first mass W1 of the wire spool for the first time (T1) in step S10. This method further includes measuring the second coil mass W2 for the second time T2 after some time elapsed from time T1 in step S12 (T2 > T1). This process also includes calculating the difference between the first measured mass W1 and the second measured mass at time T2 in step S14. The process includes calculating the theoretical mass based on the wire feed speed in step S16. In step S18, the theoretical mass based on the wire feed speed is compared with the calculated mass difference, and if the theoretical mass is greater than or less than the calculated mass difference, in step S18, the speed of the wire-pulling propulsion system is adjusted in step S20. The process is repeated after one more time step, after the speed of the propulsion system has been adjusted. If the theoretical mass matches the calculated mass difference, then the process is also repeated after one more time step without adjusting the speed of the propulsion system. This process is repeated with multiple time steps to control and/or correct for any possible slippage of the 14490 propulsion system.

[001272] This process may be implemented locally by the uLog system on the 14416 computer associated with the 14410 welding station, or implemented by the uLog system on the 14432 cloud server, or implemented by the uLog system on the 14450 intermediate computer described in the previous paragraphs.

[001273] In one embodiment of the invention, it may be desirable to monitor the use of wire at different welding stations 14410 to evaluate the overall efficiency of the welding system. For example, this will allow a predictive indication of the amount of spool required for large projects based on previous knowledge. For example, coil usage data can be uploaded to the uLog system, stored and processed by the 14432 cloud server. For example, each of the 14410 welding stations can upload coil usage data to the uLog system on the cloud server using the previously described network configurations and based on historical usage data. number of wire spools and using a Machine Learning Algorithm (MLA), the uLog system can predict the average future use of wire spools (or the amount of welding wire). For example, based on usage patterns for some welding parameters, uLog can determine the threshold at which a full weld cannot be completed. As a result, the uLog system can alert the welder with an indicator (e.g. buzzer, flashing light, etc.) that the wire in the spool is depleted and that a full weld cannot be completed based on a theoretical threshold determined by a machine learning algorithm. For example, a cloud server 14432 running 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 full weld cannot be completed based on a theoretical threshold determined using machine learning algorithm.

[001274] In another embodiment of the invention, when there is a discrepancy between the theoretical mass determined based on the wire feed speed (measured by the sensor 14492) and the measured mass (W2-W1), where W2 and W1 are measured by the weight sensors 14484, instead of adjusting the speed of the propulsion system 14490, the speed of the welding device 14500 (or travel speed) can be adjusted according to the speed V obtained from the measured mass W2-W1.

[001275] As follows from the paragraphs above, a welding system is provided that includes a plurality of welding stations 14410. Each welding station 14410 includes a welding station computer 14416 and a welding system 14412 communicating with the welding station computer 14416. Each welding station 14410 includes one or more sensors 14492, 14502, one or more sensors 14492, 14502, which are configured to measure welding data, including wire feed speed data (measured by speed sensor 14492), as shown, for example, in FIG. 162. The system further comprises a plurality of wireless devices 14450 communicating with one or more welding station computers to receive welding data, including measured wire feed speed data. The system also includes a cloud server 14432 that communicates with wireless devices 14450, the cloud server 14432 is configured to process welding data, including wire feed speed data, and is configured to determine the amount of consumable welding material used by multiple welding stations 14410 in within a given period of time. The cloud server 14432 is configured to transmit to one or more wireless devices data on the amount of weld consumed.

[001276] In one embodiment of the invention, the welding data further includes data on the speed of movement of the welding system. In one embodiment of the invention, the wireless devices 14450 are configured to additionally receive welding system movement speed data. In one embodiment of the invention, the cloud server 14432 is further configured to process the speed data.

[001277] As can be understood from the above paragraphs, a welding system is also provided, comprising a welding station, the welding station comprising a welding station computer, and a welding system communicating with the welding station computer. The welding system includes a welding material supply device 14480, a welding device 14500, and a supply device propulsion unit 14490 that moves the welding material 14486 in the welding material supply device 14480 to the welding device. The welding system further includes a weighing device 14482 operably coupled to the welding station computer 14416 and configured to measure the mass of the welding consumable feeder 14480 and to transmit the weight data of the welding consumable feeder 14480 to the welding station computer 14416 in the form of weight data, and a sensor 14492 operably coupled to the feeder motor 14490 and the welding station computer 14416 so as to transmit speed data of the feeder motor 14490 to the welding station computer 14416 as speed data. The welding station computer 14416 is operatively coupled to the feeder motor 14490 and configured to control the speed of the motor 14490 based on weight data.

[001278] As follows from the above paragraphs, a welding system is provided comprising a plurality of welding stations 14410, each welding station 14410 comprising a welding station computer 14416 and a welding system 14500 communicating with the welding station computer 14416, each welding station 14410 comprising one or more sensors 14492, one or more sensors 14492 are configured to measure welding data, including wire feed speed data. The welding system also includes a plurality of wireless devices 14450 communicating with one or more welding station computers 14416 to receive welding data, including measured wire feed speed data. Each welding station computer 14416 is configured to process welding data, including wire feed speed data, for the welding system 14500 communicating with it. The welding station computer 14416 is further configured to determine the amount of consumable welding consumable used by the welding system 14500 over a predetermined period of time and generate consumption data based thereon.

[001279] In one embodiment, each welding station 14410 further includes a motor 14490 for moving the wire feed at a wire feed speed, where the wire feed speed data is determined based on the speed of the motor 14490, each welding station 14410 further comprising a weight sensor 14484 , which determines the reduction in the weight of the consumable material. The weight sensor 14484 provides output signals to the welding station computer 14416. The 14416 welding station computer uses the output signals to determine consumption data. In one embodiment, the welding station computer 14416 uses the consumption data to control the speed of the motor 14490. In one embodiment, the system further includes a cloud server 14432 to obtain consumption data along with wire feed speed data to correlate the consumption data with the data. wire feed speed.

[001280] In Fig. 166 shows an overview of a system that can be used with a wide variety of testing and surveillance equipment, tools, processes, and methods. In the general example in FIG. 166, conduit 16610 may be constructed at the behest of owner 16670 by joining multiple pipe segments together with circumferential welds. This design can be done by the owner company, a third party, or another party. Within the parameters of quality management, non-destructive testing and supervision can be carried out during the construction process to ensure that the pipeline does not fail when performing its specific service. To achieve this goal, for example, one or more welds, such as circumferential welds, may be inspected and tested by one or more testing means, processes, or methods, such as ultrasonic testing or radiographic testing.

[001281] For example, field worker 16650 may place a test device, such as image processor 16620 on a pipeline, in close proximity to each of the circumferential welds. The test device, which may be an image processing device, may collect data related to the internal structure of the circumferential weld for analysis. This data may be any type of data required for analysis by an inspector or other person, or required for any computer processing. For example, if an ultrasonic inspection method or an X-ray inspection method, or both, is used, one or more signals may be transmitted to a pipeline and/or a weld, such as a girth weld, and data and information in response to such signals may be collected, processed, and be analyzed by one or more computers and/or one or more people.

[001282] In one embodiment, the signal responses may be received, processed, digitized, compressed, transmitted, and reported (16625) to a separate device or receiver (or which may be separated from the test device that generates the signal(s) and/or receives response(s), and which may be located at or at a remote facility 16630. In this document, a device, facility, or computer that receives data from the test unit and that is separate or can be separated from the test unit, will be referred to as the "remote site "". The remote object broadly covers any device, object or person, or anything else that can receive, use, perceive, process or transform any data received from the test block. The broad scope of this term may vary from a storage device such as memory card, up to distributed control system, cloud process litter, mobile phone, smart phone, computer, digital processor, receiver, functionality, plant-level control system or remote site, or remote centralized processing, or other device, person, or location. In one embodiment of the invention, the remote entity may be a remote installation, which may be a center for computing, processing, and monitoring. A remote entity, such as a remote installation, may be connected to a network, a wireless network, cloud-based, hybrid cloud-based, or located on a physical object or associated with a person, company, functionality, use, entity, or other. In one embodiment of the invention, the remote object may be owned and/or controlled by any desired person, customer, company, organization, inspector, third party, operator, employee, or others.

[001283] In one embodiment, a remote entity, such as a remote facility, may use a computer to process test and/or inspection data, such as compressed data, to determine the size, shape, location, and orientation of any defects present in the weld and /or pipe. The test data and/or control data or analytical results may be communicated (16635) to the control specialist 16640, who may verify the data or verify the analytical results, or otherwise use all or part of the data provided to the control specialist 16640. In this document, "test data" and "non-destructive testing data" are used interchangeably. As an example, the result or results verified by the inspection specialist can be reported (16645) to the field worker 16650. This provides support for defect elimination or management of defect repair processes for welds and pipelines. Optionally, verified results may be communicated to the Quality Assurance Inspector 16660 and the Owner Company 16670.

[001284] The technologies, processes, tools, and methods used herein may be distributed and used for testing and inspecting pipes. The equipment, processes and devices described in this document have applications far beyond welds.

[001285] In Fig. 167 shows an embodiment of the system that can be used with any of a wide variety of testing techniques and with many types of equipment. As shown in FIG. 167, in an embodiment of the invention, one or more girth welds can be tested. The girth welds 167110 that connect the pipelines 167100 together may be tested before the pipeline is put into service. One operator 167500 or multiple operators 167500 may move along a pipeline having one or more circumferential welds 167110. They may stop at each circumferential weld and use the imaging equipment 167200 to acquire images of the internal structure of one or more more of the girth welds 167110. The number of girth welds 167500 to be tested can vary from 1 to a very large number, for example up to 5 million.

[001286] The data and images obtained as a result of the check can be generated, processed, recorded, detected, digitized, compressed and transmitted on site or to a remote object, for example, a remote central object 167300. At a remote central object 167300, computer 167310 can process data and inspection images (which may be digital images or another image of data or set of data) to determine the size, shape, orientation and location of any imperfections present in the tested weld. By executing executable computer code using computer executable logic, the computer can also determine which defects are significant enough and/or large enough to have a significant impact on pipeline integrity. If the defect is identified by computer processing, one or more defects may be referred to the 167400 inspection specialist, who can check the presence and significance of computer-identified defects.

[001287] Alternatively, the inspector can directly view the data obtained from the inspection and infer the inspector's training and experience. Optionally, the inspector's conclusions can be verified by computer processing.

[001288] Verified results, both computer-generated and human-created, can then be communicated to field workers 167500 by computer means or by telephone so that welds can be repaired. The test results may also be sent to the 167600 Quality Assurance Inspector, the 167700 Pipeline Company, or other interested or intended party.

[001289] In one embodiment, the pipeline 167100 may be constructed at the behest of the owner company 167700 by joining a plurality of pipe segments 167120A, 167120B together with circumferential welds 167110. To ensure that the pipeline does not fail in service, it is desirable that the builder or others tested girth welds with non-destructive means. These tools may include magnetic particle testing, dye penetrant testing, ultrasonic testing, and x-ray radiography. Both ultrasonic inspection and X-ray radiography are data-intensive image processing methods.

[001290] Analytical work to evaluate test and/or control data requires one or more highly trained personnel 167400, 167520 and specialized imaging equipment 167200. The imaging equipment that may be used may have an emitter 167210, a receiver 167220, and analog digital (A/D) converter 167230. One or more field workers 167520 can transport the imaging equipment 167200 to the weld along the pipeline using a support truck 167530, or other vehicle.

[001291] The imaging equipment may be of any suitable type such as ultrasound or radiography.

[001292] With a segmented connection, field workers may place imaging equipment on or near the pipeline near circumferential weld 167110. The field worker may activate the imaging equipment. The radiating part can send a signal (167215) to the pipe segments and/or girth weld. The signal may be ultrasonic wave pulses in the case of ultrasonic testing, or may be x-rays in the case of x-ray radiography.

[001293] In the case of ultrasonic testing, ultrasonic pulses can reflect boundaries where the density of the circumferential weld 167110 changes. Metal-air boundaries produce the strongest reflections. The reflected pulses can be detected by the receiver. The receiver can measure the intensity of the reflected pulse (167222) and can generate an electronic signal proportional to the intensity of the reflected pulse. In one embodiment of the invention, the emitter and receiver may have multiple elements. Optionally, the emitter elements may be selectively activated to deliver an ultrasonic pulse at a specific location.

[001294] In the case of x-ray radiography, the x-ray intensity is attenuated by the material in the pipe segments and the circumferential weld. The receiver can measure the intensity of radiation that passes through the material (167224).

[001295] In one embodiment of the invention, the imaging equipment may be mounted on a motorized carriage that can move along the circumferential seam at a constant speed. The A/D converter can digitize the signal (167226) from the receiver and can compress the digitized data. The compressed image processing data and carriage location (167235) may be transmitted to the 167310 computer at a remote site, such as a 167300 remote installation. Communication may be via cable, movement of physical media, wireless, network, cloud, radio, or other means. .

[001296] In a non-limiting example, FIG. 167, on remote installation 167300, computer 167310 can analyze the data (167235). The analysis can be performed in one or more steps. For example, the computing module 167320 can identify signals (167222, 167224) that may indicate the presence of anomalies in the circumferential weld 167110. Abnormal signals (167325) can be transmitted to the AI module 167330. The AI module may be a computer running executable computer code, relational logic, and/or artificial intelligence programming. The AI module can determine the size, shape, orientation and location of defects (167335) that caused abnormal signals (167325). The AI module can execute executable computer code using rule-based logic to determine which defects are important to pipeline integrity and which need to be repaired and which do not. The computer 167310 can send data (167335) describing zero or more defects to a technician 167400, a quality assurance inspector 167600, the owner company 167700, and a representative of the operating personnel 167500 or others.

[001297] In one embodiment of the invention, the control specialist may choose to check (167215) data (167335) before they are transferred to the quality assurance inspector, the owner company, the representative of the operational personnel or others. The inspection technician may also change the defect identification from Major to Minor, or Minor to Major, or otherwise modify or annotate any results generated by computer or otherwise. Defect data (167335) that is associated with a major defect can be shared with the operations personnel representative 167500. The data can be shared with one or more field workers 167520. One or more field workers can note the location and size of significant defects on the weld(s) and /or on the pipeline (167525) for repair by the welder 167510 or others. Alternatively, the data may be transferred directly to the 167510 repair welder or others.

[001298] In Fig. 168 shows an embodiment of ultrasonic testing. As shown in FIG. 168, in an embodiment of the invention, one or more circumferential welds may be ultrasonically tested. The girth welds 168110 that connect the pipelines 168100 together can be tested before the pipeline is put into service. One operating personnel 168500 or multiple operating personnel 168500 may move along a pipeline having one or more circumferential welds 168110. They may stop at each circumferential weld and use ultrasonic inspection equipment 168200 to acquire images of the internal structure of the weld. These images may be digitized, compressed, and transmitted to a remote facility, such as a remote central site 168300. At the remote central site, a computer 168310 may process inspection data such as ultrasound, image, or image data to determine size, shape, orientation, and the location of any defects present in the tested weld. The number of 168110 girth welds tested can range from 168 to a very large number, for example up to 5 million.

[001299] By executing executable computer code using computer executable logic, the computer can also determine which defects are significant enough and/or large enough to have a significant impact on pipeline integrity. If the defect is identified by computer processing, one or more defects may be referred to the inspection specialist 168400, which may be an ultrasonic inspection specialist who can check the presence and significance of the computer detected defect.

[001300] Alternatively, the inspector can directly view the data obtained from the inspection and infer the inspector's training and experience. Optionally, the inspector's conclusions can be verified by computer processing.

[001301] The verified results, both computer-generated and human-created, can then be communicated to the operations personnel representative 168500 via computer means or by telephone so that the welds can be repaired. The test results may also be sent to the 168600 Quality Assurance Inspector, the 168700 Pipeline Company, or other interested or intended party.

[001302] In one embodiment of the invention shown in FIG. 168, conduit 168100 is constructed at the behest of owner company 168700 by joining multiple pipe segments 168120A, 168120B together with circumferential welds 168110. To ensure that the conduit does not fail in service, it is desirable that the circumferential welds be inspected by non-destructive testing. These tools may include magnetic particle testing, dye penetrant testing, ultrasonic testing, and x-ray radiography. Ultrasonic inspection is a data intensive image processing method. This requires one or more highly trained technicians 168400, 168520 and specialized imaging equipment 168200.

[001303] The imaging equipment may have an emitter 168210, a receiver 168220, and an analog-to-digital converter 168230. One or more field workers 168520 may transport the imaging equipment 168200 along the pipeline using a support truck 168530, or other vehicle. Field workers may place imaging equipment on the pipeline near the girth weld 168110, on the girth weld to be inspected. The field worker can activate the imaging equipment. The radiating part can send ultrasonic pulses (168215) to the pipe segments and the circumferential weld. Pulses can be sent in the range from 1 Hz to 20000 Hz. The frequency of the ultrasonic wave can vary from 0.5 MHz to 23 MHz. Ultrasonic pulses can reflect boundaries where density changes in the 168110 girth weld or pipe. Boundaries between metal and air give the strongest reflections. Reflected pulses can be detected by the receiver. The receiver measures the intensity of the reflected pulse (168222) and generates an electronic signal proportional to the intensity. The emitter and receiver may have several elements. Emitter elements can be selectively activated to deliver an ultrasonic pulse at a specific location.

[001304] The imaging equipment is mounted on a motor-driven carriage that can move along the annular seam at a constant speed. The A/D converter can digitize the signal (168226) from the receiver and can compress the digitized data. The compressed image processing data and carriage location (168235) may be transmitted to a remote entity, such as a computer 168310, which may optionally be located at a remote entity 168300. Communication may be via cable, movement of physical media, wireless, network, cloud technology, broadcast or other means.

[001305] In one embodiment of the invention shown in FIG. 168, on remote installation 168300, computer 168310 can analyze the data (168235). The analysis can be carried out in stages. Computing module 168320 can identify signals (168222) that may indicate the presence of anomalies in the circumferential weld 168110. Abnormal signals (168325) are reported to module 168330 AI. The AI module can determine the size, shape, orientation and location of defects (168335) that caused abnormal signals (168325). The AI module can determine which defects are significant to pipeline integrity and need to be repaired. The 168310 computer sends data (168335) describing zero or more defects to the 168400 technician, 168600 quality assurance inspector, 168700 owner company, 168500 operations personnel representative, or others.

[001306] Optionally, the control technician may directly acquire data and perform analysis, separate from the AI. Optionally, in such a case, the inspection specialist can use AI to verify or confirm the results of the technical inspection.

[001307] Optionally, the control specialist may choose to check (168405) data (168335) before they are transferred to the quality assurance inspector, the owner company, the representative of the operational personnel, or others. The inspection technician may also change the defect identification from Major to Minor, or from Minor to Major.

[001308] Defect data (168335) that is associated with a major defect may be communicated to an operations personnel representative 168500. The data may be conveyed to one or more field workers 168520. One or more field workers may note the location and size of major defects in the pipeline (168525 ) for later repair by the 168510 welder. Alternatively, the data can be transferred directly to the 168510 repair welder.

[001309] In Fig. 169 shows a variant of the implementation of x-ray control. As shown in FIG. 169, in an embodiment of the invention, one or more circumferential welds may be radiographically inspected. The girth welds 169110 that connect the pipelines 169100 together can be tested before the pipeline is put into service. One operating personnel 169500 or multiple operating personnel 169500 may move along a pipeline having one or more circumferential welds 169110. They may stop at each circumferential weld 169110 and use X-ray equipment 169200 to collect data and/or image the internal structure of each girth weld 169110.

[001310] Inspection data and/or images may be digitized, compressed, and transmitted to a remote site, such as a remote central site 169300. At the remote central site, computer 169310 may process inspection data, such as ultrasound data, image data, or images to determine the size, shape, orientation and location of any defects present in the tested weld. The number of 169110 girth welds tested can range from 1 to a very large number, for example up to 5 million.

[001311] By executing executable computer code using computer executable logic, the computer can also determine which defects are significant enough and/or large enough to have a significant impact on pipeline integrity. If a defect is identified by computer processing, one or more defects may be referred to an inspection specialist 169400, which may be a radiographic inspection specialist, who can check the presence and significance of the computer detected defect.

[001312] Alternatively, the inspector can directly view the data obtained from the inspection and draw a conclusion about the experience of the inspector. Optionally, the inspector's conclusions can be verified by computer processing.

[001313] Verified results, both computer-generated and human-created, can then be communicated to 169500 field workers by computer means or by telephone so that welds can be repaired. The test results may also be sent to the 169600 Quality Assurance Inspector, the 169700 Pipeline Company, or other interested or intended party.

[001314] In one embodiment of the invention, as shown in FIG. 169, conduit 169100 may be constructed at the behest of owner company 169700 by joining multiple pipe segments 169120A, 169120B together with girth welds 169110. . These tools may include magnetic particle testing, dye penetrant testing, ultrasonic testing, and x-ray radiography. Both ultrasonic inspection and X-ray radiography are data-intensive image processing methods. They require one or more highly trained technicians 169400, 169520 and specialized imaging equipment 169200. The imaging equipment may include an emitter 169210, a receiver 169220, and an analog-to-digital converter 169230. One or more field workers 169520 may transport the imaging equipment 169200 along the pipeline using a support truck 169530. At each segment connection, field workers can place imaging equipment on or near the pipeline near circumferential weld 169110. A field worker can activate the imaging equipment. The radiating part can send X-rays (169215) to the pipe segments and the circumferential weld. The X-ray intensity can be attenuated by the material in the pipe segments and girth weld. The receiver can measure the intensity of radiation that passes through the material (169224).

[001315] The imaging equipment may be mounted on a motor driven carriage that can move along the annular seam at a constant speed. The A/D converter can digitize the 169226 signal from the receiver and can compress the digitized data. The compressed image data and the location of the carriage (169235) may be transmitted to the computer 169310 at the remote site 169300. Communication may be via cable, movement of physical media, or radio transmission.

[001316] In the example shown in FIG. 169, on remote installation 169300, computer 169310 can analyze the data (169235). The analysis can be carried out in stages. Computing module 169320 can identify signals (169224) that may indicate the presence of anomalies in the circumferential weld 169110. Abnormal signals (169325) can be transmitted to module 169330 AI. The AI module can determine the size, shape, orientation and location of defects (169335) that caused abnormal signals (169325). The AI module can determine which defects are significant to pipeline integrity and need to be repaired. Optionally, these steps may be conducted by a control specialist based on test and/or control data with or without AI support.

[001317] In one embodiment of the invention shown in FIG. 169, the computer 169310 can send data (169335) describing zero or more defects to a technician 169400, a quality assurance inspector 169600, a company owner 169700, and a representative of operations personnel 169500, or others. The control specialist can choose to check (169405) the data (169335) before they are transferred to the quality assurance inspector, the owner company, the representative of the operating personnel or others. The inspection technician may also change the defect identification from Major to Minor, or from Minor to Major.

[001318] Defect data (169335) that is associated with a major defect can be communicated to operations personnel representative 169500.

[001319] Data can be transferred to one or more field workers 169520. One or more field workers can mark the location and size of significant defects on the pipeline (169525) for subsequent repair by a welder 169510. Alternatively, data can be transferred directly to a repair welder 169510 .

[001320] In one embodiment, the computer system may include a first device having a processor that processes pipeline construction data, where the first device transfers the pipeline construction data to a cloud storage device and the pipeline construction data is processed by the cloud processor.

[001321] In one embodiment, the pipeline construction data includes welding conditions data, pipe handling data, coating data, inspection data, or other data.

[001322] In one embodiment, the first apparatus comprises welding station equipment, pipeline welding expansion process equipment, an automatic welding tool, a welding monitoring system, a monitoring system, or other device.

[001323] In one embodiment of the invention, the first data may be transmitted from the first device to the second device, and the first data contains data about the construction of the pipeline. The first data can be processed by cloud network facilities.

[001324] In one embodiment, the first data (transmitted from the first device to the second device) may comprise weld data, pipe handling data, coating data, control data, control data, or other data.

[001325] In one embodiment, the welding hardware computer program product may comprise computer-readable program code means that provide welding conditions data to a computer storage device; computer-readable program code means that provide to a storage device data from a data set containing pipeline data; and computer-readable program code means that process the welding condition data and pipeline data to provide an output recording.

[001326] In one embodiment, the welding hardware computer software product may comprise rule-based logic executable code for processing welding data using the welding hardware code, rule-based logic executable code for processing welding data by the welding software. control code, an executable rule-based logic program code used to process welding data using a control program code or a quality control program code, or other executable program code.

[001327] In one embodiment, the welding system may comprise a plurality of welding stations, each welding station comprising a welding station computer and a welding system communicating with the welding station computer, where each welding station comprises one or more sensors and the one or more sensors are configured with the ability to measure welding data, including wire feed speed data. The welding system may include a plurality of wireless devices communicating with one or more welding station computers to receive welding data, including measured wire feed data; and a cloud server that communicates with wireless devices. The cloud server is configured to process welding data containing wire feed speed data and is configured to determine the amount of consumable welding material used by a plurality of welding stations during a predetermined period of time. The cloud server is configured to transmit data on the amount of welding material consumed to one or more wireless devices.

[001328] In one embodiment, the welding system may include an orbital welder. As an example, an orbital welder may comprise a clockwise rotation (CW) and a counterclockwise rotation (CCW) welding system.

[001329] In one embodiment of the invention, the measured welding data may additionally contain data on the speed of movement of the welding system. In one embodiment of the invention, a plurality of wireless devices are configured to additionally receive data on the speed of movement of the welding system. In one embodiment of the invention, the cloud server is further configured to process the speed data.

[001330] In one embodiment, if the current in the welding system is high, the welding station computer instructs the welding system to slow down the speed of the welding system or controls the position of the welding head in the welding system.

[001331] In one embodiment of the invention, the welding system may include a welding station. The welding station may include a welding station computer and a welding system communicating with the welding station computer. The welding system may include a welding material supply device, a welding device, and a supply device propulsion system that moves the welding material to the welding device. In one embodiment of the invention, the welding system further includes a weighing device operatively connected to the welding station computer and configured to measure the mass of the welding consumable supply device and to transmit the weight data of the welding consumable supply device to the welding station computer in the form of weight data; and a sensor operatively connected to the feeder motor system and the welding station computer so as to transmit speed data of the feeder motor system to the welding station computer as speed data. The welding station computer is operatively connected to the feeder propulsion system and is configured to control the speed of the propulsion system based on weight data.

[001332] In one embodiment of the invention, the welding device may comprise an orbital welding machine. In one embodiment of the invention, the welding material supply device includes a spool configured to hold the welding wire. In one embodiment of the invention, the weighing device includes a hub sensor, where the hub sensor is configured to hold the coil. In one embodiment of the invention, the weighing device comprises strain gauges mounted on the hub of the hub gauge. In one embodiment of the invention, the strain sensor is configured and positioned to sense the strain created by the mass of the coil. In one embodiment of the invention, the propulsion system comprises a motor and a feed wheel operatively connected to the motor. In one embodiment of the invention, the propulsion system includes a pinch roller configured to push the filler wire to bring the filler wire into contact with the feed wheel such that rotation of the feed wheel moves the wire. In one embodiment of the invention, the feed wheel is configured to rotate to engage the wire to move the wire.

[001333] In one embodiment of the invention, the welding station computer is configured to measure the difference in weight between the mass of the supply of welding consumable measured for the first time and the mass of the supply of welding consumable measured a second time after the first time, the difference in weight corresponds to the measured weight of the welding material consumed between the first and second time. In one embodiment of the invention, the welding station computer is configured to calculate a theoretical mass of welded material to be consumed based on the rotational speed of the feeder propulsion system. In one embodiment of the invention, the welding station computer is configured to calculate the difference or ratio between the measured mass of welding consumable and the theoretical mass of consumable welding consumable. In one embodiment of the invention, the welding station computer is configured to compare the measured mass of welding consumable and the theoretical mass of consumable welding consumable, and if there is a discrepancy, then the welding station computer indicates that slippage has occurred and controls the speed of the propulsion system to adjust the speed of rotation of the propulsion system. In one embodiment of the invention, the welding station computer is configured to repeat the comparison between the measured mass of welding consumable and the theoretical mass of consumable welding consumable in multiple time steps.

[001334] In one embodiment of the invention, the welding system may include a cloud server communicating with the welding station computer, where the cloud server is configured to process the feeder propulsion speed and welding material feed weight received from the welding station computer to store archive data about using welding consumable.

[001335] In one embodiment, the cloud server is further configured to process feeder propulsion speed and welding consumable feed weight received from a plurality of welding station computers associated with the plurality of welding stations to store archived data on the use of welding consumable at each of the plurality welding stations. In one embodiment of the invention, the cloud server is configured to predict the average future use of welding consumable based on historical data and use a machine learning algorithm. In one embodiment of the invention, the cloud server is configured to determine a welding consumable threshold required to complete a full weld based on usage patterns 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 full weld cannot be completed based on a theoretical threshold determined using a machine learning algorithm.

[001336] In one embodiment of the invention, the welding station computer is configured to control the speed of the welding device to adjust the speed of the welding device in accordance with the speed obtained from the measured mass of the welding material supply device.

[001337] In one embodiment of the invention, the first mass of the welding material supply device for the first time can be measured using a mass measuring device. The second mass of the welding material supply device can be measured with the mass measuring device a second time after the first time. The difference in measured mass between the first mass and the second mass can be calculated using a computer, where the difference in measured mass corresponds to the measured welding consumable used. The theoretical mass of the welding material used is calculated using a computer based on the speed of the propulsion system that supplies the welding material to the welding device. The theoretical weight of the used welding material can be compared by the computer with the measured weight of the used welding material. The speed of the propulsion system can be adjusted by the computer to correct slippage of the propulsion system.

[001338] In one embodiment of the invention, measuring the first mass, measuring the second mass, calculating the mass difference corresponding to the measured welding consumable used, calculating the theoretical used welding consumable mass, comparing the theoretical used welding consumable mass with the measured used welding consumable mass at a plurality of time steps and adjusting the speed of the propulsion system when the propulsion system slips can be repeated.

[001339] In one embodiment, the welding system may comprise a plurality of welding stations, with each welding station comprising a welding station computer and a welding system communicating with the welding station computer, where each welding station comprises one or more sensors and one or more The sensors are configured to measure welding data, including wire feed speed data. The welding system may also include a plurality of wireless devices communicating with one or more welding station computers to receive welding data, including measured wire feed speed data. Each welding station computer is configured to process welding data, including wire feed speed data, for the welding system communicating with it, and the welding station computer is configured to determine the amount of consumable welding material used by the welding system for a given period of time and generate at their consumption data.

[001340] In one embodiment of the invention, each welding station of the welding system may include a motor for moving the feed wire at a wire feed speed, where the wire feed speed data is determined based on the speed of the motor, each welding station further includes a mass sensor that measures the reduction in mass of the consumable material, the load cell provides output signals to the welding station computer, and the welding station computer uses the output signals to determine consumption data. In one embodiment of the invention, the welding station computer uses the consumption data to control the motor speed.

[001341] In one embodiment, the welding system may include a cloud server for receiving consumption data along with wire feed speed data to correlate consumption data with wire feed speed data.

[001342] In one embodiment of the invention, the pipeline inspection system may comprise a test device adapted to generate non-destructive inspection data on at least a portion of the weld. The test device may transmit the NDT data to a second device that is adapted to receive the NDT data. The test device can be adapted for remote operation by analyzing NDT data.

[001343] In one embodiment of the invention, the test device is adapted to transmit non-destructive testing data for wireless communication. In one embodiment of the invention, the test device is adapted to transmit non-destructive testing data to a recording medium that is not permanently attached to the test device. In one embodiment of the invention, the test device is adapted to transmit NDT data to an external digital recorder.

[001344] In one embodiment of the invention, a system for non-destructive testing of a pipeline may comprise imaging equipment adapted to generate non-destructive testing data on a portion of a welded pipe; and a remote processing device adapted to receive and process the data obtained from the test on the welded pipe portion.

[001345] In one embodiment of the invention, a remote processing device is adapted to analyze pipe data. In one embodiment of the invention, the remote processing device is adapted for welding data analysis. In one embodiment of the invention, the remote processing device is adapted to execute executable computer code to identify significant welding defects from non-destructive testing data.

[001346] In one embodiment of the invention, the remote processing device is adapted to execute an executable computer code algorithm to identify significant welding defects from non-destructive testing data. In one embodiment of the invention, the remote processing device is adapted to execute an executable artificial intelligence computer code to detect significant weld defects from NDT data. In one embodiment of the invention, the remote processing device is adapted to perform executable computer code logic based on a system of rules to identify significant welding defects from non-destructive testing data.

[001347] In one embodiment, the NDT data may contain one or more of the following data: the location, size, orientation, shape, and magnitude of any defects that caused anomalies in the NDT data. In one embodiment of the invention, NDT data can be analyzed without human computation or analytical intervention. In one embodiment of the invention, NDT data may be partly analyzed by computer analysis and partly by a human.

[001348] In one embodiment of the invention, a method for non-destructive testing of a pipeline may include providing imaging equipment; generation of non-destructive testing data; providing the means to provide non-destructive testing data for analysis; and providing the non-destructive testing data for analysis to a location remote from the inspected part of the pipe and equipment near the inspected part of the pipe.

[001349] In one embodiment of the invention, the method may further include providing NDT data for analysis to a location remote from the inspected pipe section and the maintenance vehicle. In one embodiment of the invention, the method may further include providing the analysis at a location remote from the test pipe part and on any computer near the test pipe part or test site.

[001350] In one embodiment of the invention, the method may further comprise processing the digital NRK data at a location significantly removed from the data collection site. In one embodiment of the invention, the method may further comprise transmitting the NDT data to a location substantially remote from the data collection site via wireless data transmission. In one embodiment of the invention, the method may further comprise transmitting the NDT data to a location substantially removed from the data collection site by moving the physical storage media. In one embodiment of the invention, the method may further comprise transmitting the NDT data to a location substantially removed from the data collection site via a data cable. In one embodiment of the invention, the method may further comprise transmitting the NRK data to a location substantially removed from the data collection site using a combination of methods.

[001351] In one embodiment of the invention, the method may further comprise transferring the results of the analysis to a location substantially remote from the data collection site. In one embodiment of the invention, the method may further comprise communicating the results of the analysis at a substantially remote location to specialists at another substantially remote location.

[001352] In one embodiment, the method may further comprise analyzing digital automated ultrasonic inspection data. In one embodiment of the invention, the method may further include transmitting digital automated ultrasonic inspection data to a location substantially removed from the data collection site via wireless data transmission; and processing the digital automated ultrasonic testing data at a location substantially remote from the data collection site. In one embodiment of the invention, the method may further include transmitting the digital automated ultrasound inspection data to a location substantially removed from the data collection site by moving the physical storage media.

[001353] In one embodiment, the method may further include transmitting the digital automated ultrasound inspection data to a location substantially removed from the data collection site using a data cable. In one embodiment of the invention, the method may further include transmitting digital automated ultrasonic inspection data to a location substantially removed from the data collection site using a combination of methods. In one embodiment, the method may further comprise using a computer algorithm to detect significant weld defects from automated ultrasonic testing data.

[001354] In one embodiment of the invention, the method may further include processing digital radiography data at a location substantially remote from the data collection site. In one embodiment of the invention, the method may further comprise transmitting the digital radiography data to a location substantially removed from the data collection site via wireless data transmission. In one embodiment of the invention, the method may further comprise transmitting the digital radiography data to a location substantially removed from the data collection site by moving the physical storage media. In one embodiment of the invention, the method may further comprise transmitting the digital radiography data to a location substantially removed from the data collection site via a data cable.

[001355] In one embodiment of the invention, the method may further comprise transmitting the digital radiography data to a location substantially removed from the data collection site using a combination of methods. In one embodiment, the method may further comprise using a computer algorithm to determine significant weld defects from digital radiography data.

[001356] In one embodiment, the pipeline construction system may comprise a real-time welding data logging system where the welding data is provided for analysis by computerized tools and/or subject matter experts. In one embodiment, the weld data comprises weld data, pipe handling data, coating data, test data, control data, or other data. In one embodiment of the invention, the system may further comprise a system for combining all available welding data into a single data set having all data related to each weld or adapted for analysis by computerized tools and/or subject matter experts.

[001357] In one embodiment, the system may further comprise machine-readable code executing rule-based program logic to identify correlations between various welding data and identify defects in that weld. In one embodiment, the system may further comprise machine-readable code executing rule-based program logic to identify correlations between the same data on different welds and the presence or absence of defects in those welds.

[001358] In one embodiment of the invention, a system for aligning and welding together two pipe segments may include a welding mechanism for applying a weld to the front joint of the two segments. The welding mechanism may include an articulated welding head, a laser sensor for reading the facade joint profile, and an electronic controller for receiving information signals from the laser sensor to control the position and/or orientation of the welding head. The system may further comprise an alignment mechanism for controlling the orientation of the longitudinal axis of at least one of the segments relative to the other. The welding mechanism may further comprise a carriage for securely fixing the position of the welding mechanism in the pipe and a welding part capable of rotating relative to the support part within the pipe. The welding head and the laser sensor can be rotatably supported by the welding part, so that during welding the welding head follows the laser sensor along the facade joint.

[001359] In one embodiment of the invention, the welding mechanism may further comprise a camera for optical examination of the facade joint. In one embodiment of the invention, the hinge movement of the tip on the welding head may include one of: radial movement towards and away from the front joint, movement of movement in the direction of the longitudinal axis of the segments, rotational movement relative to the welding mechanism on an axis parallel to the longitudinal axis of the segment pipe, and a rotational movement relative to the welding head on an axis that is perpendicular to the longitudinal axis of the pipe segment.

[001360] In one embodiment of the invention, the alignment mechanism manipulates the orientation of at least one segment by contacting the appearance of at least one segment. In one embodiment of the invention, an electronic controller receives a signal from a laser sensor to direct the alignment mechanism to adjust the relative positions of the pipe segments based on predetermined alignment parameters.

[001361] In one embodiment of the invention, the welding mechanism rotates within and relative to the inside of the facade joint of the two segments so that the welding head follows the laser sensor, and the laser sensor provides a continuous flow of facade joint profile data to the electronic controller, which, in turn, continuously positions the welding head.

[001362] In one embodiment, the camera follows the weld head along the weld and the camera sends a signal to the workstation display so that the operator can check the image of a portion of the weld.

[001363] In one embodiment, a method for aligning and welding two pipe segments may include placing a first pipe segment on an alignment device; inserting an internal welding machine having a laser and a welding head into the first pipe segment; general alignment of the second pipe segment with the first pipe segment and the internal welding machine; grasping the outer part of the first and second pipe segments to adjust the axial position of the inner welding machine so as to generally line up with the front joint of the first and second pipe segments; adjusting the relative alignment of the first and second pipe segments via the alignment device based on a signal from the internal welder; starting a root weld cycle in which the laser scans the face joint, the weld head follows the laser, and the output from the laser is used to control the position of the articulated welding torch, where the position and orientation of the weld head relative to the face joint is controlled to produce a quality weld; determination of the facade joint profile using a laser; releasing the leveling device and removing the internal welding machine from the end of the open pipe segment; and repositioned the next successive pipe segment on an external alignment mechanism in preparation for welding the next joint.

[001364] In one embodiment of the invention, the method may further include providing a rotary mechanism on which the laser and welding head rotate to perform an initial scan of the facade joint with the laser sensor; as well as; generating a signal from a rotating laser to directly align the first and second pipe segments with the aligner prior to welding.

[001365] In one embodiment of the invention, an internal heat exchanger (WHE) for pipeline welding may comprise a drive system configured to move the WTO to a position within at least one pipe section proximate a welded joint with another pipe section; a cooling section including a cooling structure configured to selectively cool one or more parts of the inner surface of at least one pipe section; and a controller communicating with the cooling structure and configured to activate the cooling section when the WTO is in position within at least one pipe section.

[001366] In one embodiment of the invention, the WTO may further comprise a connecting element configured to securely fasten the WTO to the internal mounting clip. In one embodiment of the invention, the drive system may include at least one roller activated by a motor controlled by the controller and configured to move the WTO within at least one pipe section in forward and reverse directions. In one embodiment of the invention, the drive system may include a cable and system winches, where the winch is configured to be fixed in a location external to at least one pipe section, and the cable passes between the winch and the WTO support structure, which includes a controller and a cooling section. .

[001367] In one embodiment of the invention, the controller further communicates with the remote control device to facilitate selective activation of the refrigeration section by the remote control device. In one embodiment of the invention, the cooling section comprises at least one nozzle configured to spray coolant towards the inside of the wall surface of at least one pipe section; and a coolant supply source configured to supply coolant to at least one nozzle.

[001368] In one embodiment, the WTO may further comprise a frame containing a first section that contains a refrigerant supply source, an intermediate section that contains a cooling section, and a third section that contains a controller. In one embodiment of the invention, the source of coolant supply may include a coolant pump located remotely from the cooling section, so that the coolant pump is located outside at least one section of the pipe, when the cooling section is located inside at least one section of the pipe, and the coolant pump fluid is connected to at least one nozzle through at least one fluid conduit. In one embodiment of the invention, at least one nozzle comprises a plurality of nozzles arranged in a plurality of rows, and the rows are arranged around the periphery of the central support element of the cooling section.

[001369] In one embodiment of the invention, the cooling section comprises a plurality of fin elements extending radially outward from and located around the periphery of the central support element of the cooling section. In one embodiment of the invention, at least one fin element includes at least one channel passing through the fin element, and the cooling section further comprises at least one fan that is controlled by the controller and is located in close proximity and aligned with at least one fin element to direct air flow through at least one channel of at least one fin element.

[001370] In one embodiment of the invention, at least one rib element includes a hollow body containing an inlet and outlet, and the cooling section further comprises a coolant circulation loop for selective flow of coolant through the hollow body of at least one fin element.

[001371] In one embodiment, the WTO may include one or more temperature sensors located at one or more locations along the WTO and communicating with the controller. One or more temperature sensors measure the temperature at one or more locations within at least one pipe section and provide information about the measured temperature to the controller, and the controller is configured to selectively control the activation and operation of the cooling section based on the measured temperature information.

[001372] The technology described herein solves the significant technical problem of how to control, verify, and ensure the quality of thousands and millions of welds in pipeline systems using equipment and methods that are reliable and technically sound. In one embodiment of the invention, a system for inspecting a pipeline may have a test device adapted to generate non-destructive testing ("NDT") data on at least a portion of the weld or the entire weld. The test device may transmit the NDT data to a second device that is adapted to receive the NDT data. The test device can be adapted for remote operation by analyzing NDT data. The pipeline inspection system may have a test device adapted to transmit non-destructive testing data for wireless communication. The pipeline inspection system may have a test device adapted to transmit non-destructive testing data to a recording medium that is not permanently attached to the test device. The pipeline inspection system may have a test device adapted to transmit non-destructive testing data to an external digital recorder. A system for non-destructive testing of a pipeline may include: imaging equipment adapted to generate non-destructive testing data on a portion of a welded pipe; a remote processing device adapted to receive and process data obtained as a result of the test on the welded pipe portion. The system for non-destructive testing of pipelines may contain a remote processing device designed to analyze data about pipes. The system for non-destructive testing of pipelines may have a remote processing device designed to analyze welding data. The pipeline NDT system may have a remote processing device adapted to execute executable computer code to detect significant welding defects from the NDT data. A system for non-destructive testing of a pipeline may have a remote processing device configured to execute an executable computer code algorithm to detect significant weld defects from non-destructive testing data. The pipeline NDT system may have a remote processing device adapted to execute an executable artificial intelligence computer code to detect significant welding defects from the NDT data. A system for non-destructive testing of a pipeline may have a remote processing device configured to execute executable computer code logic based on a set of rules to identify one or more significant welding defects from the non-destructive testing data. The identified weld defects can be of different types, such as inclusions, lack of material, material properties, brittleness, density, thickness, air bubbles, gas bubbles, and others. The system for non-destructive testing of pipelines may contain non-destructive testing data, such as one or more of the following data: location, size, orientation, shape and value of any defects that caused anomalies in the study. The system for non-destructive testing of pipelines may contain data of non-destructive testing, which can be analyzed by the system automatically and without human calculations, and with human analytical participation. In one embodiment of the invention, a pipeline non-destructive testing method may include the steps of: providing imaging equipment; generation of non-destructive testing data; providing the means to provide non-destructive testing data for analysis; and providing the non-destructive testing data for analysis to a location remote from the inspected part of the pipe and equipment near the inspected part of the pipe. The method for non-destructive testing of pipelines may include the step of providing non-destructive testing data for analysis to a location remote from the controlled section of the pipe and the technical support vehicle. The method for non-destructive testing of a pipeline may include the step of providing non-destructive testing data for analysis at a location remote from the inspected pipe part and on any computer near the inspected pipe part or inspection site. The method for non-destructive testing of pipelines may include the stage of processing digital NDT data at a location substantially remote from the data collection site. The pipeline non-destructive testing method may include the step of transmitting NDT data to a location substantially remote from the data collection site via wireless data transmission. The pipeline non-destructive testing method may include the step of transmitting NDT data to a location substantially remote from the data collection site by moving physical data carriers. The method for non-destructive testing of a pipeline may include the step of transmitting NDT data to a location substantially remote from the data collection site using a data cable. The pipeline non-destructive testing method may include the step of transmitting NDT data to a location substantially remote from the data collection site using a combination of methods. The method for non-destructive testing of pipelines may include the step of transferring the results of the analysis to a location substantially remote from the data collection site. The method for non-destructive testing of pipelines may include the step of communicating the results of an analysis at a substantially remote location to specialists at another substantially remote location. The method for non-destructive testing of pipelines may include the step of analyzing digital data of automated ultrasonic testing (also referred to as digital data "AUC"). The method for non-destructive testing of pipelines may include the step of processing digital data of automated ultrasonic testing in a place substantially remote from the place of data collection. The method for non-destructive testing of pipelines may include the step of processing digital data of automated ultrasonic testing at a location substantially remote from the data collection site using wireless data transmission. The pipeline non-destructive testing method may include the step of transmitting digital automated ultrasonic testing data to a location substantially remote from the data collection site via wireless data transmission. The method for non-destructive testing of pipelines may include the step of transmitting digital data of automated ultrasonic testing to a location substantially remote from the data collection site by moving physical data carriers. The method for non-destructive testing of pipelines may include the step of transmitting digital data of automated ultrasonic testing to a location substantially remote from the data collection site using a data cable. The method for non-destructive testing of pipelines may include the step of transmitting digital automated ultrasonic testing data to a location substantially remote from the data collection site using a combination of methods. The method for non-destructive testing of pipelines may include the step of using a computer algorithm to detect significant weld defects from automated ultrasonic testing data. The method for non-destructive testing of pipelines may include the step of processing digital radiography data at a location remote from the data collection site. The method for non-destructive testing of pipelines may include the step of transmitting digital radiography data to a location substantially remote from the data collection site via wireless data transmission. The pipeline non-destructive testing method may include the step of transmitting digital radiography data to a location substantially remote from the data collection site by moving physical data carriers. The pipeline non-destructive testing method may include the step of transmitting the digital radiography data to a location substantially remote from the data collection site using a data cable. The pipeline non-destructive testing method may include the step of transmitting the digital radiography data to a location substantially remote from the data collection site using a combination of methods. The method for non-destructive testing of pipelines may include the step of using a computer algorithm to detect significant welding defects from digital radiography data. In one embodiment of the invention, the universal cloud logging system ("uLog") described herein may comprise a computer system that includes a first device containing a processor that processes pipeline structure data, wherein the first device may communicate pipeline structure data with the cloud. storage device. These pipeline structures can be processed by a cloud processor. uLog can process any one or more pipeline construction data, such as but not limited to welding data, pipe handling data, coating data, and inspection data. uLog can process data from one or more of the following devices and/or equipment: a welding station, a pipeline welding expansion process, a welding tool, an automatic welding tool, a manual welding tool, a welding supervision system, an automatic welding machine, or a welding machine with a single welding head , automatic welding machine or welding machine with two welding heads, external welding machine or welding machine, internal welding machine or welding machine, control system, smartphone, mobile phone, personal digital assistant (PDA), laptop, tablet, computer, digital device, wireless device and equipment used by a welder, technician, worker, inspector, coater and/or manager. uLog may use a computer-based data management method comprising the steps of: transmitting first data from the first device to the second device, the first data being pipeline construction data; and processing of the first data by cloud network means. The data that can be transmitted by the first device and/or processed by the second device and/or processed by the uLog network can be any one or more of the following data: welding data, pipe handling data, coating data, welding data, verification data , heat treatment data and control data or other pipeline construction related data and/or control data. In one embodiment of the invention, the uLog data management method may include an additional method step of processing the first data and/or data by network means, which may be wired network means or wireless network means. In another embodiment of the invention, the uLog data management method may include an additional method step of processing the first data and/or data by network means, which is a wireless network means, a telecommunications means, or a Wi-Fi means. In yet another embodiment of the invention, the method for managing data by uLog may include an additional step of the method of processing the first data by network facilities, which are cloud network facilities. In one embodiment, the uLog may be a welding hardware computer software product that includes: computer-readable program code means that provide welding conditions data to a computer storage device; computer-readable program code means that provide to a storage device data from a data set containing pipeline data; and computer-readable program code means that process the welding condition data and pipeline data to provide an output and/or output of a result obtained from the execution of the program logic and/or analytics. In one embodiment of the invention, the welding hardware computer program product may further comprise rule logic executable code that processes the welding data with the welding hardware software code. In another embodiment of the invention, the welding hardware computer program product may further comprise an executable rule logic program code that processes the welding data with the control program code. In yet another embodiment of the invention, the welding hardware computer program product may further comprise an executable rule logic program code that processes the welding data with the control program code or the quality control program code. The pipeline construction system may have a system for verifying welding data in real time. Weld data is provided for analysis by computerized tools and/or subject matter experts. The pipeline construction system may use weld data that contains one or more of the following: weld data, pipe handling data, coating data obtained from inspection, and control data. The pipeline construction system may further comprise a system for combining all available welding data into a single dataset containing all data related to each weld or adapted for analysis by computerized tools and/or subject matter experts. The pipeline construction system may further have machine readable code executing rule-based program logic to identify correlations between various weld data and identify defects in that weld. The pipeline construction system may further have machine-readable code executing rule-based program logic to identify correlations between the same data on different welds.

[001373] In one embodiment of the invention, the universal cloud logging system ("uLog") described herein may comprise a computer system that includes a first device containing a processor that processes pipeline facility data, wherein the first device may perform facility data exchange pipeline with cloud storage. These pipeline structures can be processed by a cloud processor. uLog can process any one or more pipeline construction data, such as but not limited to welding data, pipe handling data, coating data, and inspection data. uLog can process data from one or more of the following devices and/or equipment: a welding station, a pipeline welding expansion process, a welding tool, an automatic welding tool, a manual welding tool, a welding supervision system, an automatic welding machine, or a welding machine with a single welding head , automatic welding machine or welding machine with two welding heads, external welding machine or welding machine, internal welding machine or welding machine, control system, smartphone, mobile phone, personal digital assistant (PDA), laptop, tablet, computer, digital device, wireless device and equipment used by a welder, technician, worker, inspector, coater and/or manager.

[001374] uLog may use a computer-based data management method, comprising the steps of: transmitting first data from a first device to a second device, the first data being pipeline construction data; and processing of the first data by cloud network means. The data that can be transmitted by the first device and/or processed by the second device and/or processed by the uLog network can be any one or more of the following data: welding data, pipe handling data, coating data, welding data, verification data , heat treatment data and control data or other pipeline construction related data and/or control data. In one embodiment of the invention, the uLog data management method may include an additional method step of processing the first data and/or data by network means, which may be wired network means or wireless network means. In another embodiment of the invention, the uLog data management method may include an additional method step of processing the first data and/or data by network means, which is a wireless network means, a telecommunications means, or a Wi-Fi means. In yet another embodiment of the invention, the method for managing data by uLog may include an additional step of the method of processing the first data by network facilities, which are cloud network facilities. In one embodiment, the uLog may be a welding hardware computer software product that includes: computer-readable program code means that provide welding conditions data to a computer storage device; computer-readable program code means that provide to a storage device data from a data set containing pipeline data; and computer-readable program code means that process the welding condition data and pipeline data to provide an output and/or output of a result obtained from the execution of the program logic and/or analytics.

[001375] In one embodiment of the invention, the welding hardware computer program product may further comprise an executable rules logic code that processes the welding data with the welding hardware software code. In another embodiment of the invention, the welding hardware computer program product may further comprise an executable rule logic program code that processes the welding data with the control program code. In yet another embodiment of the invention, the welding hardware computer program product may further comprise an executable rule logic program code that processes the welding data with the control program code or the quality control program code. The present patent application in its several aspects and embodiments solves the problems discussed above and greatly advances the technology of welding, pipe handling, coating, pipeline construction, building technology, control and monitoring.

[001376] Although the present patent application is described in detail for the purpose of illustration, it should be understood that such details are for that purpose only and that the present patent application is not limited to the described embodiments of the invention, but rather is intended to cover modifications and equivalent devices that are within the spirit and scope of the appended claims. In addition, it should be understood that the present patent application suggests that, if possible, one or more features of any embodiment of the invention can be combined with one or more design features of any other embodiment of the invention.

[001377] In general, the invention can be described by the following sets of features.

1. Field system for welding two pipes, comprising:

a first pipe engaging device configured to engage with an inner surface of the first pipe, allowing the first pipe engaging device to be fixed with respect to the first pipe;

a second pipe engaging device configured to engage with an inner surface of the second pipe, allowing the second pipe engaging device to be fixed relative to the second pipe;

a measuring sensor located between the first pipe engaging device and the second pipe engaging device, wherein the measuring sensor is configured to emit a research radiation beam,

an engine functionally connected to the measuring sensor for directing the research radiation beam along the contact surface between the pipes,

one or more processors operatively associated with the measurement sensor to determine the profile of the contact surface between the two pipes; and

a welding torch configured to create a weld between the pipes based on the profile data of the contact surface between the pipes.

2. The field system of claim 1, wherein the first pipe engagement device comprises a first clamp and the second pipe engagement device comprises a second clamp.

3. The field system of claim 1 or 2, wherein the first pipe engagement device comprises a first seal and the second pipe engagement device comprises a second seal.

4. The field system of claim. 3, which further comprises an inert gas source and an inert gas supply channel connecting the inert gas source to the area between the first seal and the second seal, while gas from the inert gas source is directed to the area between the first seal and the second seal to reduce the oxidation reaction during the welding procedure.

5. The field system of claim. 4, which further comprises an oxygen sensor configured to detect the amount of oxygen between the first seal and the second seal, wherein the oxygen sensor is operatively associated with one or more processors, and one or more processors provide a welding operation after after the amount of oxygen between the first seal and the second seal falls below the threshold level.

6. The field system of claim. 2, which further comprises a source of inert gas and a gas supply channel, while the gas supply channel is configured to direct inert gas from the inert gas source into the area between the first and second clamps, and towards the area located in close proximity to the welding tip of the welding torch to reduce the level of oxygen in the vicinity of the welding tip during the welding operation.

7. The field system of claim 1, wherein the first pipe engagement device comprises a clamp and the second pipe engagement device comprises a seal.

8. The field system of claim. 1, in which one or more processors interact with a measuring sensor to scan the area of the contact surface between the pipes to determine the profile of the area of the contact surface between the pipes before the welding procedure and generate, based on the scan data, profile data before welding .

9. The field system of claim 8, wherein the first pipe engagement device comprises a first clamp and the second pipe engagement device comprises a second clamp, wherein one or more processors cooperate with a measurement sensor to scan the area of the contact surface after the first clamp and the second the clamp engages with the first tube and the second tube, respectively.

10. A field system according to claim 8 or 9, wherein the outer surface of the first pipe and/or the second pipe is engaged to adjust the relative positioning of the pipes when the pre-weld profile data determines that adjustment is necessary.

11. The field system of claim 8, 9, or 10, wherein the inner surface of the first pipe and/or the second pipe is engaged to adjust the relative positioning of the pipes when it is determined by pre-weld profile data that adjustment is necessary.

12. The field system of claim 8, 9, 10, or 11, wherein one or more processors are operatively associated with the first pipe engagement device and the second pipe engagement device, wherein the one or more processors are configured to control the operation of the first pipe engagement device, and /or a second pipe engaging device based on the pre-weld profile data to change the area of the contact surface between the pipes before the welding operation.

13. The field system of claim. 12, in which one or more processors change the area of the contact surface between pipes before the welding operation by controlling the first pipe engagement device and/or the second pipe engagement device to change the roundness (of the first pipe and/or the second pipe based on profile data before welding).

14. The field system of claim. 12, wherein one or more processors change the area of the contact surface between pipes before the welding operation by operating a motor to rotate the first pipe engagement device about its axis relative to the second pipe engagement device so as to rotate the second pipe on the base profile data before welding.

15. The field system of claims 8-14, wherein one or more processors generate a weld protocol based on pre-weld profile data.

16. The field system of claim 15, wherein the welding protocol comprises a welding speed and a welding torch position protocol.

17. A field system according to any one of the preceding claims, wherein one or more processors cooperate with a measuring sensor to scan the area of the contact surface between pipes, to determine the profile of the area of the contact surface between pipes during a welding operation in the area of the contact surface before applying welding material thereto , and generating on-the-fly profile data based on the scan, and one or more processors configured to generate welding signals for controlling the welding torch based on the on-the-fly data.

18. A field system according to any one of the preceding claims, wherein one or more processors control the position and speed of the welding torch based on on-the-fly data during the welding operation.

19. A field system according to any of the preceding claims, wherein the welding torch is operatively coupled to a welding torch motor, wherein the welding torch motor is operatively coupled to one or more processors for controlling the angle of the welding torch during a welding operation.

20. A field system according to any one of the preceding claims, wherein the welding torch is mounted for angular movement to allow the welding torch to be directed forward during welding.

21. A field system according to any one of the preceding claims, wherein the welding torch is set to move such that it rotates about an axis that is slightly forward of the welding torch tip, adjacent to or in the area where the weld puddle is created by the welding tip.

22. A field system according to any one of the preceding claims, wherein the welding torch is set to move such that the welding tip is movable in and out of the pipe surface to be welded.

23. The field system of any one of the preceding claims, wherein one or more processors instruct one or more torch motors to move the welding tip away from the contact surface area after each pass of the weld to withstand a buildup of welding material.

24. A field system according to any one of the preceding claims, wherein the motor rotates the welding torch in a circumferential direction along the contact surface region, wherein the field system further comprises one or more torch motors configured to move the welding torch relative to the first and second pipe engagement devices after they have been fixation, respectively, relative to the first pipe and the second pipe, and one or more burner motors are configured to move the welding torch in the longitudinal direction inside the pipes, towards and away from the inner surface of the pipe, and also at an angle to the weld.

25. The field system of any one of the preceding claims, further comprising a platform for transporting and moving the first pipe and the second pipe, the platform being operatively coupled to one or more processors, and the one or more processors controlling the operation of the platform to provide relative moving between the first pipe and the second pipe based on the profile data before welding to change the area of the contact surface between the pipes before performing the welding operation.

26. A field system according to any one of the preceding claims, wherein the welding torch is arranged to be placed inside the first pipe and/or the second pipe to perform an internal welding operation.

27. The field system of claim 26, wherein the internal welding torch is mounted on a rotary hub, the rotary hub being driven by a motor and configured to rotate the welding torch about the longitudinal axis of the pipes to weld the contact surface area between the pipes.

28. A field system according to any one of the preceding claims, wherein the welding torch is arranged to be placed outside the first pipe and/or the second pipe to perform an external welding operation.

29. The field system of claim 28, wherein the externally placed welding torch is mounted on the outer surface of either the first pipe or the second pipe.

30. The field system of claim 28, wherein the first pipe engagement device comprises a first seal and the second pipe engagement device comprises a second seal, and further comprises a purge system configured to supply a purge gas between the first seal and the second seal to reduce oxygen levels in the the gap between the first seal and the second seal during the welding operation.

31. The field system of claim 15, wherein the welding protocol comprises one or more welding parameters that are controlled to fit the weld parameters for the pipes to be welded during the pipe welding process.

32. The field system of any one of the preceding claims, wherein the first pipe engagement device further comprises a first clamp and a first seal, and the second pipe engagement device further comprises a second clamp and a second seal.

33. A field system according to any one of the preceding claims, wherein one or more processors interact with a measurement sensor to scan a contact surface area between pipes to determine the profile of the contact surface area between pipes after a welding procedure and generate, based on the scan data, profile data after welding.

34. The field system of claim 33, wherein the one or more processors are configured to cause another welding operation to be performed in the area of the contact surface between the pipes based on the post-weld profile data.

35. Field system according to claim 33 or 34, in which the profile data after welding is obtained using a measuring sensor located inside the first pipe and / or second pipe, without disengaging, respectively, the first pipe engagement device or the second pipe engagement device, from the inner surface of the first pipe or the inner surface of the second pipe.

36. A field system according to any one of the preceding claims, further comprising a monitoring camera configured to be placed between the first pipe engaging device and the second pipe engaging device, wherein one or more processors are configured to receive monitoring camera data from the monitoring camera before, after or during the welding operation.

37. The field system according to any one of the preceding claims, further comprising a control camera that scans the welded area of the contact surface after the welding operation, wherein the control camera sends signals to one or more processors based on the scan, and one or more processors determine the characteristics of the welded area contact surface based on these signals.

38. A field system according to any one of the preceding claims, wherein the measuring sensor comprises an emitter emitting a research beam of radiation and a receiver for receiving control signals due to reflected radiation.

39. A field system according to any one of the preceding claims, further comprising one or more welding torch motors, wherein the one or more welding torch motors and the welding torch are configured to be located within the inner surface of the first and/or second pipes, and wherein one or more processors control one or more welding torch motors to control the positioning and orientation of the welding torch.

40. A field system according to any one of the preceding claims, wherein the motor that directs the research beam also moves the welding torch through an angle of at least 360 degrees relative to the pipe axis so as to perform a continuous turning pass when welding the root of the weld.

41. A field system according to any one of the preceding claims, wherein the welding torch comprises a welding tip, wherein one or more processors are configured to control one or more welding torch motors to adjust the radial distance of the welding tip within the pipes with respect to the contact surface area, and one or more processors control one or more motors to move the welding torch tip radially away from the contact area after the root pass so as to hold the weld material deposited during the root pass and provide a hot weld pass over the root pass seam inside pipes.

42. A field system according to any one of the preceding claims, wherein the motor moves the welding torch in the first direction of rotation during the root pass, and moves the welding torch in another direction opposite the first direction during the hot welding pass.

43. A field system according to any one of the preceding claims, wherein the welding torch is arranged to move about an axial point close to or at the location of the welding tip of the welding torch such that the weld pool created by the welding tip is effectively aligned with the axis of rotation.

44. Field system according to claim 43, in which the annular arc between the axial point and the point of reflection of the research radiation beam from the area of the contact surface remained virtually constant during the welding operation.

45. Field system according to claim 43, in which the axial point is located in front of the welding tip.

46. A field system according to any one of the preceding claims, wherein the motor that guides the measuring sensor also rotates the welding torch circumferentially in the plane of rotation to create a weld along the area of the contact surface, and further comprises a torch motor that provides angular rotation of the welding torch, in fact, inside the plane of rotation, since the motor rotates the welding torch along the plane of rotation, while the angular orientation of the welding torch is controlled based on the position of the torch.

47. A field system according to any one of the preceding claims, wherein the motor that moves the welding torch in a circle around the area of the contact surface also moves the sensor around the area of the contact surface at the same time as the welding torch, while the welding torch tows the sensor.

48. A field system according to any one of the preceding claims, wherein one or more processors are operatively coupled to a measurement sensor via a wired communication channel that transmits signals from the measurement sensor to one or more processors, wherein the wired communication channel comprises (i) a moving part, which moves together with the measuring sensor, while the measuring sensor directs the research radiation beam along the area of the contact surface, and (ii) a fixed part, which remains fixed during the movement of the moving part, and additionally contains a slip ring that provides an interface between the moving and fixed part of the communication a channel that allows signals to pass from the moving part to the fixed part.

49. Field system for welding two pipes, containing:

a first pipe engaging device configured to engage with an inner surface of the first pipe, allowing the first pipe engaging device to be fixed with respect to the first pipe;

a second pipe engaging device configured to engage with an inner surface of the second pipe, allowing the second pipe engaging device to be fixed relative to the second pipe;

a measuring sensor located axially between the first pipe engaging device and the second pipe engaging device, wherein the measuring sensor is configured to check the area of the contact surface between the pipes and generate profile data based on such a check

one or more orientation motors, operatively associated with the measuring sensor, for directing the research beam of radiation along the area of the contact surface between the tubes,

one or more processors operatively associated with the measurement sensor, and configured to receive profile data from the measurement sensor to determine one or more characteristics of the area of the contact surface between the pipes; and

a welding torch assembly comprising a welding torch and at least one welding torch motor, wherein the welding torch and at least one welding torch motor are driven by one or more processors to create a weld between pipes based on one or more characteristics of the contact surface area between pipes.

50. The field system of claim 49, wherein the first pipe engagement device comprises a first clamp and the second pipe engagement device comprises a second clamp.

51. The field system of claim 49 or 50, wherein the first pipe engagement device comprises a first seal and the second pipe engagement device comprises a second seal.

52. The field system of claim. 51, which further comprises a source of inert gas and an inert gas supply channel connecting the source of inert gas to the area between the first seal and the second seal, while gas from the inert gas source is directed to the area between the first seal and the second seal to reduce the oxidation reaction during the welding procedure.

53. The field system of claim. 52, which further comprises an oxygen sensor configured to detect the amount of oxygen between the first seal and the second seal, wherein the oxygen sensor is operatively associated with one or more processors, and one or more processors provide a welding operation after after the amount of oxygen between the first seal and the second seal falls below the threshold level.

54. The field system of claim. 50, which further comprises a source of inert gas and a gas supply channel, while the gas supply channel is configured to direct inert gas from the inert gas source into the area between the first and second clamps, and towards the area located in close proximity to the welding tip of the welding torch to reduce the level of oxygen in the vicinity of the welding tip during the welding operation.

55. The field system of claim 49, wherein the first pipe engagement device comprises a clamp and the second pipe engagement device comprises a seal.

56. The field system of claim. 49, wherein one or more processors interact with a measuring sensor to scan the entire area of the contact surface between the pipes and generate profile data before welding material welding when welding two pipes together in such a way that the profile data is based on profile data before welding.

57. The field system of claim 56, wherein the first pipe engagement device comprises a first clamp and the second pipe engagement device comprises a second clamp, wherein one or more processors interact with a measurement sensor to scan the area of the contact surface and obtain pre-weld profile data after of how the first clamp and the second clamp engage, respectively, with the first pipe and the second pipe.

58. Field system according to claim 56 or 57, in which the outer surface of the first pipe and / or second pipe is movably engaged using external rotary elements to facilitate adjustment of the relative positioning of the pipes in the case when it is determined by profile data before welding that adjustment is necessary.

59. The field system of claim 56, 57, or 58, wherein the inner surface of the first pipe and/or second pipe is engaged and controlled to adjust the relative positioning of the pipes when it is determined by pre-weld profile data that adjustment is necessary.

60. The field system of claim 56, 57, 58, or 59, wherein one or more processors are operatively coupled to one or more motors to orient to rotate the first pipe engagement device with respect to the second pipe engagement device so as to rotate the first pipe with respect to the second pipe based on the profile data to change the area of the contact surface between the pipes before the welding operation.

61. The field system of claim 60, wherein the one or more processors change the area of the contact surface between the pipes prior to the welding operation by controlling the first pipe engagement device and/or the second pipe engagement device to change the roundness (of the first pipe and/or the second pipe based on profile data before welding).

62. The field system of claim 60 wherein the one or more processors change the area of the contact surface between the pipes prior to the welding operation by operating the motor to rotate the first pipe engaging device about its axis relative to the second pipe engaging device so as to rotate the first pipe about its own axis. axis relative to the second pipe based on pre-weld profile data.

63. The field system of any one of claims 56-62, wherein one or more processors generate a weld protocol based on pre-weld profile data.

64. The field system of claim 63, wherein the welding protocol contains a welding speed and a welding torch position protocol.

65. The field system of any one of claims 49-64, wherein one or more processors interact with a measurement sensor to scan a contact surface area between pipes to generate profile data during a welding operation in the contact surface area prior to application of welding material thereto, and generating on-the-fly profile data based on the scan, wherein one or more processors are configured to generate welding signals for controlling the welding torch and/or at least one welding torch motor based on the on-the-fly data.

66. A field system according to any one of claims 49-65, wherein one or more processors control at least one welding torch motor so as to control the position and/or speed of the welding torch based on profile data acquired on the fly, generated by the measuring sensor during the welding operation.

67. The field system of any one of claims 49-66, wherein at least one welding torch motor is operatively coupled to one or more processors to control the angle of the welding torch during a welding operation.

68. The field system of any one of claims 49-67, wherein the welding torch is coupled to at least one welding torch motor such that the welding torch is fixed for angular movement to allow the welding torch to be directed forward during welding.

69. The field system of any one of claims 49-68, wherein the welding torch is arranged to be moved by at least one welding torch motor such that it rotates about an axis that is slightly forward of the welding torch tip, adjacent to or in an area where the weld pool is created by the welding tip.

70. The field system of any one of claims 49-69, wherein at least one welding torch motor is coupled to the welding torch to allow movement of the welding torch such that the welding tip of the welding torch is able to move towards and away from the pipe surface to be welded. her.

71. The field system of any one of clauses 49-70, wherein one or more processors instruct at least one welding torch motor to move the welding tip away from the contact surface area after each pass of the weld to hold the deposition of the welding material.

72. The field system of any one of claims 49-71, wherein one or more orientation motors rotate the welding torch circumferentially along the contact surface region, wherein at least one torch motor is configured to move the welding torch relative to the first and second engagement devices. pipes after their fixation, respectively, relative to the first pipe and the second pipe, and at least one burner motor is configured to move the welding torch in the longitudinal direction inside the pipes, towards and away from the inner surface of the pipe, and also at an angle to the weld .

73. The field system of any one of the preceding claims 49-72, further comprising a platform for transporting and moving the first pipe and the second pipe, the platform being operatively coupled to one or more processors, the one or more processors controlling the operation of the platform, to provide relative movement between the first pipe and the second pipe, based on the profile data for changing the contact surface area between pipes before the welding operation, based on one or more characteristics of the contact surface area, while the profile data used to change the contact surface area before welding operation contain profile data before welding.

74. The field system of any one of claims 49-73, wherein the welding torch is configured to be placed within the first pipe and/or the second pipe to perform an internal welding operation.

75. The field system of claim 74, wherein the internal welding torch is mounted on a rotary hub, wherein the rotary hub is driven by one or more motors for orientation and is configured to rotate the welding torch about the longitudinal axis of the pipes to weld the area of contact surface between pipes.

76. The field system of any one of claims 49-75, wherein the welding torch is operable to be placed outside the first pipe and/or the second pipe to perform an external welding operation.

77. The field system of claim 76, wherein the externally placed welding torch is mounted on the outer surface of either the first pipe or the second pipe.

78. The field system of claim 76, wherein the first pipe engagement device comprises a first seal and the second pipe engagement device comprises a second seal, and further comprises a purge system configured to supply a purge gas between the first seal and the second seal to reduce oxygen levels in the the gap between the first seal and the second seal during the welding operation.

79. The field system of any one of claims 58-64, wherein the relative positioning of the pipes is achieved without disengaging the first pipe engaging device from the inside surface of the first pipe and without disengaging the second pipe engaging device from the inside surface of the second pipe.

80. The field system of any one of claims 49-79, wherein the first pipe engagement device further comprises a first clamp and a first seal, and the second pipe engagement device further comprises a second clamp and a second seal.

81. A field system according to any one of claims 49-80, wherein one or more processors interact with a measurement sensor to scan an area of contact surface between pipes to determine the profile of an area of contact surface between pipes after a welding procedure and generate, based on the scan data, data on profile after welding.

82. The field system of claim 81, wherein the one or more processors are configured to cause another welding operation to be performed in the area of the contact surface between the pipes based on the post-weld profile data.

83. Field system according to claim 81 or 82, in which the profile data after welding is obtained using a measuring sensor located inside the first pipe and / or second pipe, without disengaging the first pipe engagement device or the second pipe engagement device, respectively, from the internal the surface of the first pipe or the inner surface of the second pipe.

84. The field system of any one of claims 49-83, further comprising a monitoring camera configured to be placed between the first pipe engaging device and the second pipe engaging device, wherein one or more processors are configured to receive monitoring camera data from the monitoring camera before, after or during a welding operation.

85. The field system according to any one of claims 49-84, further comprising a control camera that scans the welded area of the contact surface after the welding operation, wherein the control camera sends signals to one or more processors based on the scan, and one or more processors determine the characteristics welded area of the contact surface based on these signals.

86. The field system according to any one of claims 49-85, wherein the measurement sensor comprises an emitter that emits a research beam of radiation and a receiver for receiving measurement signals due to reflected radiation.

87. The field system of any one of claims 49-86, wherein one or more orientation motors that guide the research beam also drive the welding torch circumferentially along the contact surface region to create a weld between the pipes.

88. The field system of any one of claims 49-87, wherein the one or more orientation motors move the welding torch through at least 360 degrees about the pipe axis so as to perform a continuous rotary pass in root welding.

89. The field system of any one of claims 49-88, wherein the welding torch comprises a welding tip, wherein the one or more processors are configured to control at least one welding torch motor to adjust the radial distance of the welding tip within the pipes with respect to the contact area. surface, and one or more processors control one or more motors to move the welding torch tip radially away from the contact area after the root pass so as to hold the weld material deposited during the root pass and provide a hot weld pass over the pass when welding the root of the seam inside the pipes.

90. The field system of any one of claims 49-89, wherein the one or more orientation motors move the welding torch in a first direction of rotation during a root pass, and move the welding torch in another direction opposite the first direction during hot welding pass.

91. The field system of any one of claims 49-90, wherein the measuring sensor comprises a laser emitting a research beam of radiation, wherein the welding torch is positioned to move about an axial point close to or at the location of the welding tip of the welding torch or located near it. in such a way that the weld pool created by the welding tip actually coincides with the axial point, while the annular arc between the weld pool and the point of reflection of the research radiation beam from the contact surface area actually remains constant during the welding operation.

92. The field system of any one of claims 49-91, wherein the one or more orientation motors also rotate the welding torch circumferentially in the plane of rotation to create a weld along the contact surface region, wherein the at least one torch motor causes the welding torch to rotate at an angle, in fact, inside the plane of rotation, since one or more orientation motors rotate the welding torch along the plane of rotation.

93. The field system of any one of claims 49-92, wherein the welding torch assembly comprises a first welding torch assembly and further comprises a second welding torch assembly, wherein during a welding operation, the first welding torch assembly and the second welding torch assembly simultaneously deposit welding material between pipes, wherein the first welding torch assembly and the second welding torch assembly are moved circumferentially, by means of one or more orientation motors, in the same direction of rotation when welding material is deposited, wherein during the welding operation, the first welding torch assembly is moved in the direction upwards against gravity during at least part of its movement during welding consumable deposition, and the second welding torch assembly moves downwardly against gravity during at least part of its movement during welding consumable deposition.

94. The field system of claim 93, further comprising a third welding torch assembly that welds welding material between the pipes simultaneously with the first and second welding torch assemblies, wherein the third welding torch assembly is moved circumferentially by means of one or more motors to move in the same direction of rotation as the first and second welding torch units when welding material is deposited, while during the welding operation, the third welding torch unit moves in an upward direction, against gravity, when welding material is deposited, and also moves in a downward direction, in the direction of gravitational force, when welding material is deposited.

95. The field system according to any one of paragraphs 49-94, wherein one or more processors are operatively coupled to the measurement sensor via a wired communication channel that transmits signals from the measurement sensor to one or more processors, wherein the wired communication channel includes (i) a moving part , which moves with the measuring sensor, wherein the measuring sensor checks the area of the contact surface between the pipes and generates profile data based on such a check, and (ii) a fixed part, which remains fixed during the movement of the moving part, and additionally contains a slip ring, providing an interface between the movable and fixed part of the communication channel, allowing signals to pass from the movable part to the fixed part.

96. Field system according to claim 95, in which the measuring sensor is installed on the outer surface of the cylindrical hub, while the cylindrical hub has opposite ends and radial holes between the ends, and the movable part passes through the inside of the cylindrical hub, through the radial hole and connects with measuring sensor.

97. The field system of any one of claims 49-96, further comprising an inert gas source conveying inert gas through a pneumatic conduit to a location between the first pipe engaging device and the second pipe engaging device.

98. The field system of claim 97, wherein the pneumatic conduit has a stationary part connected to an inert gas source and a movable part that extends into the pivot hub, the movable part being connected to the stationary part via a rotating coupling.

99. The field system of any one of claims 49-98, further comprising a cylinder of compressed air, wherein the first pipe engagement device or the second pipe engagement device, or both, can be moved from the first position of disengagement from the inner surface of the pipe, to the second position engagement with the inner surface of the pipe, wherein the compressed air from the compressed air cylinder is transmitted to the first or second pipe engaging device, or both, to perform the movement, respectively, from the first position to the second position.

100. The field system of claim 99, wherein the compressed air cylinder receives compressed air from an external source supplying the compressed air cylinder through a compressed air conduit that passes through a pair of rotating couplings.

101. The field system of claim 84, wherein the one or more processors are configured to detect that an inappropriate welding temperature was used during the welding operation based on signals from the camera.

102. The field system of claim 1, wherein the one or more processors are communicatively connected to the first pipe engagement device, the second pipe engagement device, measurement sensor, motor, or welding torch via one or more wired or wireless connections.

103. The field system of claim. 1, in which one or more processors are connected with the possibility of communicating with the first pipe engaging device, the second pipe engaging device, measuring sensor, motor or welding torch through one or more wireless connections, and at the same time one or More wireless connections include a Wi-Fi connection, a Bluetooth connection, a Near Field Communication (NFC) connection, or a cellular connection.

104. The field system of claim. 1, in which one or more processors are connected with the possibility of communicating with a remote computer system and are configured to transmit the profile of the area of the contact surface between the pipes to the remote computer system, while one or more processors are configured to receive confirmation contact surface area profile or a modified version of the contact surface profile from a remote computer system, wherein the welding torch creates a weld in the contact surface area between pipes based on the confirmation or modified version of the contact surface profile.

105. The field system of claim. 1, in which one or more processors interact with the measuring sensor to scan the area of the contact surface between the pipes to determine the profile of the area of the contact surface between the pipes before the welding operation and generate profile data before welding based on such sanitization, when wherein one or more processors are communicatively coupled to a remote computer system and configured to transmit the pre-weld profile data to the remote computer system, wherein the one or more processors are configured to receive pre-weld profile data confirmation or a modified version of the pre-weld profile data. the pre-weld profile from the remote computer system in response to the transmission of the pre-weld profile data, wherein the weld is performed based on the confirmation or modified version of the pre-weld profile data.

106. The field system of claim 105, wherein the one or more processors are configured to control the operation of the first pipe engagement device and/or the second pipe engagement device based on a confirmation or modified version of the pre-weld profile data to change the area of the contact surface between pipes before welding operation.

107. The field system of claim 105, wherein the one or more processors are configured to generate a weld protocol based on a confirmation or modified version of the pre-weld profile data.

108. The field system of claim. 1, in which one or more processors interact with the measurement sensor to scan the area of the contact surface between the pipes to determine the profile of the area of the contact surface between the pipes after the welding operation and generate profile data after welding based on such a scan, when wherein one or more processors are communicatively coupled to a remote computer system and configured to transmit the post-weld profile data to the remote computer system, wherein the one or more processors are configured to receive a confirmation of the post-weld profile data or a modified version of the post-weld profile data. the post-weld profile from the remote computer system in response to the transmission of the post-weld profile data, wherein the weld is performed based on the confirmation or modified version of the post-weld profile data.

109. The field system of claim 108, wherein the one or more processors are configured to cause another welding operation to be performed in the area of the contact surface between the pipes, based on a confirmation or modified version of the profile data after welding.

110. Field system according to claim 1, in which one or more processors are connected with the possibility of communicating with a remote computer system and are configured to transmit to the remote computer system control data related to checking the area between the pipes, while the control data contains laser control data , inspection camera data, X-ray inspection data, ultrasonic inspection data, magnetic particle inspection data, eddy current inspection data and temperature inspection data.

111. Field system according to claim 110, in which the control data contains control data before welding, and wherein one or more processors are configured to:

receive a response from the remote computer system before the welding operation in response to the transmission of control data before welding to the remote computer system,

the weld between the pipes is based on the answer.

112. The field system of claim 111, wherein the pre-weld inspection data includes pre-weld laser inspection data.

113. The field system of claim 111, wherein the pre-weld inspection data comprises inspection camera data or pre-weld x-ray inspection data.

114. The field system of claim 111, wherein the response contains a welding protocol derived from pre-weld control data, and

the welding torch creates a weld between the pipes based on this welding protocol.

115. The field system according to claim 114, in which the welding protocol contains one or more parameters that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, power level of the weld arc, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

116. The field system according to claim 110, in which the control data contains control data before welding, and wherein one or more processors are configured to:

receive a response from the computer system before the welding operation in response to the transmission of control data before welding to the remote computer system, the response contains information about the need to change the area of the contact surface before the welding operation; and

control the operation of the first pipe engagement device and/or the second pipe engagement device to change the area of the contact surface between the pipes before the welding operation based on the knowledge of such a need.

117. The field system according to claim 110, in which the control data contains control data before welding, obtained on the fly, and at the same time one or more processors are configured to:

receive a response from the remote computer system during the welding operation in response to the transmission of control data received on the fly to the remote computer system,

the weld between the pipes is based on the answer.

118. The field system of claim 117, wherein the response contains one or more on-the-fly updates to the welding protocol that is derived from the on-the-fly control data, and

whereby the welding torch creates a weld between pipes based on that weld protocol and on-the-fly updates to the weld protocol.

119. The field system of claim 118, wherein the one or more processors are configured to control the position and speed of the welding torch based on on-the-fly updates of the welding protocol during a welding operation.

120. The field system of claim 117, wherein the on-the-fly inspection data contains on-the-fly laser inspection data.

121. The field system of claim 117, wherein the on-the-fly inspection data contains on-the-fly inspection camera data.

122. The field system according to claim 110, in which the control data contains control data after welding, and wherein one or more processors are configured to:

to receive a response from the remote computer system after the welding operation in response to the transmission of control data after welding to the remote computer system; and

cause the welding torch to perform a subsequent welding operation between the pipes based on the response.

123. The field system of claim 110, wherein the one or more processors are configured to communicate to the remote computer system one or more welding parameters used to perform the welding operation to create the weld.

124. The field system according to claim 123, in which one or more processors are configured to:

receive a response from the remote computer system in response to the transmission of control data and welding parameters to the remote computer system; and

prompting the welding torch to perform a welding operation between pipes based on the response.

125. The field system according to claim 123, in which the welding parameters contain one or more parameters that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, power level of the welded arc, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

126. The field system according to claim 110, in which one or more processors are configured to:

receive a response from the remote computer system in response to the transmission of control data to the remote computer system, the response being due to the control data and additional data received by the remote computer system, the additional data relating to (i) the results of observation of one or more operations performed on pipes , (ii) checking other pipes, or (iii) one or more input parameters used to perform the learned operations; and

prompting the welding torch to perform a welding operation between pipes based on the response.

127. The field system according to claim 1, in which one or more processors are connected with the possibility of exchanging data with a remote computer system and are configured to:

transmit to the remote computer system the laser inspection data related to the inspection of the area between the pipes and the inspection camera data related to the inspection of the area between the pipes;

receive a response from the remote computer system in response to transmitting the laser inspection data and inspection camera data to the remote computer system; and

prompting the welding torch to perform a welding operation between pipes based on the response.

128. The field system according to claim 1, in which one or more processors are connected with the possibility of exchanging data with a remote computer system and are configured to:

transmitting, to the remote computer system, laser inspection data related to inspecting an area between pipes, inspection camera data related to inspecting an area between pipes, and X-ray inspection data related to inspecting an area between pipes;

receiving a response from the remote computer system in response to transmitting the laser inspection data, inspection camera data, and X-ray inspection data to the remote computer system; and

prompting the welding torch to perform a welding operation between pipes based on the response.

129. A welding data processing system facilitating pipe welding remotely from the field system to perform pipe welding operations between the first pipe and the second pipe, wherein the remote field system includes a measuring sensor configured to emit a research radiation beam to scan the profile of the contact area. surfaces between the first and second pipes, and a welding torch configured to create a weld between the first and second pipes based on the profile of the area of the contact surface between the first and second pipes, wherein the welding data processing system includes:

a receiver configured to receive from the remote welding system profile data determined by scanning the area of the contact surface between the pipes by the measuring sensor;

one or more processors configured to compare one or more characteristics of the profile data obtained by scanning the area of the contact surface with one or more characteristics of predefined profile data of the predefined area of the contact surface and configured to determine the control operation data for the remote field system based on such a comparison; and

a transmitter configured to transmit control operation data to a remote field system, the control operation data being configured to cause the welding torch to perform one or more welding operations on the area of the contact surface between the pipes.

130. The welding data processing system according to claim 129, in which the profile data contains profile data before welding, determined by scanning the contact surface area between pipes before the welding operation, and wherein one or more predefined profile characteristics are associated with one or more a suitable preset profile before welding, and these control operations indicate whether the field system should start the welding operation.

131. The welding data processing system according to clause 129, in which one or more processors are configured to:

determine one or more matching profile characteristics between one or more characteristics from the profile data and one or more predefined profile characteristics based on such a comparison; and

select one or more welding protocols based on one or more matched profile characteristics,

wherein these control operations are generated to include one or more selected welding protocols, and one or more welding operations are performed by the welding torch based on one or more selected welding protocols.

132. The welding data processing system according to clause 131, in which one or more processors are configured to:

obtain from one or more field systems data related to (i) examining one or more operations performed on pipes, (ii) testing other pipes, or (iii) one or more input parameters used to perform the studied operations;

generate, based on associated data received from one or more field systems, a welding protocol associated with setting predefined profile parameters; and

select a generated welding protocol to include in the control operation data based on one or more matched profile parameters containing a set of predefined profiles associated with the generated welding protocol,

wherein these control operations are generated to include the selected welding protocol, and one or more welding operations are performed by the welding torch based on the one or more selected welding protocols.

133. The welding data processing system according to claim 129, in which the profile data contains profile data obtained on the fly, determined by scanning the contact surface area between pipes during the welding operation, and the control operation data contains updates " on the fly" for one or more welding parameters for a welding operation.

134. The welding data processing system of claim 133, wherein the transmission of the control operation data causes the field system to generate welding signals for controlling the welding torch based on on-the-fly updates of one or more welding parameters during the welding operation.

135. The welding data processing system according to claim 129, in which the profile data contains profile data after welding, determined by scanning the contact surface area between pipes after the welding operation, and wherein one or more predefined profile characteristics are associated with one or more a suitable predetermined profile after welding, and these control operations indicate whether the result of the welding operation is acceptable.

136. The welding data processing system of claim 135, wherein the transmission of the control operation data causes the welding torch to perform another welding operation in the area of the contact surface between the pipes.

137. The welding system according to any one of paragraphs 1-48, which further comprises a frame assembly, a drive motor and a plurality of rollers, while the rollers are configured to engage with the inner surface of one or more pipes, a drive motor configured to drive the rollers in such a way so as to move the frame assembly, the first pipe engaging device, the second pipe engaging device, and the measurement sensor along at least one of the pipes in its interior.

138. The welding system of claim 137, further comprising a motor power supply carried by the frame assembly, the motor power supply being configured to provide power to the drive motor.

139. The welding system of claim 138, further comprising a torch power source carried by the frame assembly, the torch power source configured to provide power to the torch.

140. The welding system of claim 138, wherein the engine power supply includes a battery.

141. Welding system according to claim 139, in which the torch power supply contains a battery.

142. The welding system of claim 137, further comprising a sensor that detects the end of the pipe.

143. Field system for welding two pipes, containing:

a frame configured to be placed inside the pipes;

a plurality of rollers configured to rotatably hold the frame;

a drive motor that drives rollers to move the frame inside the tubes;

a brake system holding the frame in a predetermined position inside the pipes from moving;

a measurement sensor carried by the frame, the measurement sensor being configured to characterize a contact surface area between pipes;

a welding torch carried by the frame;

one or more batteries carried by the frame, wherein the one or more batteries are configured to provide power to the drive motor, the measurement sensor, and the welding torch; and

one or more processors operatively associated with the drive motor, the measurement sensor and the welding torch.

144. The welding system of claim. 143, in which the brake system includes a first pipe clamp, configured to fix the first of the two pipes, and a second pipe clamp, configured to fix the second of the two pipes.

145. The welding system according to claim 143, in which the measuring sensor contains a measuring sensor that emits a research beam of radiation.

146. The welding system of claim 143, wherein the one or more batteries comprise a plurality of independent batteries, wherein the batteries for the welding torch are independent of the batteries for the drive motor and the measurement sensor.

147. The welding system of claim. 146, in which the batteries for the drive motor are independent of the batteries for the measuring sensor.

148. A method for welding a pair of insulated pipes to each other, wherein each pipe contains an internal metal part of the pipe surrounded by an insulating material, while the ends of the pipes to be welded have protruding internal metal parts of the pipe, and the method includes:

alignment of the protruding metal ends of the welded pipe;

welding the protruding metal ends of the pipe to be welded to each other;

heating the protruding ends of the welded pipes;

applying an insulator to the heated protruding ends of the welded pipes such that the insulator adheres to the outer surface of the inner metal part of the pipe, thus insulating the previously protruding pipe ends; and

application of cooling energy inside pipes to the inner surface of metal pipes.

149. The method according to p. 148, characterized in that the cooling power is applied by means of a fluid released into the interior of the pipes in such a way that the fluid is in direct contact with the inner surface of the pipes.

150. The method according to p. 148, characterized in that the cooling power is applied by means of a moving fluid located inside the heat exchanger, while the contact surface of the heat exchanger is made with the possibility of placing it in contact with the inner surface of the welded pipes to remove heat from the welded pipes.

151. The method according to p. 149 or 150, characterized in that the fluid contains a liquid.

152. The method according to p. 149 or 150, characterized in that the fluid contains a gas.

153. A system for welding a pair of insulated pipes to each other, wherein each pipe contains an internal metal part of the pipe surrounded by an insulating material, while the ends of the pipes to be welded have protruding internal metal parts of the pipe, while the system contains:

a welding torch configured to weld the protruding metal ends of the pipe to each other;

a heater configured to heat protruding metal ends of the welded pipes;

an insulator supply source configured to apply an insulating material to the heated protruding ends of the welded pipes so that the insulator is adhered to the outer surface of the inner metal part of the pipe, thereby insulating the previously protruding ends of the pipes; and

a cooling system configured to be placed inside the pipes, wherein the cooling system applies cooling energy to the inner surface of the metal pipes, which contributes to the cooling of the metal pipes after the application of the insulating material.

154. The system of claim 153, wherein the source of insulator comprises a container configured to contain insulating material and an outlet fitting configured to supply insulating material to the protruding ends of the welded pipes.

155. The system according to claim 153 or 154, in which the cooling system includes a heat exchanger configured to transfer a mobile fluid through it, while the contact surface of this heat exchanger is configured to be placed in contact with the inner surface of the welded pipes to remove heat from the welded pipes .

156. The system of claim 155, wherein the cooling system comprises a motor, wherein the motor is configured to move the contact surface outward to engage with the inner surface of the metal pipes.

157. The system of any one of items 153-156, wherein the cooling system comprises a blower configured to supply cooling gas to the inside surface of the welded pipes to remove heat from the welded pipes.

158. The system of any one of items 153-157, wherein the cooling system comprises fluid nozzles configured to apply coolant to the inside surface of the welded pipes to remove heat from the welded pipes.

159. The system according to any one of paragraphs 153-158, further comprising an ultrasonic measuring station configured to check the weld between the welded metal pipes, and wherein the cooling system is configured to contribute to the cooling of the metal pipes after the pipes are welded, and before checking the weld with an ultrasonic measuring station.

160. The system of claim 159, further comprising a temperature sensor, wherein the ultrasonic measurement station test begins after the temperature sensor detects that the temperature of the pipe near the weld is below a predetermined threshold.

161. The method of claim 148 further comprising performing the pipeline deployment procedure, wherein application of cooling energy reduces the waiting time between applying the insulator and performing the pipeline deployment procedure.

162. The method according to p. 161, characterized in that the procedure for deploying the pipeline is a procedure for enlarging sections of the pipeline.

163. The method of claim 161, wherein the pipeline deployment procedure is an S-lay pipe procedure.

164. The method of claim 161, wherein the procedure for deploying the pipeline is a procedure for lowering the pipeline.

165. A method for welding pipes, including:

aligning the ends of the two pipes to be welded, wherein the pipes comprise an inner metal part of the pipe surrounded by an insulating material, and the inner metal parts of the pipe protrude beyond the pipe parts near the ends of the pipes to be welded;

welding the aligned pipe ends to each other within the pipes to form a welded joint;

generating welding data during welding of the aligned ends, the welding data corresponding to the welding parameters associated with this welding;

inspection of the welded joint with a control laser from inside the welded pipes to obtain data from the internal inspection of the weld;

checking the welded joint with a research radiation source to obtain radiation control data;

transmitting welding data, internal weld inspection data, and radiation inspection data to a remote computer system to produce additional welding data; and

obtaining the additional welding data produced, wherein the additional welding data is produced based on the transmitted data and the additional control data obtained by the remote system while testing other pipes.

166. The method according to p. 165, characterized in that the pipes have an outer diameter of less than 24 inches.

167. The method according to p. p. 165 or 166, additionally including:

perform an additional welding procedure between pipes based on additional welding data.

168. The method of claim 167, wherein performing the additional welding procedure includes performing the additional welding procedure on the outside of the pipes based on the additional welding data.

169. The method of claim 167, wherein performing the additional welding procedure includes performing an additional welding procedure inside the pipes based on the additional welding data.

170. The method according to any one of paragraphs 165-169, characterized in that the reference laser and the source of research radiation are part of the field system, and while additional control data is received by a remote computer system from the field system.

171. The method according to any one of paragraphs 165-169, characterized in that the reference laser and the source of research radiation are part of the field system, and at the same time additional control data is received by a remote computer system from a second field system different from the first field system.

172. The method according to any one of paragraphs 165-171, characterized in that the source of research radiation contains a source of radiographic research radiation, and the research radiation data contains X-ray radiation control data, while welding data, internal welding check data, and data X-ray controls are transferred to a remote computer system.

173. The method according to any one of paragraphs 165-172, characterized in that the welding data, internal welding check data or research radiation control data are transmitted to the remote computer system on the fly.

174. The method according to any one of paragraphs 173, additionally including:

receiving on-the-fly profile data from a remote computer system during welding of aligned ends, wherein the on-the-fly profile data is based on welding data, internal control data, or radiation control data; and

generation of welding signals to control the welding torch based on on-the-fly data during welding of aligned ends.

175. The method of claim 173, further comprising:

receiving on-the-fly profile data from a remote computer system during welding of aligned ends, wherein the on-the-fly profile data is based on internal control data or radiation control data; and

generation of welding signals to control the welding torch based on on-the-fly data during welding of aligned ends.

176. The method of claim 173, further comprising:

receiving on-the-fly updates for welding parameters, wherein the on-the-fly updates for welding parameters are based on welding data, internal control data, or radiation control data; and

generation of welding signals for on-the-fly welding torch control based on on-the-fly updates during welding of aligned ends.

177. The method according to any one of paragraphs 165-176, characterized in that the welding parameters contain parameters that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, level welding arc power, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip in relation to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded .

178. A field system facilitating field testing and operations based on it, comprising:

a field device configured to perform operations that physically affect the object;

a control device configured to scan the object; and

one or more processors connected with the possibility of communicating with the verification device and configured to receive control data associated with the scanning of the object from the control device,

wherein one or more processors are connected to the possibility of exchanging data with a remote computer system, and are configured to transmit control data to the remote computer system,

wherein one or more processors are configured to receive data related to performing operations from a remote computer system capable of responding to the transmission of control data and causing the field device to perform operations that physically affect the object, based on data related to performing operations , and

wherein the data related to the execution of operations is produced based on the control data and other control data associated with a particular scan of another object.

179. The field system according to claim 178, in which one or more processors are configured to:

receive other control data associated with scanning another object; and

transmit other control data to a remote computer system.

180. The field system of claim 178 wherein the other control data is received by the remote computer system from another field system.

181. A field system according to any one of paragraphs 178-180, in which the field device performs one or more operations before scanning an object, while one or more processors transmit one or more input parameters of one or more operations to a remote computer system, and wherein the transaction-related data received from the remote computer system is based on control data and one or more input parameters.

182. The field system according to any one of paragraphs 178-181, in which the object contains the first object, and the data associated with the operation contains instructions associated with the welding operation between the first object and the second object,

wherein the verifier scans the area between the first object and the second object, and

wherein the one or more processors cause the field device to weld the area between the first object and the second object based on the instructions associated with the welding.

183. The field system of claim 182, wherein the welding-related instructions contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, welding arc power level welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

184. A field system according to any one of paragraphs 178-181, in which the data associated with the operation contains instructions related to applying a coating to an object, and at the same time one or more processors induce the field device to apply one or more layers of a coating on the object based on the instructions relating to the application of the coating.

185. The field system of claim 184, wherein the coating instructions include instructions relating to preheat temperature or coating thickness.

186. A field system according to any one of paragraphs 178-181, in which the data associated with the operation contains instructions related to the alignment of the object, and wherein one or more processors cause the field device to align the object based on the instructions related to the alignment of the object. alignment.

187. The field system according to any one of paragraphs 178-181, in which the data associated with the operation contains instructions related to changing the object, and wherein one or more processors cause the field device to change the object based on the instructions related to change.

188. The field system of claim 187, wherein the change to the first object comprises expanding at least a portion of the object.

189. The field system of claim 187, wherein changing the first object comprises reducing at least a portion of the object.

190. The field system of claim 187, wherein the change in the first object comprises a radial change in the size of at least a portion of the object.

191. The field system according to any one of paragraphs 178-190, in which the control device contains a control laser, a control camera, an X-ray control device, or an ultrasonic control device, and the control data contains laser control data, control camera data, X-ray data control or ultrasonic control data.

192. A field system according to any one of paragraphs 178-190, in which the control device contains a control laser, a control camera, an X-ray control device, a gamma control device, an ultrasonic control device, a magnetic particle tester, an eddy current control device, or a temperature control device, wherein the test data comprises laser test data, test camera data, X-ray test data, gamma test data, ultrasonic test data, magnetic particle test data, eddy current test data, or temperature control data.

193. Field system facilitating field testing and physical operations based on it, comprising:

scanning the control device of the field system of the object to provide control data associated with scanning the object, one or more processors;

transmission by one or more processors of the field system of control data to a remote computer system;

receiving by one or more processors of data associated with the execution of the operation, which physically affect the object, from a remote computer system capable of responding to the transmission of control data; and

inducing one or more processors of a field device of a field system to perform operations that physically affect an object, based on data associated with the operation,

wherein the data related to the execution of operations is produced based on the control data and other control data associated with a particular scan of another object.

194. The method of claim 193, further comprising:

scanning the other object to provide other control data associated with scanning the other object to one or more processors; and

transmission by one or more processors of other control data to a remote computer system.

195. The field system of claim 193 wherein the other control data is received by the remote computer system from another field system.

196. A field system according to any one of paragraphs 193-195, in which the field device performs one or more operations before scanning the object, while one or more processors transmit one or more input parameters of one or more operations to a remote computer system, and wherein the data associated with the operation received from the remote computer system is based on control data and one or more input parameters.

197. The method according to any one of paragraphs 193-196, characterized in that the object contains the first object, and the data associated with the operation contains instructions associated with the welding operation between the first object and the second object,

wherein the verifier scans the area between the first object and the second object, and

wherein the one or more processors cause the field device to weld the area between the first object and the second object based on the instructions associated with the welding.

198. The method according to p. 197, characterized in that the instructions associated with welding contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, power level of the welded arc, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

199. The method according to any one of paragraphs 193-196, characterized in that the data associated with the operation contains instructions related to coating the object, and wherein one or more processors induce the field device to apply one or more layers coating on the object based on the instructions related to coating.

200. The method of claim. 199, characterized in that the instructions associated with the application of the coating contain instructions related to the preheat temperature or coating thickness.

201. The method according to any one of paragraphs 193-196, characterized in that the data associated with the operation contains instructions related to the alignment of the object, and wherein one or more processors cause the field device to align the object based on the instructions related to the alignment of the object. to alignment.

202. The method according to any one of paragraphs 193-196, characterized in that the data associated with the operation contains instructions related to changing the object, and wherein one or more processors cause the field device to change the object based on the instructions related to changing the object. to change.

203. The method of claim 202, wherein changing the first object comprises expanding at least a portion of the object.

204. The method of claim 202, wherein changing the first object comprises reducing at least a portion of the object.

205. The method of claim 202, wherein changing the first object comprises a radial resizing of at least a portion of the object.

206. The method according to any one of paragraphs 193-205, in which the control device contains a control laser, a control camera, an x-ray control device or an ultrasonic control device, and the test data contains laser control data, control camera data, x-ray data control or ultrasonic control data.

207. The method according to any one of paragraphs 193-205, characterized in that the control device contains a control laser, a control camera, an X-ray control device, a gamma control device, an ultrasonic control device, a magnetic particle control device, an eddy current control device or a temperature control device, and wherein the test data includes laser test data, test camera data, X-ray test data, gamma test data, ultrasonic test data, magnetic particle test data, eddy current test data, or temperature control data.

208. A computer system facilitating field testing and physical operations based on it remotely from the field system on which field testing and physical operations are performed, while the remote field system includes a control device configured to scan an object, and a field device configured to perform operations that physically affect the object, while the computer system contains:

a receiver configured to receive from the remote field system control data associated with scanning the object by the control device;

one or more processors configured to process control data to generate data associated with performing operations that physically affect the object; and

a transmitter configured to transmit data associated with the operation to the remote field system causing the remote field system to perform operations that physically affect the object, the operations being performed based on the data associated with the operation.

209. The computer system of claim 208, wherein the receiver is configured to receive from the remote field system other control data associated with scanning another object, and wherein the data associated with the operation is generated by one or more processors based on the control data and other control data.

210. The computer system of claim 208, wherein the receiver is configured to receive from another remote field system located remotely from the remote field system, other control data associated with scanning another object, and wherein the data associated with the operation is generated by one or more processors based on control data and other control data.

211. The computer system of claim 208-210, wherein one or more operations are performed on an object prior to scanning the object, wherein the receiver is configured to receive one or more inputs of one or more operations from a remote field system, and wherein the data, associated with an operation are generated by one or more processors based on control data and one or more input parameters.

212. The computer system according to clause 208-211, in which the object contains the first object and the data associated with the operation contains instructions associated with the welding operation between the first object and the second object, and while the welding operation is performed to weld the first object to the second object based on the instructions associated with the welding operation.

213. The computer system of claim 212, wherein the welding-related instructions contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, welding arc power level welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

214. The computer system according to any one of paragraphs 208-211, in which the data associated with the operation contains instructions related to applying a coating to an object, and wherein the coating operation is performed to apply one or more layers of a coating to an object on on the basis of the instructions relating to the application of the coating.

215. The computer system of claim 214, wherein the coating instructions include instructions relating to preheat temperature or coating thickness.

216. The computer system according to any one of paragraphs 208-211, wherein the data associated with the operation contains instructions related to the alignment of the object, and the alignment operation is performed to align the object based on the instructions related to the alignment.

217. The computer system according to any one of paragraphs 208-211, in which the data associated with the operation contains instructions related to changing the object, and the change operation is performed to change the object based on the instructions related to the change.

218. A computer system according to any one of paragraphs 208-217, in which the control data contains laser control data, control camera data, X-ray control data, or ultrasonic control data.

219. The computer system according to any one of paragraphs 208-217, in which the control data contains laser control data, control camera data, X-ray control data, gamma control data, ultrasonic control data, magnetic particle control data, vortex control data currents or temperature control data.

220. A method facilitating field testing and physical operations based on it remotely from the field system on which field testing and physical operations are performed, while the remote field system includes a control device configured to scan an object, and a field device configured to perform operations that physically affect an object, the method further comprising:

receipt by the receiver from the remote field system of control data related to the scanning of the object by the control device;

processing by one or more processors of control data to generate data associated with the execution of operations that physically affect the object; and

transmission by the transmitter of data associated with the operation, the remote field system, causing the remote field system to perform operations that physically affect the object, while the operations are performed based on the data associated with the operation.

221. The method of claim 220, further comprising:

receipt by the receiver from a remote field system of other control data associated with scanning another object,

wherein the data associated with the operation is generated by one or more processors based on the control data and other control data.

222. The method of claim 220, further comprising:

receiving by the receiver from another field system located remotely from this remote field system, other control data associated with scanning another object,

wherein the data associated with the operation is generated by one or more processors based on the control data and other control data.

223. The method according to any one of paragraphs 220-222, characterized in that one or more operations are performed on the object before scanning the object, while the method further includes:

receiving by the receiver one or more input parameters of one or more operations from a remote field system,

wherein the data associated with the operation is generated by one or more processors based on the control data and one or more input parameters.

224. The method according to any one of paragraphs 220-223, characterized in that the object contains the first object, and the data associated with the operations contains instructions associated with the welding operation between the first object and the second object, and while the welding operation is performed for welding the first object to the second object based on the instructions associated with the welding operation.

225. The method according to p. 224, characterized in that the instructions associated with the welding operation contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, power level welding arc, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

226. The method according to any one of paragraphs 220-223, characterized in that the data associated with the operation contains instructions related to coating the object, and the coating operation is performed to apply one or more layers of coating to the object based on instructions relating to coating application.

227. The method according to p. 226, characterized in that the instructions associated with the application of the coating contain instructions related to the preheat temperature or coating thickness.

228. A method according to any one of paragraphs 220-223, characterized in that the data associated with the operation contains instructions related to the alignment of the object, and the alignment operation is performed to align the object based on the instructions related to the alignment.

229. The method according to any one of paragraphs 220-223, in which the data associated with the operation contains instructions related to changing the object, and wherein the change operation is performed to change the object based on the instructions related to the change.

230. The method according to any one of paragraphs 220-229, characterized in that the control data contains laser control data, control camera data, X-ray control data or ultrasonic control data.

231. The method according to any one of paragraphs 220-229, characterized in that the control data contains laser control data, control camera data, X-ray control data, gamma control data, ultrasonic control data, magnetic particle control data, control data eddy current or temperature monitoring data.

232. A computer system that facilitates field testing on a field system and physical operations based on it, wherein the field system includes a control device configured to scan an object and one or more field devices configured to perform one or more operations that physically affect the object, while the computer system contains:

a receiver configured to receive from the field system control data associated with scanning of the object by the control device, wherein the scanning of the object by the control device follows the performance of one or more operations by one or more field devices that physically affect the object, and one or more operations are performed using the first set of input parameters;

one or more processors configured to:

detect defects associated with an object based on control data;

generate an operation protocol associated with at least one or more operations type in response to the detection of a defect, wherein the operation protocol comprises a second set of input parameters having at least one input parameter different from the first set of input parameters;

select an operation protocol for performing a subsequent operation similar to at least one or more operations; and

generate, based on at least one input parameter of the operation protocol, data associated with the execution of the subsequent operation; and

a transmitter configured to transmit data associated with the operation to one or more field systems, prompting one or more field systems to perform subsequent operations, the subsequent operation being based on the data associated with the operation.

233. The computer system of claim 232, wherein the transaction protocol is generated by modifying a predetermined transaction protocol to include a second set of input parameters.

234. The computer system of claim 233, wherein prior to the modification, the first set of input parameters was used to perform one or more operations based on a predefined operation protocol selected to perform one or more operations.

235. A computer system according to any one of paragraphs 232-234, in which one or more processors compare the control data with a predetermined quality profile and the detection of a defect associated with an object is based on this comparison.

236. The computer system according to any one of paragraphs 232-235, in which one or more processors provide control data or the results of their analysis for demonstration to the user, and receive user input informing about the defect, and at the same time detecting a defect associated with object based on defect information.

237. A computer system according to any one of paragraphs 232-236, in which the operation protocol is generated based on the detection of a defect and the first set of input parameters.

238. The computer system according to clause 232-237, in which the data associated with the operation contains instructions associated with the welding operation between the first object and the second object, and while the welding operation is performed to weld the first object to the second object based on the instructions, associated with the welding operation.

239. The computer system of claim 238, wherein the welding-related instructions contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, welding arc power level welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

240. The computer system according to any one of paragraphs 232-237, in which the data associated with the operation contains instructions related to applying a coating to an object, and wherein the coating operation is performed to apply one or more layers of a coating to an object on on the basis of the instructions relating to the application of the coating.

241. The computer system of claim 240, wherein the coating instructions include instructions relating to preheat temperature or coating thickness.

242. A computer system according to any one of paragraphs 232-237, wherein the data associated with the operation contains instructions related to the alignment of the object, and the alignment operation is performed to align the object based on the instructions related to the alignment.

243. A computer system according to any one of paragraphs 232-237, wherein the data associated with the operation contains instructions related to changing an object, and wherein the change operation is performed to change the object based on the instructions related to the change.

244. A computer system according to any one of paragraphs 232-243, in which the control data contains laser control data, control camera data, X-ray control data, or ultrasonic control data.

245. The computer system according to any one of paragraphs 232-243, in which the control data contains laser control data, control camera data, X-ray control data, gamma control data, ultrasonic control data, magnetic particle control data, vortex control data currents or temperature control data.

246. A method facilitating field testing on a field system and physical operations based on it, wherein the field system comprises a control device configured to scan an object, and one or more field devices configured to perform one or more operations that physically affect on the object, the method includes:

receipt by the receiver from the field system of control data related to the scanning of the object by the control device, wherein the scanning of the object by the control device follows the performance of one or more operations by one or more field devices that physically affect the object, and one or more operations are performed using the first set input parameters;

detection by one or more processors of a defect associated with the object, based on the control data;

one or more processors generating an operation protocol associated with at least one type of one or more operations in response to the detection of a defect, wherein the operation protocol comprises a second set of input parameters having at least one input parameter different from the first set of input parameters ;

one or more processors selecting an operation protocol to perform a subsequent operation similar to at least one or more operations; and

generating data associated with the execution of a subsequent operation, one or more processors based on at least one input parameter of the operation protocol; and

transmission by the transmitter of data associated with the operation, one or more field systems, prompting one or more field systems to perform subsequent operations, while the subsequent operation is based on data associated with the operation.

247. The method of claim 246, wherein generating the transaction protocol comprises modifying a predefined transaction protocol to include a second set of input parameters.

248. The method of claim 247, wherein before the modification, the first set of input parameters was used to perform one or more operations based on a predefined operation protocol selected to perform one or more operations.

249. The method according to any one of paragraphs 246-248, characterized in that it additionally includes:

comparison by one or more control data processors with a predetermined quality profile,

wherein the detection of the defect associated with the object is based on this comparison.

250. The method according to any one of paragraphs 246-249, characterized in that it additionally includes:

providing one or more processors with control data, or the results of their analysis for demonstration to the user and receiving user input informing about the defect,

wherein the detection of the defect associated with the object is based on this information.

251. The method according to any one of paragraphs 246-250, characterized in that the operation protocol is generated based on the detection of a defect and the first set of input parameters.

252. The method according to any one of paragraphs 246-251, characterized in that the data associated with the operation contains instructions associated with the welding operation between the first object and the second object, and while the welding operation is performed to weld the first object to the second object based on the instructions associated with the welding operation.

253. The method according to p. 252, characterized in that the instructions associated with welding contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, power level of the welded arc, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

254. The method according to any one of paragraphs 246-251, characterized in that the data associated with the operation contains instructions related to coating the object, and the coating operation is performed to apply one or more layers of coating to the object based on instructions relating to coating application.

255. The method according to p. 254, characterized in that the instructions associated with the application of the coating contain instructions related to the preheat temperature or coating thickness.

256. A method according to any one of paragraphs 246-251, characterized in that the data associated with the operation contains instructions related to the alignment of the object, and the alignment operation is performed to align the object based on the instructions related to the alignment.

257. The method according to any one of paragraphs 246-251, in which the data associated with the operation contains instructions related to changing the object, and wherein the change operation is performed to change the object based on the instructions related to the change.

258. The method according to any one of paragraphs 246-257, characterized in that the control data contains laser control data, control camera data, X-ray control data or ultrasonic control data.

259. The method according to any one of paragraphs 246-257, characterized in that the control data contains laser control data, control camera data, X-ray control data, gamma control data, ultrasonic control data, magnetic particle control data, control data eddy current or temperature control data.

260. A computer system facilitating field testing on a field system and physical operations based thereon, wherein the field system comprises a control device configured to scan an object and one or more field devices configured to perform one or more operations that physically affect the object, while the computer system contains:

a receiver configured to receive from the field system control data associated with scanning the object, the scanning of the object following the execution of one or more operations that physically affect the object, and one or more operations are performed using the first set of input parameters;

one or more processors configured to:

determine, based on the control data, whether the quality of one or more aspects of the object obtained as a result of one or more operations exceeds the quality standards specified in the predefined quality profile;

generate an operation protocol associated with at least one type of one or more operations, wherein the operation protocol is generated to include one or more sets of input parameters in response to the fact that the quality of one or more aspects of the object exceeds the quality standards specified in a predefined quality profile;

select an operation protocol for performing a subsequent operation similar to at least one or more operations; and

generate, based on at least one input parameter of the operation protocol, data associated with the execution of the subsequent operation; and

a transmitter configured to transmit data associated with the operation to one or more field systems, prompting one or more field systems to perform subsequent operations, the subsequent operation being based on the data associated with the operation.

261. The computer system of claim 260, wherein in response to exceeding the quality of one or more aspects of an object of quality standards specified in a predefined quality profile, one or more processors store a second predefined quality profile used to analyze the quality of one or more aspects obtained as a result of one or more subsequent operations, while the second predefined quality profile is determined based on control data.

262. The computer system according to claim 260 or 261, in which the data associated with the operation contains instructions associated with the welding operation between the first object and the second object, and while the welding operation is performed to weld the first object to the second object based on the instructions, associated with the welding operation.

263. The computer system of claim 262, wherein the welding-related instructions contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, welding arc power level welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

264. The computer system of claim 260 or 261, wherein the data associated with the operation contains instructions related to applying a coating to an object, and wherein the coating operation is performed to apply one or more layers of a coating to an object based on instructions related to to coating.

265. The computer system of claim 264, wherein the coating instructions include instructions relating to preheat temperature or coating thickness.

266. The computer system of claim 260 or 261, wherein the data associated with the operation contains instructions related to alignment of the object, and wherein the alignment operation is performed to align the object based on the instructions related to alignment.

267. The computer system of claim 260 or 261, wherein the data associated with the operation contains instructions related to changing an object, and wherein the change operation is performed to change the object based on the instructions related to the change.

268. A computer system according to any one of paragraphs 260-267, in which the control data contains laser control data, control camera data, X-ray control data, or ultrasonic control data.

269. The computer system according to any one of paragraphs 260-267, in which the control data contains laser control data, control camera data, X-ray control data, gamma control data, ultrasonic control data, magnetic particle control data, vortex control data currents or temperature control data.

270. A method facilitating field testing on a field system and physical operations based on it, wherein the field system comprises a control device configured to scan an object and one or more field devices configured to perform one or more operations that physically affect on the object, wherein the method includes:

receiving by the receiver from the field system control data associated with scanning the object, wherein the scanning of the object follows the execution of one or more operations that physically affect the object, and one or more operations are performed using the first set of input parameters;

determining by one or more processors, based on the control data, whether the quality of one or more aspects of the object, obtained as a result of one or more operations, exceeds the quality standards specified in a predefined quality profile;

one or more processors generating an operation protocol associated with at least one type of one or more operations, wherein the operation protocol is generated to include one or more sets of input parameters in response to the fact that the quality of one or more aspects of the object exceeds the quality standards specified in the predefined quality profile;

one or more processors selecting an operation protocol to perform a subsequent operation similar to at least one or more operations; and

generating data associated with the execution of a subsequent operation, one or more processors based on at least one input parameter of the operation protocol; and

transmission by one or more processors of data associated with the operation to one or more field systems, prompting one or more field systems to perform subsequent operations, with the subsequent operation based on the data associated with the operation.

271. The method according to p. 270, characterized in that it further includes:

in response to exceeding the quality of one or more aspects of an object of quality standards specified in a predefined quality profile, by one or more processors, a second predefined quality profile used to analyze the quality of one or more aspects resulting from one or more subsequent operations, when In this second predefined quality profile is determined based on the control data.

272. The method according to claim 270 or 271, characterized in that the data associated with the operation contains instructions associated with the welding operation between the first object and the second object, and the welding operation is performed to weld the first object to the second object based on the instructions associated with the welding operation.

273. The method according to p. 272, characterized in that the instructions associated with welding contain instructions that relate to wire feed speed, wire consumption, oscillation width, oscillation shape, oscillation amplitude, welding time, gas flow rate, power level of the welded arc, welding current, welding voltage, welding impedance, welding torch travel speed, positioning of the welding torch welding tip along the pipe axis, angular positioning of the welding torch welding tip with respect to the plane of rotation, or distance of the welding torch welding tip from the inner surface of the pipes to be welded.

274. The method according to p. 270 or 271, characterized in that the data associated with the operation contains instructions related to coating the object, and the coating operation is performed to apply one or more coating layers to the object based on the instructions, related to coating.

275. The method according to p. 274, characterized in that the instructions associated with the application of the coating contain instructions related to the preheat temperature or coating thickness.

276. The method of claim. 270 or 271, wherein the data associated with the operation contains instructions related to the alignment of the object, and the alignment operation is performed to align the object based on the instructions related to the alignment.

277. The method of claim. 270 or 271, characterized in that the data associated with the operation contains instructions related to changing the object, and the change operation is performed to change the object based on the instructions related to the change.

278. The method according to any one of paragraphs 270-277, characterized in that the control data contains laser control data, control camera data, X-ray control data or ultrasonic control data.

279. The method according to any one of paragraphs 270-277, characterized in that the control data contains laser control data, control camera data, X-ray control data, gamma control data, ultrasonic control data, magnetic particle control data, control data eddy current or temperature control data.

280. A computer system facilitating field testing and operations based on it, comprising:

one or more processors configured to:

receiving data from one or more field systems related to the investigation of one or more operations performed on a plurality of objects, wherein the plurality of objects contains (i) one or more objects determined to be defective as a result of one or more of the investigated operations, and (ii ) one or more items free from defects;

comparing, based on study-related data, a first set of operations studies performed on an item determined to be defective with another set of operations studies performed on one or more items not having defects;

determining, based on comparison, the overall differences that the first set of studies have with one or more other sets of studies; and

induce, based on the common difference, to implement an operation trigger such that the field system is prompted to perform the operation associated with the operation trigger when a condition corresponding to the common difference occurs during a subsequent operation that physically affects one or more additional objects.

281. The computer system of claim 280, wherein one or more processors are configured to:

determine a first set of common differences that the first set of studies has with one or more other sets of studies based on a comparison of the first set of studies with one or more other sets of studies;

compare, based on data associated with the study, the second set of operations studies performed on the second object determined to be defective, with one or more other set of operations studies performed on one or more other objects that do not have defects;

determine, based on a comparison of the second set of studies with one or more other sets of studies, a second set of common differences that the second set of studies has with one or more other sets of studies; and

determine one or more matches between the first set of common differences and the second set of common differences,

wherein the operation trigger is prompted to be implemented based on one or more matches, where one or more matches contain common differences.

282. The computer system according to claim 280 or 281, in which one or more processors are configured to:

control one or more subsequent operations performed at the additional facility; and

cause the operation associated with the operation trigger to be performed on the additional object based on the operation trigger and monitoring determining the condition corresponding to the common differences during one or more subsequent operations.

283. The computer system of claim 282, wherein the operation associated with the operation trigger comprises modifying one or more input parameters for one subsequent operation during that one subsequent operation.

284. The computer system of claim 283, wherein the one or more input modified parameters comprise one or more welding parameters, coating parameters, alignment parameters, or change parameters.

285. The computer system of claim 282, wherein the operation associated with the operation trigger comprises modifying one or more input parameters for at least one more of the subsequent operations.

286. The computer system of claim 282, wherein the operation associated with the operation trigger comprises stopping a subsequent operation.

287. The computer system of claim 282, wherein the operation associated with the operation trigger comprises generating an alarm indicating the occurrence of the specified condition during one subsequent operation.

288. A computer system according to any one of paragraphs 280-287, in which one or more processors are configured to:

control one or more operations performed on a set of objects,

however, the data associated with the study is obtained on the basis of monitoring one or more operations.

289. The computer system according to claim 288, in which one or more processors control one or more operations performed on a plurality of objects through one or more control devices, while the control devices contain a control laser, a control camera, an X-ray control device, a gamma-ray device inspection device, ultrasonic inspection device, magnetic particle inspection device, eddy current inspection device or temperature control device.

290. The computer system according to any one of paragraphs 280-289, in which the data associated with the study contains (i) data associated with the study of one or more field devices during the execution of one or more operations, or (ii) data, associated with the examination of one or more objects during the execution of one or more operations.

291. Field system facilitating field testing and physical operations based on it, comprising:

acquisition by one or more processors from one or more field systems of data related to the investigation of one or more operations performed on a plurality of objects, wherein the plurality of objects contains (i) one or more objects determined to be defective as a result of one or more of the investigated operations , and (ii) one or more items free from defects;

comparing, by one or more processors, based on data associated with the study, a first set of operation studies performed on an object determined to be defective with another set of operation studies performed on one or more objects that do not have defects;

determining by one or more processors, based on such comparison, the general differences that the first set of studies has with one or more other sets of studies; and

causing one or more processors, based on common differences, to implement an operation trigger in such a way that the field system is induced to perform the operation associated with the operation trigger when a condition corresponding to the common difference occurs during a subsequent operation that physically affects one or more additional objects.

292. The method according to p. 291, characterized in that it additionally includes:

determining by one or more processors of the first set of general differences that the first set of studies has with one or more other sets of studies, based on a comparison of the first set of studies with one or more other sets of studies;

comparing by one or more processors, based on data associated with the study, the first set of operations studies performed on the second object determined to be defective with one or more other sets of operations studies performed on one or more objects that do not have defects;

determining by one or more processors, based on comparison, a second set of studies with one or more other sets of studies, a second set of common differences that the second set of studies has with one or more other sets of studies;

one or more processors determining one or more matches between the first set of common differences and the second set of common differences,

wherein the operation trigger is prompted to be implemented based on one or more matches, where one or more matches contain common differences.

293. The method according to p. p. 291 or 292, characterized in that it additionally includes:

monitoring by one or more processors of one or more subsequent operations performed at an additional object; and

causing one or more processors to perform an operation associated with the operation trigger on an additional object based on the operation trigger and monitoring determining a condition corresponding to the common differences during one or more subsequent operations.

294. The method of claim 293, wherein the operation associated with the operation trigger comprises modifying one or more input parameters for said one subsequent operation during that one subsequent operation.

295. The method according to p. 294, characterized in that one or more input modified parameters contains one or more welding parameters, coating parameters, alignment parameters, or change parameters.

296. The method of claim 293, wherein the operation associated with the operation trigger comprises modifying one or more input parameters for at least one or more subsequent operations.

297. The method of claim 293, wherein the operation associated with the operation trigger comprises stopping the subsequent operation.

298. The method of claim 293, wherein the operation associated with the operation trigger comprises generating an alarm indicating the occurrence of said condition during one subsequent operation.

299. The method according to any one of paragraphs 291-298, characterized in that it additionally includes:

monitoring by one or more processors of one or more operations performed on a plurality of objects; and

however, the data associated with the study is obtained on the basis of monitoring one or more operations.

300. The method according to p. 299, characterized in that one or more processors control one or more operations performed on a plurality of objects by means of one or more control devices, while the control devices contain a control laser, a control camera, an X-ray control device, a gamma device -control, ultrasonic testing device, magnetic particle testing device, eddy current testing device or temperature monitoring device.

301. The method according to any one of paragraphs 291-300, characterized in that the data associated with the study contains (i) data associated with the study of one or more field devices during the execution of one or more operations, or (ii) data associated with the examination of one or more objects during the execution of one or more operations.

302. Welded pipe assembly, containing:

a first metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches;

a second metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches;

welding material connecting the first pipe to the second pipe, wherein the welding material contains a plurality of layers of the weld passage, and the plurality of weld layers contain a passage layer when welding the root of the weld, and a hot passage layer located on top of the passage layer when welding the root of the weld,

in this case, the layer of the hot passage is located closer to the inner longitudinal axis of the welded first and second pipes than the layer of the passage when welding the root of the weld.

303. The welded pipe assembly according to claim 302, characterized in that the hot pass layer of the weld material has at least a part of it located closer to the longitudinal axis than the inner surfaces of the welded pipes in areas of the welded pipes immediately adjacent to the weld material on the opposite sides of the weld material.

304. The welded pipe assembly according to claim 302 or 303, characterized in that the first end of the first pipe is welded to the second end of the second pipe, while the first end of the first pipe has an internal groove and an external groove, and the second end of the second pipe has an internal groove the weld and the outer groove of the seam, while the passage when welding the root of the seam is located in the internal groove of the seam, and the layer of the hot passage is located on top of the layer of the passage when welding the root of the seam.

305. A welded pipe assembly according to any one of paragraphs 302-304, which further comprises an additional layer of weld passage located on top of the hot pass layer and located closer to the inner longitudinal axis of the welded first and second pipes than the hot run layer.

306. Welded pipe assembly, containing:

a first metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches;

a second metal pipe having a length of at least 30 feet and an outside diameter of less than 24 inches;

a welded joint comprising a first metal pipe and a second metal pipe, wherein the welded joint comprises a first internal groove made in the first metal pipe and a second internal groove made in the second metal pipe, and a passage when welding the root of the seam with the weld material, located in the area defined by the first internal groove and the second internal groove.

307. The welded pipe assembly of claim 306, which further comprises a hot pass layer located on top of the root pass layer and located closer to the inner longitudinal axis of the welded first and second pipes than the root pass layer.

308. Field system for welding two pipes, containing:

a first pipe engaging device configured to engage with an inner surface of the first pipe, allowing the first pipe engaging device to be fixed with respect to the first pipe;

a second pipe engaging device configured to engage with an inner surface of the second pipe, allowing the second pipe engaging device to be fixed relative to the second pipe;

one or more welding torches configured to be placed inside the pipes to create an internal weld in the area of the contact surface between the pipes;

a motor operatively associated with the one or more welding torches for rotating the one or more welding torches along a contact surface area between the pipes; and

one or more processors that control the motor and one or more welding torches, wherein the one or more processors control the operation of the motor and one or more welding torches to generate a complete circumferential weld along the area of the contact surface by rotating one or more welding torches along the area contact surface in one direction of rotation until a complete girth weld is made.

309. The field system of claim 308, wherein the one or more welding torches comprise a plurality of welding torches, wherein at least one of the plurality of welding torches performs an upward rotational weld while at least a second of the plurality of welding torches performs a weld with downward rotation.

310. The field system of claim 308 or 309, further comprising a measurement sensor and wherein the motor drives the measurement sensor.

311. Control system for pre-checking the area of the contact surface between butt-welded pipes, while the system contains:

a frame configured to be placed inside the pipes;

a plurality of rollers configured to rotatably hold the frame;

a drive motor that drives rollers to move the frame inside the tubes;

a brake system holding the frame in a predetermined position inside the pipes from moving;

a sensor movable with the frame, capable of detecting the area of the contact surface between the pipes;

a measuring sensor configured to generate signals based on the profile of the contact surface between the pipes;

a motor that rotates the measuring sensor along the area of the contact surface; and

one or more processors operatively associated with a drive motor, a sensor, a measurement sensor, and a motor,

one or more processors controlling a drive motor to move the frame through at least one of the tubes until the sensor detects a contact surface area,

and one or more processors control a braking system to hold the frame in position within the tubes from moving, which allows the measurement sensor to be positioned with respect to the contact surface region, allowing the measurement sensor to detect the profile of the contact surface region between the pipes;

one or more processors controlling a sensor and a motor to scan the contact area between the pipes, and in response to detecting one or more undesirable characteristics of the contact surface, one or more processors send instructions based on them.

312. The control system of claim 311, wherein the braking system comprises a plurality of radially retractable clips that engage the inner surface of the tubes to hold the carcass from moving.

313. The control system of claim 311, wherein the braking system includes a wheel lock that prevents one or more rollers from rotating to keep the carcass from moving.

314. The monitoring system of any one of clauses 311-313, wherein the sensor comprises a linear rotation angle sensor configured to be operatively coupled to the rollers.

315. The control system according to any one of paragraphs 311-314, in which the measuring sensor transmits radiation towards the area of the contact surface, while the measuring sensor contains a receiver for receiving radiation reflected from the surfaces of the area of the contact surface, and generates electronic signals based on it , wherein one or more processors receive signals to determine whether correction is needed for undesirable characteristics.

316. The monitoring system of claim 315, wherein the measurement sensor comprises a plurality of measurement sensors transmitting radiation towards the contact surface region, wherein the measurement sensors comprise a receiver for receiving radiation reflected from the surfaces of the contact surface region and generating signals based on it.

317. The control system according to any one of paragraphs 311-316, in which the measuring sensor scans all 360 degrees of the area of the contact surface between the pipes.

318. The control system of any one of paragraphs 311-318, in which one or more processors send instructions to the engine controlling the axial rotational position of one of the pipes to cause the engine to rotate one of the pipes relative to the second pipe to correct undesirable characteristics.

319. The control system of claim 318, wherein the motor is configured to move the radially retractable clip.

320. A method for pre-checking the contact surface area between butt-welded pipes, the method comprising:

moving the frame inside at least one of the pipes to be welded;

detection of the area of the contact surface between the pipes;

keeping the frame from moving in the area of the contact surface between the pipes;

detection of the profile of the area of the contact surface between the pipes;

generating, in response to the detection of one or more undesirable characteristics of the area of the contact surface between the pipes, instructions based on them.

321. The method of claim 320, further comprising adjusting the relative positioning between the pipes based on these instructions.

322. The method according to claim 320 or 321, characterized in that the retention comprises the use of clips to fix the frame inside the pipes.

323. The method of claim 322, wherein the clamps are released before adjusting the relative positioning between the pipes.

324. The method according to any one of paragraphs 320-323, characterized in that the pipes are engaged from the outside to adjust the relative positioning.

325. Field system for pre-checking the area of the contact surface between butt-welded pipes, while the system contains:

a frame configured to be placed inside the pipes;

a plurality of rollers configured to rotatably hold the frame;

a drive motor that drives rollers to move the frame inside the tubes;

a brake system holding the frame in a predetermined position inside the pipes from moving;

a measuring sensor configured to generate signals based on the profile of the contact surface between the pipes;

one or more orientation motors that rotate the measurement sensor along the area of the contact surface; and

one or more processors operatively associated with the drive motor, the measuring sensor and the motor,

one or more processors controlling a brake system to hold the frame from moving in a predetermined position within the pipes, which allows you to position the sensor in relation to the area of the contact surface, allowing the measurement sensor to detect the profile of the area of the contact surface between the pipes;

one or more processors controlling a sensor and a motor to scan the area of the contact surface between pipes to generate pre-weld profile data, and, in response to detecting one or more undesirable characteristics in the pre-weld profile data, one or more processors send instructions to their basis.

326. The field system of claim 325, wherein one or more processors interact with a measurement sensor to scan the entire contact surface area between pipes to generate profile data prior to deposition of welding material when welding two pipes together.

327. The field system according to claim 325 or 326, in which the brake system includes a first clamp and a second clamp, with one or more processors interacting with a measuring sensor to scan the area of the contact surface to obtain profile data before welding, after the first the clip and the second clip engage the first tube and the second tube, respectively.

328. The field system according to any one of paragraphs 325-327, in which the outer surface of the first pipe and / or second pipe is rotatably engaged with an external rotary element, which helps to adjust the relative position of the pipes based on instructions from one or more processors.

329. The field system of claim 327, wherein the inner surface of the first tube and/or the second tube is engaged and controlled, respectively, by the first clip and the second clip to adjust the relative positioning of the tubes based on instructions from one or more processors.

330. A field system according to any one of paragraphs 325-329, in which one or more processors are operatively connected to one or more motors for orientation to rotate the first clamp relative to the second clamp so as to rotate the first pipe relative to the second pipe based on instructions from one or more processors.

331. The field system according to any one of paragraphs 325-330, which further comprises a platform for transporting and moving the first pipe and the second pipe, while the platform is operatively connected to one or more processors, and one or more processors control the operation platform to provide relative movement between the first pipe and the second pipe based on pre-weld profile data to change the area of the contact surface between the pipes before performing the welding operation based on instructions from one or more processors.

332. A field system according to any one of paragraphs 325-331, which further comprises a welding torch operatively associated with one or more processors, and configured to perform a welding operation to weld two pipes together in response to the fact that one or more more processors do not detect the presence of undesirable characteristics.

333. The field system according to any one of paragraphs 325-332, characterized in that it further includes a sensor operatively associated with one or more processors, while the sensor detects that the frame is located in the area of the contact surface between the pipes.

334. The field system of claim 333, wherein the sensor comprises a rotary switch and/or a linear rotation angle sensor.

335. The field system of claim 333, wherein the sensor comprises a measuring sensor.

336. The field system of claim 335, wherein the measurement sensor includes a laser.

337. The field system of claim 333, wherein the sensor includes a camera.

338. Field system according to any one of paragraphs 325-337, in which the measuring sensor transmits radiation towards the area of the contact surface, while the measuring sensor contains a receiver for receiving radiation reflected from the surfaces of the area of the contact surface and generates electronic signals on it basis, with one or more processors receiving signals to determine whether correction is necessary for undesirable characteristics.

339. Field system according to any one of paragraphs 325-338, in which the measuring sensor scans all 360 degrees of the area of the contact surface between the pipes.

340. Pipe cooling system, containing:

a frame configured to be placed inside the welded pipes;

a plurality of rollers configured to rotatably hold the frame;

a drive motor that drives rollers to move the frame inside the tubes;

a brake system holding the frame in a predetermined position inside the pipes from moving;

a cooler carried by the frame, wherein the cooler applies cooling energy to the inner surface of the metal pipes, which contributes to cooling the welded metal pipes; and

one or more processors operatively associated with the drive motor, the brake system, and the cooler, wherein the one or more processors control the operation of the cooler to reduce the temperature of the welded pipes to a predetermined level.

341. The pipe cooling system of claim 340, further comprising one or more batteries carried by the frame, wherein the one or more batteries are configured to power the drive motor and brake system.

342. The pipe cooling system according to any one of paragraphs 340-341, in which the brake system contains one or more clamps that fix certain places located in a certain way along the circumference on the inner surface of the welded pipes.

343. The pipe cooling system according to any one of paragraphs 340-342, in which the braking system includes a wheel lock that prevents the rollers from rotating.

344. The pipe cooling system according to any one of paragraphs 340-343, in which the cooler contains a heat exchanger in which the coolant is transferred, while the heat exchanger has a surface in contact with the pipe, which contacts the inner surface of the pipe, which contributes to cooling the welded pipes.

345. The pipe cooling system of claim 344, further comprising a heat exchanger motor, wherein the heat exchanger motor is configured to move the heat exchanger radially outward such that the pipe contact surface engages with the inner surface of the welded pipes after the frame is in position inside the pipes.

346. The pipe cooling system according to any one of paragraphs 340-343, in which the cooler contains a blower that supplies air to the inner surface of the pipe, which helps to cool the welded pipes.

347. The pipe cooling system according to any one of paragraphs 340-343, in which the cooler contains a water fitting that supplies liquid to the inner surface of the pipe, which helps to cool the welded pipes.

348. The pipe cooling system according to any one of paragraphs 340-347, which further comprises one or more batteries carried by the frame, while one or more batteries are configured to provide energy to the cooler.

349. A pipe cooling system according to any one of paragraphs 340-348, in which one or more processors are connected with the possibility of exchanging data with a brake system, a drive motor or a cooler through one or more wired or wireless connections.

350. A pipe cooling system according to any one of paragraphs 340-349, in which one or more processors are connected with the possibility of exchanging data with a brake system, a drive motor or a cooler through one or more wireless connections, and at the same time one or more wireless connections contains a Wi-Fi connection, a Bluetooth connection, a Near Field Communication (NFC) connection, or a cellular connection.

351. The pipe cooling system according to any one of paragraphs 340-350, which further comprises a temperature sensor that measures the temperature of the pipes, while the temperature sensor is operatively associated with one or more processors, and one or more processors send functional instructions to the cooler on based on the signals received from the temperature sensor.

352. The pipe cooling system of claim 351, wherein one or more processors control the operation of the cooler until the sensor and processor detect that the temperature of the pipes has dropped below a temperature threshold.

353. The pipe cooling system according to any one of paragraphs 340-352, in which one or more processors are connected with the possibility of communicating with a remote computer system and configured to transmit pipe cooling data to the remote computer system.

354. The pipe cooling system of claim 353, wherein the pipe cooling data transmitted by one or more processors contains information about the cooling time graph, wherein the cooling time graph information contains a change in pipe temperature over time.

355. The pipe cooling system of Claim 353 or 354, wherein the remote computer system collects cooling data from other welding systems and calculates the expected time for the temperature of the welded pipes to drop below a threshold value.

356. The pipe cooling system of claim 355, wherein the expected time is communicated to one or more processors.

357. The pipe cooling system of claim 356, further comprising a user interface, wherein the expected time and/or pipe temperature are sent to the user interface by one or more processors.

358. The pipe cooling system of claim 355, wherein the expected time is calculated at least in part based on the size of the welded pipe.

359. The pipe cooling system according to any one of paragraphs 340-357, in which one or more processors are configured to calculate the expected time for which the temperature of the welded pipes will fall below the temperature threshold, while the calculation is based at least in part, on welded pipe size.

360. The pipe cooling system of clause 359, wherein the calculation is additionally based on the cooling output of the cooler.

361. The pipe cooling system of claim 360, wherein the cooling output of the cooler is based on information received from a remote computer system.

362. The pipe cooling system of claim 360, wherein the cooling output is predetermined.

363. A pipe cooling system according to any one of paragraphs 340-362, in which one or more processors are connected with the possibility of communicating with a remote computer system and configured to transmit data on the flow rate of the coolant.

364. System for aligning and welding two pipe segments together:

a welding mechanism for applying a weld to the mating surfaces of two segments, the welding mechanism comprising an articulated torch, a laser sensor for reading the profile of the mating surface, an electronic controller for receiving information signals from the laser sensor to control the position and/or orientation of the torch;

an alignment mechanism for controlling the orientation of the longitudinal axis of at least one of the segments with respect to the other; and

wherein the welding mechanism further comprises a carriage for fixing the position of the welding mechanism in the pipe and a part of the welding mechanism capable of rotating with respect to the support part inside the pipe; and

wherein the torch and the laser sensor are supported in rotation by a part of the welding mechanism such that the torch follows the laser sensor along the mating surface during welding.

365. A method for aligning and welding together two pipe segments, which comprises the steps of:

placing the first pipe segment on the alignment device;

installing an internal welding machine having a laser and a welding torch in the first pipe segment;

overall alignment of the second pipe segment with respect to the first segment and the internal welding machine;

clamping the outer portion of the first and second pipe segments to adjust the axial position of the inner welding machine so as to generally align it with the mating surface of the first and second segments;

adjusting the relative alignment of the first and second pipe segments by the alignment device based on a signal from the internal welder;

beginning of a root pass cycle in which the laser scans the mating surfaces, the torch follows the laser, and the laser output is used to control the position of the articulated torch, while the position and orientation of the torch in relation to the mating surfaces is controlled to produce a quality weld ;

determination of the profile of mating surfaces by means of a laser;

releasing the alignment device and removing the inner welder from the exposed pipe segment; and

re-positioning the next pipe segment on the external alignment mechanism in preparation for welding the next weld joint.

366. An internal heat exchanger (IHEX) for welding a pipeline, while the internal heat exchanger contains:

a drive system configured to move the IHEX to a position within at least one pipe section adjacent to the location of a welded joint to another pipe section;

a cooling section including a refrigerated structure configured to selectively cool one or more interior surface portions of at least one pipe section; and

a controller connected to the structure to be cooled and configured to activate the cooling section when the IHEX is in a certain position within at least one pipe section.

367. Welding system, containing:

a plurality of welding stations, wherein each welding station comprises a welding station computer and a welding system connected to communicate with the welding system computer, and each welding station contains one or more sensors, wherein one or more sensors are configured to measure welding data , including welding wire speed data;

a plurality of wireless devices communicatively connected to one or more welding station computers to obtain welding data, including measured welding wire speed; and

a cloud server connected to communicate with wireless devices, wherein the cloud server is configured to process welding data, including welding wire speed, and configured to determine the amount of consumed welding material used by a plurality of welding stations during a given period of time, when therein, the cloud server is configured to transmit information about the amount of consumable welding material that is used to one or more wireless devices.

368. Welding system, containing:

a welding station, wherein the welding station comprises a welding system computer and a welding system connected to the possibility of exchanging data with the welding system computer,

the welding system includes a source of welding material, a welding device and a welding material supply motor assembly that moves the welding material to the welding device;

a welding device operatively associated with the welding station computer and configured to measure the mass of the supplied welding material and transmit the mass of the supplied welding material to the welding station computer in the form of mass data; and

a sensor operatively coupled to the welding material supply motor assembly and the welding station computer so as to transmit a speed of the welding material supply assembly to the welding station computer as speed data;

wherein the welding station computer is operatively coupled to the welding material supply motor assembly and configured to control the speed of the motor assembly based on the mass data.

369. Welding control method, including:

measuring the first mass of the supplied welding material at the first time using the mass measuring device;

measuring a second mass of the supplied welding material at a second time point following the first time point using the mass measuring device;

calculating, using a computer, a difference in the measured mass between the first mass and the second mass, wherein the difference in the measured mass corresponds to the measured used welding consumable;

calculating, using the computer, a theoretical mass of used welding material based on the speed at which the motor assembly supplies welding material to the welding device;

computer comparing the theoretical weight of the used welding consumable with the measured weight of the used welding consumable; and

computer adjusting the speed of the motor assembly so as to correct slippage of the motor assembly.

370. Welding system, containing:

a plurality of welding stations, wherein each welding station comprises a welding station computer and a welding system connected to communicate with the welding system computer, and each welding station contains one or more sensors, wherein one or more sensors are configured to measure welding data , including welding wire speed data;

a plurality of wireless devices communicatively connected to one or more welding station computers to obtain welding data, including measured welding wire speed; and

each welding station computer is configured to process welding data, including the welding wire feed rate for the welding system connected to it, wherein the welding station computer is configured to determine the amount of consumed welding material used by the welding system during a given period of time and generate at its consumption data basis.

371. A pipeline testing system, comprising:

a testing device adapted to generate non-destructive testing data on at least a portion of the weld;

said test device transmits said non-destructive test data to a second device that is adapted to receive said non-destructive test data; and

said test device is adapted to operate remotely from a means for analyzing said non-destructive testing data.

372. A system for non-destructive testing of a pipeline, comprising:

visualization equipment adapted to generate non-destructive test data on a welded pipe;

a remote processing device adapted to receive and process test data on said portion of said welded pipe.

373. A method for non-destructive testing of a pipeline, including the steps:

provision of imaging equipment;

generating non-destructive test data;

providing means to provide said non-destructive test data for analysis; and

specified non-destructive test data is provided for analysis at a location remote from the tested pipe part and equipment adjacent to the tested pipe part.

374. A pipeline design system, comprising:

welding data recording system in real time; and

said welding data is provided for analysis by computerized means and/or experts in the field.

375. Computer software product that provides the possibility of welding, containing:

computer readable program code means providing welding data to a computer memory;

computer readable program code means providing a data set containing pipeline data to said memory;

computer readable program code means that process said welding data and said pipeline data to provide a report output.

376. Method of data management, performed on a computer, containing the steps:

transmitting first data from the first device to the second device, said first data being data that relates to the design of the pipeline;

processing said first data by means of cloud computing.

377. Computer system containing:

a first device comprising a processor that processes piping design data, wherein said first device transmits said piping design data to cloud storage,

the specified pipeline design data is processed by the cloud processor.

378. Method for welding two pipes, containing:

fixing the first tube internally with the first clamp;

fixing the second tube internally with a second clamp, wherein the first and second tubes are fixed so that they are butted against each other, with a contact surface area therebetween;

scanning the area of the contact surface inside the pipes and between the clamps to obtain profile data from the area of the contact surface;

welding two pipes located end-to-end with respect to each other, based on profile data; and

internal inspection of welded pipes within pipes and between clamps.

379. The method according to p. 378, characterized in that the internal check of welded pipes inside the pipes and between the clamps is performed without releasing the clamps.

380. The method according to p. 378 or 379, characterized in that the welding is performed by at least one welding torch located outside the pipes.

381. The method according to p. 378 or 379, characterized in that welding is performed from the inside by at least one welding torch located inside the pipes.

382. The method according to any of the preceding paragraphs 378-381, characterized in that the verification is performed by a camera or a laser.

383. The method according to any of the preceding paragraphs 378-381, characterized in that the verification is performed by a laser.

Claims (103)

1. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of a plurality of welded pipes fixed to each other by a welded joint; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame, configured to power the drive motor and the braking system; a cooler held by the frame, the cooler comprising a blower for purging cooling gas within at least one pipe and to a welded joint to cool the welded pipes; and at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes. 2. The system of claim 1, wherein the braking system comprises at least one clamp for clamping at circumferentially spaced locations on the interior surfaces of the welded pipes. 3. The system of claim 1, wherein the braking system includes a wheel stop to prevent the plurality of rollers from rotating. 4. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame, configured to power the drive motor and the braking system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; and at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes, wherein the cooler comprises a heat exchanger with a cooling liquid, wherein the heat exchanger comprises a pipe contacting surface which is designed to contact the inner surfaces of the welded pipes to facilitate cooling of the welded pipes. 5. The system of 4, which further comprises a heat exchanger motor configured to move the heat exchanger radially outward so that the pipe contact surface engages with the inner surfaces of the welded pipes after the frame is positioned at the desired location within the welded pipes. 6. The system of claim 1 wherein the blower is configured to blow air to facilitate cooling of the welded pipes. 7. The system of claim 1, wherein the at least one battery held by the frame is capable of being powered by a cooler. 8. The system of claim 1, wherein the at least one processor is configured to communicate with the brake system, drive motor, and/or cooler via at least one wired or wireless connection. 9. The system of claim 1, wherein the at least one processor is configured to communicate with the brake system, drive motor, and/or cooler via at least one wireless connection, including a Wi-Fi connection, a Bluetooth connection, an NFC connection, or a cellular connection. 10. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame, configured to power the drive motor and the braking system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes; and a temperature sensor for measuring the temperature of the welded pipes, wherein the temperature sensor is operatively connected to at least one processor configured to issue commands to the cooler based on the signals received from the temperature sensor. 11. The system of claim 10, wherein the at least one processor is configured to control the operation of the cooler until the sensor and processor determine that the temperature of the welded pipes is below a threshold temperature. 12. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame, configured to power the drive motor and the braking system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; and at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes; wherein at least one processor is configured to connect to the remote computer system and transmit pipe cooling data to the remote computer system. 13. The system of claim 12, wherein said refrigeration data transmitted by the one or more processors includes information including temperature variation of the pipes over time. 14. The system of claim 13, wherein the at least one processor is configured to receive from the remote computer an expected time for the temperature of the welded pipes to fall below a threshold. 15. The system of claim 14, further comprising a user interface configured to receive expected pipe time and/or temperature data from at least one processor. 16. The system of claim 13 wherein the expected time is calculated based at least in part on the size of the welded pipe. 17. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame, configured to power the drive motor and the braking system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; and at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes; wherein at least one processor is configured to calculate an expected time for which the temperature of the welded pipes will drop below a threshold value, the calculation being based at least in part on the size of the welded pipe. 18. The system of claim 17, wherein the calculation is further based on the cooling output of the cooler. 19. The system of claim 18, wherein the cooling power output is based on information received from the remote computer system. 20. The system of claim 18, wherein the cooling output is predetermined. 21. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame, configured to power the drive motor and the braking system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; and at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes; wherein at least one processor is configured to connect to a remote computer system and transmit data on the consumption of the coolant. 22. The system of claim 1, wherein the cooling gas contains air, wherein the cooler comprises at least one fan configured to move air through the interior surfaces of the welded pipes. 23. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving the plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame and configured to power the drive motor and brake system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes; and heat exchanger, wherein the cooling gas contains air, while the cooler comprises at least one fan configured to move air through the heat exchanger elements of the cooling system. 24. The system of claim 23, wherein the at least one fan is associated with at least one processor to selectively control the at least one fan during cooling of the welded pipes. 25. A system for cooling pipes after welding, comprising: a frame configured to be placed inside at least one pipe of the plurality of welded pipes; a plurality of rollers configured to rotatably hold the frame; a drive motor for driving a plurality of rollers to move the frame within the at least one pipe; a brake system for holding the frame from moving in a predetermined position within at least one pipe; at least one battery held by the frame and configured to power the drive motor and brake system; a cooler held by the frame, the cooler being configured to purge cooling gas within the at least one pipe to assist in cooling the welded pipes; and at least one processor operatively associated with the drive motor, brake system and cooler, wherein at least one processor is configured to control the cooler to reduce the temperature of the welded pipes; moreover, the cooling gas contains air, while the cooler contains at least one fan configured to provide air movement through the inner surfaces of the welded pipes, wherein the pipe cooling system further comprises a temperature sensor for measuring the temperature of the welded pipes, wherein the temperature sensor is operatively connected to at least one processor configured to issue commands to at least one fan based on signals received from the temperature sensor. 26. The system of claim 25, wherein the at least one processor is configured to control the operation of at least one fan until the temperature sensor and the processor determine that the temperature of the welded pipes has dropped below a threshold temperature. 27. The system according to claim 25, which is equipped with heat exchanger elements containing ribs, while the ribs extend radially outward from the central longitudinal axis of the frame in direct thermal contact with the internal surfaces of the welded pipes at or near the welded joint between the welded pipes to cool the internal surfaces of welded pipes. 28. The system of claim 27, wherein the at least one fan is configured to force air flow through the fins to cool the fins and thus force heat to be removed through the convective air flows away from the fins. 29. The system of claim 27, wherein the at least one fan is configured to operate at variable speed so as to selectively control the fan speed and the corresponding air flow through the fins differently and as needed during the cooling of the welded pipes. 30. The system of claim 27, wherein at least one fan is operable to provide cooling air flow at one or more flow rates through the fins, and the fins are configured to remove heat from the inner surfaces of the welded pipes, while forced air flows provided by at least one fan remove heat from the fins. 31. The system of claim 27, wherein the fins comprise curved outer surface portions that generally conform in shape to the inner surfaces of the welded pipes to which the fins extend. 32. The system of claim 27, wherein the fins are made of a material having suitable thermal conductivity to promote a high rate of heat transfer from the interior surfaces of the welded pipes. 33. The system according to claim 27, in which the ribs contain open channels passing through the ribs in the longitudinal direction, while at least one fan is located in close proximity to the ends of the fins and is aligned with the open channels of the fins so as to provide air flow through the open channels of the fins to cool them. 34. The system according to claim 1, in which the frame is located at the junction of two adjacent pipes so that the frame has sections located simultaneously in two different pipes. 35. The system of claim 34, wherein the braking system is configured to hold the frame from moving at the junction of two adjacent tubes such that the sections of the frame are held by two different tubes. 36. The system of claim 1, wherein the at least one processor is configured to control the operation of the cooler to reduce the temperature of the welded pipes to a predetermined level.

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