WO2016153562A1 - Systems and methods for use in welding pipe segments of a pipeline - Google Patents

Systems and methods for use in welding pipe segments of a pipeline Download PDF

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Publication number
WO2016153562A1
WO2016153562A1 PCT/US2015/062558 US2015062558W WO2016153562A1 WO 2016153562 A1 WO2016153562 A1 WO 2016153562A1 US 2015062558 W US2015062558 W US 2015062558W WO 2016153562 A1 WO2016153562 A1 WO 2016153562A1
Authority
WO
WIPO (PCT)
Prior art keywords
weld
pipe
inspection
data
pipes
Prior art date
Application number
PCT/US2015/062558
Other languages
English (en)
French (fr)
Inventor
Shankar T. Rajagopalan
Siddharth MALLICK
Brian L. Kirk
Jose C. BOUCHE
Jason W. CURBO
Jonathan B. KETTELKAMP
Lawrence SNIDERMAN
Shailesh RADHARKISHNAN
Marcus JANES
Jared PROEGLER
Original Assignee
Crc-Evans Pipeline International
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=56978897&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=WO2016153562(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Priority claimed from PCT/US2015/022665 external-priority patent/WO2015148765A1/en
Priority claimed from PCT/US2015/047603 external-priority patent/WO2016033568A1/en
Priority to EP15886707.7A priority Critical patent/EP3274125A4/en
Priority to MYPI2017703554A priority patent/MY191994A/en
Priority to CA2980559A priority patent/CA2980559A1/en
Priority to AU2015387441A priority patent/AU2015387441B2/en
Priority to RU2017134991A priority patent/RU2708721C2/ru
Priority to MX2017012366A priority patent/MX2017012366A/es
Priority to BR112017020431-2A priority patent/BR112017020431B1/pt
Application filed by Crc-Evans Pipeline International filed Critical Crc-Evans Pipeline International
Priority to US15/560,954 priority patent/US10695876B2/en
Priority to CN201580080511.1A priority patent/CN107614193A/zh
Priority to US15/056,293 priority patent/US9969031B2/en
Priority to PCT/US2016/020227 priority patent/WO2016140951A1/en
Publication of WO2016153562A1 publication Critical patent/WO2016153562A1/en
Priority to US15/441,804 priority patent/US10480862B2/en
Priority to ZA2017/06249A priority patent/ZA201706249B/en
Priority to US15/714,117 priority patent/US10589371B2/en
Priority to US15/714,054 priority patent/US11767934B2/en
Priority to US16/589,637 priority patent/US11175099B2/en
Priority to AU2021229209A priority patent/AU2021229209A1/en

Links

Classifications

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

Definitions

  • the present patent application relates to various field systems and methods that are used for the purpose of welding pipe segments of a pipeline.
  • Pipeline systems which can include long stretches of pipe sections or segments (e.g., miles of pipe segments) comprising steel, stainless steel or other types of metal, are used to transport fluids such as water, oil, and natural gas between two locations (e.g., from a source of origin that may be land or water based to a suitable storage location).
  • Construction of pipeline systems typically involves connection of pipe segments of suitable diameter and lengthwise dimensions together via weld joints, for example, capable of providing a liquid tight seal for the connected pipe segments.
  • a weld joint between two pipe segments e.g., two pipe segments having the same or similar transverse cross-sectional dimensions
  • an end of one pipe section or segment is brought into close proximity or contact with an end of a second pipe section or segment.
  • the pipe segments are held in relation to each other and a weld joint is formed to connect the two ends of the pipe segments using a suitable welding process.
  • the weld may be inspected. After inspection, it may be desirable to apply external protective coatings to the weld joint.
  • the conventional process of internal welding usually involves internal or external alignment and an insertion of the internal welder so that torches align with the face joint.
  • this process it is sometimes difficult to assess the accuracy of positioning of the internal welder in general and the torch in particular. It is even more difficult to assess the accuracy of the position of the torch as the torch traverses the inside of the pipe along its orbital path during welding.
  • the pipes are typically preheated to a suitable temperature prior to welding, and a significant amount of heat is also generated during the welding process.
  • the weld may be inspected. It is desirable to inspect the weld at a temperature closer to the pipe operating temperature than to the raised weld temperature. Therefore, cooling after the welding process may be desired before inspection. After inspection, it may be desirable to apply external protective coatings to the joint. To facilitate this coating, heat may be added to the pipe in order to raise the pipe temperature required for application of certain external coatings (e.g., polypropylene).
  • external coatings e.g., polypropylene
  • the pipe connection is ideally be allowed to cool to a suitable temperature before further processing steps are performed occur (e.g., before spooling of the connected piping sections or handling /placement of the piping sections in water or at some other suitable location on land).
  • Internal cooling could be useful during certain portions of the fabrication process (i.e., even when external cooling is available). Internal cooling within the pipes can be challenging due to the size of the pipes and the difficulty of accessibility to the interior portion of the piping section that is located at or near the weld joint. It would therefore be especially desirable to provide internal cooling so that during portions of the process where external surfaces of the pipe are inaccessible, cooling can be implemented to more quickly condition the pipe for future steps that require lower temperatures (e.g., spooling).
  • the present application relates to a field system and methods that can be deployed in the application of pipe welding.
  • the field system provides many embodiments relating to pipe welding systems and methods, that can be used in combination with one another, or individually.
  • Such welding systems and methods include, for example, internal welding systems and methods, tie-in welding system and methods, pipe inspection systems and methods, pipe handling systems and methods, internal pipe cooling systems and methods, non-destructive testing systems and methods, as well as remote interface and database systems and methods (uLog), to name a few.
  • the application further relates to welded pipes that result from some or all of such processes.
  • the field system includes a first pipe engagement structure; a second pipe engagement structure; an inspection detector; a motor; one or more processors; and a weld torch.
  • the first pipe engagement structure is configured to engage the interior surface of a first pipe to enable the first pipe engagement structure to be fixed relative to the first pipe.
  • the second pipe engagement stmcture is configured to engage the interior surface of a second pipe to enable the second pipe engagement structure to be fixed relative to the second pipe.
  • the inspection detector is positioned between the first pipe engagement structure and the second pipe engagement structure, the inspection detector configured to emit an inspection beam of radiation.
  • the motor is operatively associated with the inspection detector to direct the inspection beam of radiation along an interface region between the pipes.
  • the one or more processors are operatively associated with the inspection detector to determine a profile of the interface region between the pipes.
  • the weld torch is configured to create a weld between the pipes based on the profile of the interface region between the pipes.
  • the field system includes a first pipe engagement structure; a second pipe engagement structure; an inspection detector; one or more orientation motors; one or more processors; and a weld torch assembly.
  • the first pipe engagement structure is configured to engage the interior surface of a first pipe to enable the first pipe engagement structure to be fixed relative to the first pipe.
  • the second pipe engagement structure is configured to engage the interior surface of a second pipe to enable the second pipe engagement structure to be fixed relative to the second pipe.
  • the inspection detector is positioned axially between the first pipe engagement structure and the second pipe engagement structure, the inspection detector configured to inspect an interface region between the pipes and generate profile data based thereon.
  • the one or more orientation motors are operatively associated with the inspection detector to direct the inspection beam of radiation along the interface region between the pipes.
  • the one or more processors are operatively associated with the inspection detector and configured to receive the profile data from the inspection detector to determine one or more characteristics of the interface region between the pipes.
  • the weld torch assembly includes a weld torch and at least one weld torch motor, the weld torch and the at least one weld torch motor being actuated by the one or more processors to create a weld between the pipes based on the one or more characteristics of the interface region between the pipes.
  • the field system includes a frame configured to be placed within the pipes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the pipes; a brake system that secures the frame from movement at a desired location within the pipes; an inspection detector carried by the frame, the inspection detector configured to detect a characteristic of an interface region between the pipes; a weld torch carried by the frame; one or more battery cells carried by the frame, the one or more battery cells configured to power the drive motor, the inspection detector and the weld torch; and one or more processor operatively connected with the drive motor, the inspection detector and the weld torch.
  • Yet another aspect of the present patent application provides a method for welding a pair of insulated pipes to one another.
  • Each pipe includes a metal pipe interior surrounded by an insulator material. End portions of the pipes to be welded have the metal pipe interior exposed.
  • the method includes aligning the exposed metal pipe ends to be welded, welding the exposed metal pipe ends to one another, heating the exposed end portions of the welded pipes, applying an insulator to the heated exposed end portions of the welded pipes such that the insulator is adhered to an exterior surface of the metal pipe interior, thus insulating the formerly exposed end portions of the pipes, and applying cooling energy from within the pipes to an interior surface of the metal pipes.
  • Yet another aspect of the present patent application provides a system for welding a pair of insulated pipes to one another.
  • Each pipe comprises a metal pipe interior surrounded by an insulator material. End portions of the pipes to be welded have the metal pipe interior exposed.
  • the system includes a weld torch configured to weld the exposed metal pipe ends to one another; a heater configured to heat the exposed end portions of the welded pipes; an insulator supply configured to apply insulator material to the heated exposed end portions of the welded pipes such that the insulator is adhered to an exterior surface of the metal pipe interior, thus insulating the formerly exposed end portions of the pipes; and a cooler system configured to be positioned within the pipes, the cooler system applying cooling energy to an interior surface of the metal pipes to facilitate cooling of the metal pipes after the insulator material is applied.
  • Yet another aspect of the present patent application provides a method for welding a pair of insulated pipes to one another.
  • Each pipe includes a metal pipe interior surrounded by an insulator material. End portions of the pipes to be welded have the metal pipe interior exposed.
  • the method includes aligning the exposed metal pipe ends to be welded, welding the exposed metal pipe ends to one another, heating the exposed end portions of the welded pipes, applying an insulator to the heated exposed end portions of the welded pipes such that the insulator is adhered to an exterior surface of the metal pipe interior, thus insulating the formerly exposed end portions of the pipes, and applying cooling energy from within the pipes to an interior surface of the metal pipes after applying the insulator; and performing a pipeline deployment procedure. Applying the cooling energy reduces a wait time between applying the insulator and performing the pipeline deployment procedure.
  • the welded pipe assembly includes a first metal pipe having a length of at least 30' and an exterior diameter of less than 24"; a second metal pipe having a length of at least 30' and an exterior diameter of less than 24"; weld material connecting the first pipe with the second pipe, the weld material comprising a plurality of weld pass layers, the plurality of weld pass layers including a root pass layer and a hot pass layer disposed on top of the root pass layer, wherein the hot pass layer is positioned closer to an interior longitudinal axis of the welded first and second pipes than the root pass layer.
  • Yet another aspect of the present patent application provides a welded pipe assembly.
  • the assembly includes a first metal pipe having a length of at least 30' and an exterior diameter of less than 24"; a second metal pipe having a length of at least 30' and an exterior diameter of less than 24"; a welded joint connecting the first metal pipe and the second metal pipe, the welded joint comprising a first internal bevel formed in the first metal pipe and a second internal bevel formed in the second metal pipe, and a root pass layer of weld material disposed in a region defined by the first internal bevel and the second internal bevel.
  • the pipe cooling system includes a frame, a plurality of rollers, a drive motor, a brake system, a cooler, and one or more processors.
  • the frame is configured to be placed within welded pipes.
  • the plurality of rollers is configured to rotatably support the frame.
  • the drive motor drives the rollers to move the frame within the pipes.
  • the brake system secures the frame from movement at a desired location within the pipes.
  • the cooler is cooler carried by the frame, the cooler applying cooling energy to an interior surface of the metal pipes to facilitate cooling of the welded metal pipes.
  • the one or more processors are operatively connected with the drive motor, the brake system and the cooler. The one or more processors operating the cooler to reduce the temperature of the welded pipes to a predetermined level.
  • the welded pipe assembly includes a first metal pipe; a second metal pipe and weld material connecting the first metal pipe with the second metal pipe.
  • the first metal pipe has a length of at least 30 feet and an exterior diameter of less than 24 inches.
  • the second metal pipe has a length of at least 30 feet and an exterior diameter of less than 24 inches.
  • the weld material includes a plurality of weld pass layers. The plurality of weld pass layers including a root pass layer and a hot pass layer disposed on top of the root pass layer. The hot pass layer is positioned closer to an interior longitudinal axis of the welded first and second pipes than the root pass layer.
  • the welded pipe assembly includes a first metal pipe, a second metal pipe and a welded joint connecting the first metal pipe and the second metal pipe.
  • the first metal pipe has a length of at least 30 feet and an exterior diameter of less than 24 inches.
  • the second metal pipe has a length of at least 30 feet and an exterior diameter of less than 24 inches.
  • the welded joint includes a first internal bevel formed in the first metal pipe and a second internal bevel formed in the second metal pipe, and a root pass layer of weld material disposed in a region defined by the first internal bevel and the second internal bevel.
  • the field system includes a first pipe engagement structure configured to engage the interior surface of a first pipe to enable the first pipe engagement structure to be fixed relative to the first pipe; a second pipe engagement structure configured to engage the interior surface of a second pipe to enable the second pipe engagement structure to be fixed relative to the second pipe; one or more weld torches configured to be positioned within the pipes to create an internal weld at an interface region between the pipes; a motor operatively associated with the one or more weld torches to rotate the one or more weld torch along the interface region between the pipes; and one or more processors that control the motor and the one or more weld torches, the one or more processors operating the motor and the one or more weld torches to generate a complete circumferential weld along the interface region by rotating the one or more weld torches along the interface region in a single rotational direction until the complete circumferential weld is completed.
  • Yet another aspect of the present patent application provides an inspection system for pre-inspecting an interface region between two pipes to be welded end-to-end.
  • the system includes a frame configured to be placed within the pipes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the pipes; a brake system that secures the frame from movement at a desired location within the pipes; a sensor movable with the frame that detects the interface region between the pipes; an inspection detector configured to generate signals based upon a profile of the interface region between the pipes; a motor that rotationally moves the inspection detector along the interface region; and one or more processors operatively associated with the drive motor, the sensor, the inspection detector and the motor, the one or more processors operating the drive motor to move the frame through at least one of the pipes until the sensor detects the interface region, the one or more processors operating the brake system to secure the frame from movement at a location within the pipes that positions the inspection detector in relation to the interface region to enable the inspection detector
  • Yet another aspect of the present patent application provides a field system for pre- inspecting an interface region between two pipes to be welded end-to-end.
  • the system includes a frame configured to be placed within the pipes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the pipes; a brake system that secures the frame from movement at a desired location within the pipes; an inspection detector configured to generate signals based upon a profile of the interface region between the pipes; one or more orientation motors that rotationally moves the inspection detector along the interface region; and one or more processors operatively associated with the drive motor, the inspection detector and the motor, the one or more processors operating the brake system to secure the frame from movement at a location within the pipes that positions the inspection detector in relation to the interface region to enable the inspection detector to detect the profile of the interface region between the pipes; the one or more processors operating the inspection detector and the motor to scan the interface region between the pipes to generate pre-weld profile data, and in response to detecting one
  • Yet another aspect of the present patent application provides a method for pre- inspecting an interface region between two pipes to be welded end-to-end.
  • the method includes moving a frame within at least one of the pipes to be welded; detecting the interface region between the pipes; securing the frame from movement at the interface region between the pipes; detecting a profile of the interface region between the pipes; and in response to detecting one or more undesirable characteristics of the interface region between the pipes, generating instructions based thereon.
  • the pipe cooling system includes a frame configured to be placed within welded pipes; a plurality of rollers configured to rotatably support the frame; a drive motor that drives the rollers to move the frame within the pipes; a brake system that secures the frame from movement at a desired location within the pipes; a cooler carried by the frame, the cooler applying cooling energy to an interior surface of the metal pipes to facilitate cooling of the welded metal pipes; and one or more processor operatively connected with the drive motor, the brake system and the cooler, the one or more processors operating the cooler to reduce the temperature of the welded pipes to a predetermined level.
  • One aspect of the present patent application provides a method of welding two pipes.
  • the method includes internally clamping a first pipe with a first clamp; internally clamping a second pipe with a second clamp, the first and second pipes being clamped so that they are disposed in end-to-end adjacent relationship, with an interface region therebetween; scanning the interface region from a location within the pipes and between the clamps to obtain profile data from the interface region; welding the two pipes in end-to-end relationship based on the profile data; and internally inspecting the welded pipes from a location within the pipes and between the clamps
  • the remote field system comprises an inspection detector configured to emit an inspection beam of radiation to scan a profile of an interface region between the first and second pipes and a weld torch configured to create a weld between the first and second pipes based on the profile of the interface region between the first and second pipes.
  • the welding processing system comprises: a receiver configured to receive, from the remote weld system, profile data determined from the scan of the interface region between the pipes by the inspection detector; one or more processors configured to compare one or more characteristics of the profile data of the scan of the interface region with one or more characteristics of predefined profile data of predetermined interface regions and configured to determine control operation data for the remote field system based on the comparison; and a transmitter configured to transmit the control operation data to the remote field system.
  • the control operation data is configured to cause the weld torch to perform one or more welding operations on the interface region between the pipes.
  • One aspect of the present application provides a method for welding pipes.
  • the method comprises: aligning ends of the two pipes to be welded, the pipes comprising a metal pipe interior surrounded by an insulator material, the metal pipe interior being exposed at portions of the pipes adjacent the ends of the pipes to be welded; welding the aligned ends of the pipes to one another from within the pipes to form a weld joint; generating weld data during the welding of the aligned ends, the weld data corresponding to welding parameters associated with the welding; inspecting the welded joint with an inspection laser from within the welded pipes to derive internal weld inspection data; inspecting the welded joint with an inspection radiation source to derive radiation inspection data; transmitting the weld data, the internal weld inspection data, and the radiation inspection data to a remote computer system to derive additional weld data; and receiving the derived additional weld data.
  • the additional weld data is derived from the transmitted data and additional inspection data received by the remote system from inspection of other pipes.
  • the field system comprises: a field device configured to perform an operation that physically affects an object; an inspection device configured to scan the object; and one or more processors communicatively connected to the inspection device and configured to receive inspection data associated with the scan of the object from the inspection device.
  • the one or more processors are communicatively connected to a remote computer system and configured to transmit the inspection data to the remote computer system.
  • the one or more processors are configured to receive data related to performing the operation from the remote computer system responsive to transmitting the inspection data, and cause, based on the operation-related data, the field device to perform the operation that physically affects the object.
  • the operation-related data is derived from the inspection data and other inspection data associated with a separate scan of another object.
  • One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon.
  • the method comprises: scanning, by an inspection device of a field system, an object to provide inspection data associated with the scan of the object to one or more processors; transmitting, by one or more processors of the field system, the inspection data to a remote computer system; receiving, by the one or more processors, data related to performing an operation that physically affects an object from the remote computer system responsive to transmitting the inspection data; and causing, by the one or more processors, based on the operation-related data, a field device of the field system to perform the operation that physically affects the object.
  • the operation-related data is derived from the inspection data and other inspection data associated with a separate scan of another object.
  • the remote field system comprises an inspection device configured to scan the object and a field device configured to perform an operation that physically affects the object.
  • the computer system comprises: a receiver configured to receive, from the remote field system, inspection data associated with the scan of the object by the inspection device; one or more processors configured to process the inspection data to generate data related to performing the operation that physically affects the object; and a transmitter configured to transmit the operation-related data to the remote field system to cause the remote field system to perform the operation that physically affects the object, wherein the operation is performed based on the operation- related data.
  • the remote field system comprises an inspection device configured to scan the object and a field device configured to perform an operation that physically affects the object.
  • the method comprises: receiving, by a receiver, from the remote field system, inspection data associated with the scan of the object by the inspection device; processing, by one or more processors, the inspection data to generate data related to performing the operation that physically affects the object; and transmitting, by a transmitter, the operation-related data to the remote field system to cause the remote field system to perform the operation that physically affects the object, wherein the operation is performed based on the operation-related data.
  • the field system comprises an inspection device configured to scan the object and one or more field devices configured to perform one or more operations that physically affect an object.
  • the computer system comprises a receiver configured to receive, from the field system, inspection data associated with the scan of the object by the inspection device.
  • the scan of the object by the inspection device is subsequent to a performance of the one or more operations by the one or more field devices that physically affected the object.
  • the one or more operations are performed using a first set of input parameters.
  • the computer system also comprises one or more processors configured to: detect, based on the inspection data, a defect related to the object; generate, an operation protocol associated with at least one operation type of the one or more operations responsive to the defect detection, wherein the operation protocol comprises a second set of input parameters having at least one input parameter different from the first set of input parameters; select the operation protocol for performing a subsequent operation similar to at least one of the one or more operations; and generate, based on at least one input parameter of the operation protocol, data related to performing the subsequent operation.
  • the computer system further comprises a transmitter configured to transmit the operation-related data to one or more field systems to cause the one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the operation-related data.
  • the field system comprises an inspection device configured to scan the object and one or more field devices configured to perform one or more operations that physically affects an object.
  • the method comprises receiving, by a receiver, from the field system, inspection data associated with the scan of the object by the inspection device.
  • the scan of the object by the inspection device is subsequent to a performance of the one or more operations by the one or more field devices that physically affected the object.
  • the one or more operations are performed using a first set of input parameters.
  • the method also comprises: detecting, by one or more processors, based on the inspection data, a defect related to the object; generating, by the one or more processors,, an operation protocol associated with at least one operation type of the one or more operations responsive to the defect detection, wherein the operation protocol comprises a second set of input parameters having at least one input parameter different from the first set of input parameters; selecting, by the one or more processors, the operation protocol for performing a subsequent operation similar to at least one of the one or more operations; generating, by the one or more processors, based on at least one input parameter of the operation protocol, data related to performing the subsequent operation; and transmitting, by a transmitter, the operation-related data to one or more field systems to cause the one or more field systems to perform the subsequent operation.
  • the subsequent operation is performed based on the operation-related data.
  • the field system comprises an inspection device configured to scan the object and one or more field devices configured to perform one or more operation that physically affects the object.
  • the computer system comprises a receiver configured to receive, from the field system, inspection data associated with the scan of the object.
  • the scan of the object is subsequent to a performance of the one or more operations that physically affected the object.
  • the one or more operations are performed using a first set of input parameters.
  • the computer system also comprises one or more processors configured to: determine, based on the inspection data, whether a quality of one or more aspects of the object resulting from the one or more operations exceeds a quality standard indicated by a predefined quality profile; generate an operation protocol associated with at least one operation type of the one or more operations, wherein the operation protocol is generated to comprise one or more of the set of input parameters responsive to the quality of the one or more aspects of the object exceeding the quality standard indicated by the predefined quality profile; select the operation protocol for performing a subsequent operation similar to at least one of the one or more operations; and generate, based on at least one input parameter of the operation protocol, data related to performing the subsequent operation.
  • the computer system further comprises a transmitter configured to transmit the operation-related data to one or more field systems to cause the one or more field systems to perform the subsequent operation. The subsequent operation is performed based on the operation-related data.
  • One aspect of the present patent application provides a method for facilitating field testing at a field system and physical operations based thereon.
  • the field system comprises an inspection device configured to scan the object and one or more field devices configured to perform one or more operation that physically affects the object.
  • the method comprises receiving, by a receiver, from the field system, inspection data associated with the scan of the object.
  • the scan of the object is subsequent to a performance of the one or more operations that physically affected the object.
  • the one or more operations are performed using a first set of input parameters.
  • the method also comprise: determining, by one or more processors,, based on the inspection data, whether a quality of one or more aspects of the object resulting from the one or more operations exceeds a quality standard indicated by a predefined quality profile; generating, by the one or more processors, an operation protocol associated with at least one operation type of the one or more operations, wherein the operation protocol is generated to comprise one or more of the set of input parameters responsive to the quality of the one or more aspects of the object exceeding the quality standard indicated by the predefined quality profile; selecting, by the one or more processors, the operation protocol for performing a subsequent operation similar to at least one of the one or more operations; generating, by the one or more processors, based on at least one input parameter of the operation protocol, data related to performing the subsequent operation; and transmitting, by the one or more processors, the operation-related data to one or more field systems to cause the one or more field systems to perform the subsequent operation.
  • the subsequent operation is performed based on the operation-related data.
  • One aspect of the present patent application provides a computer system for facilitating field testing and physical operations based thereon.
  • the computer system comprises one or more processors configured to: obtain, from one or more field systems, data related to observations of one or more operations performed on a plurality of objects.
  • the plurality of objects comprises (i) one or more objects determined to have a defect resulting from the one or more observed operations and (ii) one or more objects without the defect.
  • the one or more processors are also configured to: compare, based on the observation-related data, a first set of observations of an operation performed on an object determined to have the defect with one or more other sets of observations of the operation performed on one or more other objects without the defect; determine, based on the comparison, a common difference that the first set of observations has with the one or more other sets of observations; and cause, based on the common difference, an operation trigger to be implemented such that a field system is caused to perform an operation associated with the operation trigger when a circumstance corresponding to the common difference occurs during a subsequent operation that physically affects one or more additional objects.
  • One aspect of the present patent application provides a method for facilitating field testing and physical operations based thereon.
  • the method comprises obtaining, by one or more processors, from one or more field systems, data related to observations of one or more operations performed on a plurality of objects.
  • the plurality of objects comprises (i) one or more objects determined to have a defect resulting from the one or more observed operations and (ii) one or more objects without the defect.
  • the method also comprises: comparing, by the one or more processors, based on the observation-related data, a first set of observations of an operation performed on an object determined to have the defect with one or more other sets of observations of the operation performed on one or more other objects without the defect; determining, by the one or more processors, based on the comparison, a common difference that the first set of observations has with the one or more other sets of observations; and causing, by the one or more processors, based on the common difference, an operation trigger to be implemented such that a field system is caused to perform an operation associated with the operation trigger when a circumstance corresponding to the common difference occurs during a subsequent operation that physically affects one or more additional objects.
  • One aspect of the present patent application provides a system for aligning and welding together two segments of a pipe.
  • the system includes a welding mechanism for applying a weld to a face joint of the two segments, the welding mechanism including an articulating torch, a laser sensor for reading a profile of the face joint, and an electronic controller for receiving information signals from the laser sensor to control the position and/or orientation of the torch; an alignment mechanism for manipulating the orientation of the longitudinal axis of at least one of the segments relative to the other; and wherein the welding mechanism further includes a carriage for securing a position of the welding mechanism in the pipe and a welding portion capable of rotating relative to the supporting portion within the pipe; and wherein the torch and the laser sensor are rotatably supported by the welding portion such that during welding, the torch follows the laser sensor along the face joint.
  • One aspect of the present patent application provides a method of aligning and welding together two segments of a pipe.
  • the method includes the steps of: placing a first pipe segment on an alignment device; inserting an internal welding machine having a laser and a weld torch into the first pipe segment; generally aligning a second pipe segment with the first pipe segment and internal welding machine; griping an external portion of the first and second pipe segments to adjusting an axial position of the internal welding machine so as to generally line up with a face joint of the first and second pipe segments; adjusting a relative alignment of the first and second pipe segments via the alignment device based on a signal from the internal welder; beginning a root weld cycle in which the laser scans the face joint, the torch follows the laser, and the output from the laser is used to control the position of articulated torch, where the position and orientation of the torch with respect to the face joint is controlled to produce a quality weld; determining a face joint profile from the laser; releasing the alignment device and removing internal welding machine from an open pipe segment end;
  • the internal heat exchanger includes a drive system configured to move the IHEX into a position within at least one pipe section near a weld joint location with another pipe section; a cooling section including cooling structure configured to selectively cool one or more interior surface portions of the at least one pipe section; and a controller in communication with the cooling structure and configured to activate the cooling section when the IHEX is at the position within the at least one pipe section.
  • a welding system configured to move the IHEX into a position within at least one pipe section near a weld joint location with another pipe section.
  • a cooling section including cooling structure configured to selectively cool one or more interior surface portions of the at least one pipe section
  • a controller in communication with the cooling structure and configured to activate the cooling section when the IHEX is at the position within the at least one pipe section.
  • the welding system includes a plurality of welding stations, each welding station including a weld station computer and weld system in communication with the weld station computer, each welding station including one or more sensors, the one or more sensors configured to measure weld data including lead wire speed data; a plurality of wireless devices in communication with the one or more of the welding station computers to receive the weld data including the measured lead wire speed data; and a cloud server in communication with the wireless devices, the cloud server being configured to process the weld data including the lead wire speed data, and configured to determine an amount of consumable welding material used by the plurality of welding stations for a given period of time, wherein the cloud server is configured to communicate the amount of consumable welding material used to one or more of the wireless devices.
  • the welding system includes a welding station, the welding station including a weld station computer and a weld system in communication with the weld station computer, the weld system including a supply of weld material, a welding device, and a weld supply motor assembly that moves the weld material to the welder device; a weighting device operatively connected with the weld station computer and configured to measure a weight of the supply of weld material and to communicate the weight of the supply of weld material to the weld station computer in the form of weight data; and a sensor operatively connected with the weld supply motor assembly and the weld station computer so as to communicate the speed of the weld supply motor assembly to the weld station computer in the form of speed data; wherein the weld station computer is operatively connected to the weld supply motor assembly and is configured to control the speed of the motor assembly based on the weight data.
  • One aspect of the present patent application provides a method of controlling welding.
  • the method includes measuring, using a weight measuring device, a first weight of a supply of weld material at a first time; measuring, using the weight measuring device, a second weight of the supply of weld material at a second time subsequent to the first time; calculating, using a computer, a difference in measured weight between the first weight and the second weight, the difference in measured weight corresponding to measured used weld material; calculating, using the computer, a theoretical weight of used weld material based on a speed of a motor assembly feeding the weld material to a welding device; comparing, by the computer, the theoretical weight of used weld material to the measured weight of used weld material; and adjusting, by the computer, the speed of the motor assembly so as to correct a slippage of the motor assembly.
  • the welding system includes a plurality of welding stations, each welding station including a weld station computer and weld system in communication with the weld station computer, each welding station including one or more sensors, the one or more sensors configured to measure weld data including lead wire speed data; a plurality of wireless devices in communication with the one or more of the welding station computers to receive the weld data including the measured lead wire speed data; and each weld station computer being configured to process the weld data, including the lead wire speed data, for the weld system in communication therewith, the weld station computer configured to determine an amount of consumable welding material used by the weld system for a given period of time and generating consumption data based thereon.
  • One aspect of the present patent application provides a system for pipeline testing.
  • the system includes a testing device adapted to generate nondestructive test data regarding at least a portion of a weld; said testing device communicating said nondestructive test data to a second device which is adapted to receive said nondestructive test data; and said testing device adapted to operate remotely from a means of analyzing said nondestructive test data.
  • One aspect of the present patent application provides a system for nondestructive pipeline testing.
  • the system includes an imaging equipment adapted to generate nondestructive test data regarding a portion of a welded pipe; a remote processing device adapted to receive and process inspection data regarding said portion of said welded pipe.
  • One aspect of the present patent application provides a method of nondestructive pipeline testing.
  • the method includes the steps of: providing an imaging equipment; generating a nondestructive test data; providing a means to provide said nondestructive test data for analysis; and said nondestructive test data provided for analysis at a location remote from the tested portion of a pipe and the equipment proximate to the tested portion of a pipe.
  • One aspect of the present patent application provides a system for pipeline construction.
  • the system includes a system for real-time logging of weld data; and said weld data is provided for analysis by computerized means and/or by subject experts.
  • the computer program product includes a computer readable program code means which provides to a computer memory a welding data; a computer readable program code means which provides to said memory a data from a data set comprising a pipeline data; a computer readable program code means which processes said welding data and said pipeline data to provide a record output.
  • One aspect of the present patent application provides a method of data management executed on a computer.
  • the method includes the steps of: communicating a first data from a first device to a second device, said first data which is a data regarding a pipeline construction; processing said first data by a cloud-based network means.
  • One aspect of the present patent application provides a computer system.
  • the system includes a first device having a processor which processes a pipeline construction data, said first device communicating said pipeline construction data to a cloud-based memory, said pipeline construction data processed by a cloud-based processor.
  • the same configuration can be used for additional weld torch heads provided in the same system (e.g., in an internal welding system), and can also be used in other welding systems (such as the tie- in internal welders) described herein.
  • various components such as the clamps, seals, brakes, weld consumption detection systems, or other components described herein, can be used with various embodiments described herein.
  • the braking system, motors, clamps seals, as described in one embodiment can be applied to other embodiments described herein, as will be appreciated by those skilled in the art.
  • FIGS. 1A and IB show block diagrams of a method for welding pipe segments, wherein FIG. 1A shows a high level block diagram of the method and FIG. IB shows a more detailed block diagram of the method, in accordance with an embodiment of the present patent application;
  • FIG. 2 shows a cross-sectional view of a welded joint connecting a first pipe and a second pipe in accordance with an embodiment of the present patent application
  • FIGS. 2A and 2B show bevel details for a single pipe segment and for a joint (prior to welding) between two pipe segments in accordance with an embodiment of the present patent application;
  • FIGS. 2C-2F show a front view, a perspective view, a side view and a detailed view of a bevel gage used to gage the pipe bevel in accordance with an embodiment of the present patent application;
  • FIGS. 2G-2I show cross-sectional views of pipelines with weld joints formed between their pipes, where FIG. 2G shows a weld joint in which root pass and hot pass weld layers are formed by an internal weld system and the fill and cap pass weld layers are formed by an external weld system, FIG. 2H shows a weld joint in which a root pass weld layer is formed by an internal weld system and the hot, fill and cap pass weld layers are formed by an external weld system and FIG. 21 shows a weld joint formed by an external weld system in accordance with an embodiment of the present patent application;
  • FIGS. 3-7 show block diagrams of the methods for welding pipe segments for different weld situations in accordance with an embodiment of the present patent application
  • FIGS. 7A and 7B show views of an external clamp being used to clamp pipes together from the outside in accordance with an embodiment of the present patent application
  • FIG. 8 shows a perspective view of a system for welding two pipe segments in accordance with an embodiment of the present patent application
  • FIG. 9 shows an enlarged view of a pipe interface of two pipe segments to be welded using the system of FIG. 8 in accordance with an embodiment of the present patent application;
  • FIG. 9A shows a partial cross-sectional view of the pipeline in which an ideal alignment of a weld torch to an internal bevel (along longitudinal axes of the pipes) in accordance with an embodiment of the present patent application;
  • FIG. 10-1 shows the system of FIG. 8 in which an internal weld system is inserted into a first pipe segment in accordance with an embodiment of the present patent application
  • FIGS. 10-2 and 10-3 show the system of FIG. 8 in which the internal weld system is inserted into the first pipe segment and a second pipe segment is being aligned with the first pipe segment in accordance with an embodiment of the present patent application;
  • FIGS. 10A and 10B show views of the internal weld system being constructed and arranged to be positioned in pipes having an external diameter of 26 to 28 inches external diameter and in pipes having an external diameter of less than 24 inches, respectively in accordance with an embodiment of the present patent application;
  • FIGS. IOC and 10D show a left side perspective view and a bottom perspective view of a cradle for carrying and moving the first pipe and the second pipe in accordance with an embodiment of the present patent application;
  • FIGS. 10E and 10F show two pipe alignment errors, while FIG. 10E shows an angular pipe alignment error and FIG. 10F shows a position pipe alignment error;
  • FIG. 11 shows the internal weld system for welding two pipe segments in accordance with an embodiment of the present patent application
  • FIG. 11A shows a view of an umbilical operatively connected to the internal weld system in accordance with an embodiment of the present patent application
  • FIG. 12 shows a detailed view of a forward-most section of the internal weld system in accordance with an embodiment of the present patent application
  • FIGS. 13-22 show views of various components of the forward-most section of the internal weld system in accordance with an embodiment of the present patent application
  • FIG. 22A shows an exemplary weld wire spool in accordance with an embodiment of the present patent application
  • FIG. 22B shows an exemplary weld feed assembly in accordance with an embodiment of the present patent application
  • FIGS. 23 and 24 show a front view and a cross-sectional view of a center section of the internal weld system in accordance with an embodiment of the present patent application;
  • FIGS. 25-31 show views of various components of the center section of the internal weld system in accordance with an embodiment of the present patent application;
  • FIGS. 32A and 32B show side and top views of a drive section of the internal weld system in accordance with an embodiment of the present patent application;
  • FIG. 33 shows a view of the center section of the internal weld system being positioned inside the pipe segments, where both clamps and seals are engaging the inner surfaces of the pipes, and where some components of the center section are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 34 shows a cross-sectional view of the center section of the internal weld system being positioned inside the pipe segments, where some components of the center section are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 35 shows a view of the center section of the internal weld system being positioned inside the pipe segments, where only clamps are engaging the inner surfaces of the pipes and where some components of the center section are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIGS. 35A and 35B show cross-sectional views of the center section of the internal weld system, where the clamps are in their extended and retracted positions, respectively and where some components of the center section are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 35C shows a side (head-on) view of the internal weld system in accordance with an embodiment of the present patent application
  • FIG. 36 shows a view of a clamp shoe of the internal weld system in accordance with an embodiment of the present patent application
  • FIG. 37 shows a view of a spider member of an clamp of the internal weld system in accordance with an embodiment of the present patent application
  • FIG. 38 shows a view of a clamp shoe pin member of the internal weld system in accordance with an embodiment of the present patent application
  • FIGS. 39 and 40 show views of a hub of the clamp of the internal weld system with the clamp shoe pin member and the link member connected thereto in accordance with an embodiment of the present patent application;
  • FIGS. 41 and 42 show front perspective and rear perspective views of a weld head assembly of the internal weld system in accordance with an embodiment of the present patent application;
  • FIG. 43 shows another rear perspective view of the weld head assembly of the internal weld system, wherein a weld torch of the weld head assembly has been raised to a desired welding position, in accordance with an embodiment of the present patent application;
  • FIGS. 44-46 show a left side perspective view, a perspective view and a cross- sectional view of the weld head assembly, where some components of the weld head assembly are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIGS. 47, 48 and 49 show perspective views of the weld head assembly, where the weld torch is positioned, by an axial positioning system, in its centered axial position in FIG. 47, and the weld torch is positioned, by the axial positioning system, in the right and left axial positions in FIGS. 48 and 49, respectively, in accordance with an embodiment of the present patent application;
  • FIGS. 50 and 51 show a left side perspective view and an exploded view of the weld head assembly, where some components of the weld head assembly are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 52 shows a bottom perspective view of a top positioning member of the weld head assembly in accordance with an embodiment of the present patent application
  • FIG. 53 shows a top elevational view of the weld head assembly, where some components of the weld head assembly are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 54 shows a cross-sectional view of the weld head assembly wherein the weld torch is positioned in a normal, non-tilted position in accordance with an embodiment of the present patent application;
  • FIGS. 55 and 56 show a rear perspective view and a cross-sectional view of the weld head assembly, respectively, wherein the weld torch is positioned by a tilt positioning system to +5° of angular tilt in accordance with an embodiment of the present patent application;
  • FIG. 56A shows a cross-sectional view of the weld head assembly in accordance with an embodiment of the present patent application
  • FIGS. 57 and 58 show a rear perspective view and a cross-sectional view of the weld head assembly, respectively, wherein the weld torch is positioned by a tilt positioning system to -5° of angular tilt in accordance with an embodiment of the present patent application;
  • FIG. 59 shows an exploded view of the weld head assembly, where some components of the weld head assembly are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIGS. 60A-63 show schematic views of the internal weld system with one weld torch, an inspection camera and two inspection detectors in accordance with an embodiment of the present patent application;
  • FIGS. 64-69 show schematic views of the internal weld system with two weld torches, an inspection camera and an inspection detector in accordance with an embodiment of the present patent application;
  • FIG. 70 shows a schematic diagram showing the flow of compressed air through the internal weld system in accordance with an embodiment of the present patent application
  • FIG. 71 shows a schematic diagram showing the flow of power, including weld power, communication data, and controls data through the internal weld system in accordance with an embodiment of the present patent application;
  • FIG. 72 shows a schematic diagram showing the flow of shield gas through the internal weld system in accordance with an embodiment of the present patent application
  • FIGS. 72A, 72B and 72C show close-up views of an internal weld torch used in a prior art system and the internal weld system, respectively, where the pipes have a gap and radial offset (Hi-Lo) alignment;
  • FIG. 72D shows exemplary weld parameters that are used for uphill and downhill weld procedures in accordance with an embodiment of the present patent application
  • FIG. 73 shows a perspective view of a system for welding two externally aligned pipe segments supported on alignment mechanisms in accordance with an embodiment of the present patent application
  • FIG. 74 shows an enlarged, external view of a pipe interface of two pipe segments to be welded using the system of FIG. 73 in accordance with an embodiment of the present patent application;
  • FIG. 75 shows the system in which a weld system is inserted into a pipe segment in accordance with an embodiment of the present patent application, wherein one of the pipe segments is not shown for the sake of clarity;
  • FIG. 76 shows an enlarged view of a section of FIG. 75 showing a weld portion of the weld system positioned for welding in a pipe segment in accordance with an embodiment of the present patent application, wherein one of the pipe segments is not shown for the sake of clarity.
  • FIG. 77 shows a cross-sectional view of FIG. 76 taken along the axis B-B showing the arrangement of various weld portion elements in accordance with an embodiment of the present patent application;
  • FIGS. 78 and 79 show side views of the weld system of FIG. 75, where the pipe segment is not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 80 shows a perspective view of the system of FIG. 73 in a configuration showing a first procedure in which a pipe segment is placed on an external alignment mechanism in accordance with an embodiment of the present patent application;
  • FIG. 81 shows a perspective view the system of FIG. 73 in a configuration showing a procedure subsequent to FIG. 80 in which the weld system is inserted into a pipe segment in accordance with an embodiment of the present patent application;
  • FIG. 82 shows a side view of the weld portion of the system of FIG. 73 in accordance with an embodiment of the present patent application
  • FIG. 83 shows an enlarged perspective view of a section of the weld portion of the system of FIG. 73 in accordance with an embodiment of the present patent application
  • FIG. 84 shows another enlarged perspective view of a section of the weld portion of the system of FIG. 73 in accordance with an embodiment of the present patent application
  • FIG. 85 shows an enlarged perspective view of a rotary mechanism of the system of FIG. 73 in accordance with an embodiment of the present patent application
  • FIG. 86 shows a purge and inspection system in accordance with an embodiment of the present patent application
  • FIG. 87 shows a detailed view of a forward-most section of the purge and inspection system in accordance with an embodiment of the present patent application
  • FIG. 88 shows a purge assembly of the purge and inspection system in accordance with an embodiment of the present patent application
  • FIGS. 89 and 90 show a front view and a cross-sectional view of a center section of the purge and inspection system in accordance with an embodiment of the present patent application;
  • FIG. 91 shows purge seals of the purge and inspection system in accordance with an embodiment of the present patent application
  • FIG. 92 shows of the rotatable hub of the purge and inspection system in accordance with an embodiment of the present patent application
  • FIG. 93 shows a detailed view of a drive section of the purge and inspection system in accordance with an embodiment of the present patent application
  • FIG. 94 shows a schematic diagram showing the flow of purge gas through the purge and inspection system in accordance with an embodiment of the present patent application
  • FIG. 95 shows a schematic diagram showing the flow of compressed air through the purge and inspection system in accordance with an embodiment of the present patent application.
  • FIG. 96 shows a schematic diagram showing the flow of purge gas through the purge and inspection system in accordance with another embodiment of the present patent application.
  • FIG. 97 shows a partial view of the purge and inspection system in accordance with an embodiment of the present patent application.
  • FIG. 98 shows a close-up view of an external weld torch of an external weld system used in the purge and inspection system in accordance with an embodiment of the present patent application
  • FIGS. 99 and 100 show close-up views of the external weld torch of the external weld system used in a prior art system and the purge and inspection system, respectively, where the pipes have a gap and radial offset (Hi-Lo) alignment;
  • FIG. 101 shows a tie-in internal weld system in accordance with an embodiment of the present patent application
  • FIG. 102 shows a detailed view of a power section of the tie-in internal weld system in accordance with an embodiment of the present patent application
  • FIG. 103 shows a schematic diagram showing the flow of power including weld power, communication data, and controls data through the tie-in internal weld system in accordance with an embodiment of the present patent application;
  • FIG. 103A shows a cross-sectional view of the center section of the tie-in internal weld system, where the clamps are in their retracted positions, and where some components of the center section are not shown for sake of clarity, in accordance with an embodiment of the present patent application;
  • FIG. 103B shows a method for aligning two pipes, pre-inspecting an interface region between the two pipes to be welded end-to-end, welding the two pipes, post-weld inspecting the weld joint formed between the two pipes in accordance with an embodiment of the present patent application;
  • FIG. 103C shows a side view of a tie-in internal weld system in accordance with another embodiment of the present patent application;
  • FIG. 103D shows a perspective view of the tie-in internal weld system in accordance with another embodiment of the present patent application.
  • FIG. 103E shows a perspective view of weld head assemblies of the tie-in internal weld system in accordance with another embodiment of the present patent application.
  • FIG. 103F shows a front view of the weld head assemblies of the tie-in internal weld system in accordance with another embodiment of the present patent application.
  • FIGS. 103G-103J show a procedure in which one or more weld head assemblies are operated in clockwise and counterclockwise directions to perform a welding operation in the tie-in internal weld system in accordance with another embodiment of the present patent application;
  • FIG. 104 shows a perspective view of an exemplary internal cooling system for use in pipeline welding in accordance with an embodiment of the present patent application
  • FIG. 105 shows a perspective view of the internal cooling system of FIG. 104 immediately prior to insertion within an end of a pipe section in accordance with an embodiment of the present patent application;
  • FIG. 106 shows a perspective view of the internal cooling system of FIG. 104 located within a first pipe section that is secured via a weld joint to a second pipe section in accordance with an embodiment of the present patent application;
  • FIG. 107 shows another view of FIG. 106 in which the internal cooling system is located within the first and second pipe segments at a suitable location in relation to the weld joint to facilitate internal cooling at the weld joint in accordance with an embodiment of the present patent application;
  • FIG. 108 shows a perspective view of the internal cooling system of FIG. 104 connected with a tie-in clamp in accordance with an embodiment of the present patent application;
  • FIG. 109 shows a perspective view of the internal cooling system of FIG. 104 connected with a tie-in clamp in accordance with another embodiment of the present patent application;
  • FIGS. 1 10A and 1 10B show perspective and partial perspective views, respectively, of the internal cooling system for use in pipeline welding in accordance with another embodiment of the present patent application;
  • FIGS. 111A and 11 IB show partial perspective views of portions of the internal cooling system for use in pipeline welding in accordance with another embodiment of the present patent application, in which the portion of the internal heat exchanger is within two pipe segments secured to each other via a weld joint, and a water pump is provided at an end of a portion of a pipe section;
  • FIGS. 112A and 1 12B show partial perspective views of portions of the internal cooling system for use in pipeline welding in accordance with another embodiment of the present patent application, in which the portion of the internal heat exchanger is within two pipe segments secured to each other via a weld joint, and a water pump is provided at an end of a portion of a pipe section;
  • FIG.113 shows a cross-sectional view of the pipes with their exposed metal pipe ends aligned in accordance with an embodiment of the present patent application
  • FIG. 114 shows a cross-sectional view of the pipes with the weld joint formed between their exposed metal pipe ends in accordance with an embodiment of the present patent application
  • FIGS. 1 15A and 1 15B show a cross-sectional view and a perspective view of the pipes with the weld joint formed between their exposed metal pipe ends and a heater positioned on the pipes to heat the exposed end portions of the welded pipes, respectively in accordance with an embodiment of the present patent application;
  • FIGS. 116A and 116B show a cross-sectional view and a perspective view of the pipes with the weld joint formed between their exposed metal pipe ends and an insulator supply positioned on the pipes to apply an insulator material to the heated the exposed end portions of the welded pipes, respectively in accordance with an embodiment of the present patent application;
  • FIGS. 117A and 1 17B show a cross-sectional view and a perspective view of the pipes with the weld joint formed between their exposed metal pipe ends and an insulator supply positioned on the pipes to apply an insulator material to the heated exposed end portions of the welded pipes in accordance with an embodiment of the present patent application;
  • FIG. 118 shows a cross-sectional view of the pipes with the weld joint formed between their exposed metal pipe ends and an insulator adhered to the exterior surface of the metal pipe interior, thus insulating the formerly exposed end portions of the pipes in accordance with an embodiment of the present patent application;
  • FIG. 119 shows a perspective view of a cooler system configured to apply cooling energy to an interior surface of the pipes to facilitate cooling of the pipes after the insulator material is applied in accordance with an embodiment of the present patent application;
  • FIG. 120 shows a partial, cross-sectional view of the cooler system being positioned within the pipes in accordance with an embodiment of the present patent application
  • FIGS. 121 and 122 show partial, cross-sectional views of the cooler system being positioned within the pipes, where FIG. 121 shows a heat exchanger of the cooler system positioned in contact with the interior surface of the welded pipes to remove heat from the welded pipes and FIG. 122 shows the heat exchanger is in its retracted position and is not in contact with the interior surface of the welded pipes in accordance with an embodiment of the present patent application;
  • FIG. 123 shows a perspective view of the cooler system, wherein fluid nozzles configured to apply a cooling liquid onto the interior surface of the welded pipes to remove heat from the welded pipes are shown in accordance with another embodiment of the present patent application;
  • FIGS. 124 and 125 show a perspective view and a front view of a heat exchanger element or a fin member of the cooler system in accordance with another embodiment of the present patent application;
  • FIGS 126-128 show perspective views of a system that is configured to facilitate the placement of the cooler system within and/or withdrawal of the cooler system from the pipes in accordance with another embodiment of the present patent application;
  • FIG. 129 shows a partial perspective view of the cooler system, where a plurality of rollers configured to engage the interior surface of one or more of the pipes and a drive motor configured to drive the rollers so as to move a frame assembly of the cooler assembly are shown in accordance with another embodiment of the present patent application;
  • FIG. 130 shows a perspective view of a cooler system in accordance with another embodiment of the present patent application.
  • FIG. 13 1 shows a top view of a motor power source carried by the frame assembly of the cooler system in accordance with another embodiment of the present patent application
  • FIG. 132 shows a heat exchanger of the cooler system positioned in contact with the interior surface of the welded pipes to remove heat from the welded pipes in accordance with another embodiment of the present patent application;
  • FIGS. 133 and 134 show perspective views of a cooler system in accordance with another embodiment of the present patent application;
  • FIGS. 135 and 136 show a perspective view and a partial cross-section view of a cooler system in accordance with another embodiment of the present patent application;
  • FIG. 136A shows a perspective view of an ultrasound inspection station that is configured to inspect the weld between the welded metal pipes in accordance with an embodiment of the present patent application;
  • FIG. 136B shows a method showing the pipeline deployment procedures in accordance with an embodiment of the present patent application
  • FIGS. 136C and 136D show schematic views of the S-lay procedure and of the J- lay procedure in accordance with an embodiment of the present patent application
  • FIG. 136E shows S-lay and J-lay unspooling barges in accordance with an embodiment of the present patent application
  • FIG. 137A shows a system for facilitating field system testing or operations thereof in accordance with another embodiment of the present patent application
  • FIG. 137B shows communication links between the remote computer system, the field computer system of the field system, and other components of the field system in accordance with another embodiment of the present patent application;
  • FIG. 137C shows communication links between the remote computer system and components of the field system without the field computer system in accordance with another embodiment of the present patent application;
  • FIG. 138 shows a flowchart of a method for facilitating, by a field system, field testing and physical operations based thereon in accordance with another embodiment of the present patent application;
  • FIG. 139-142 show flowcharts of methods for facilitating, by a computer system, field testing and physical operations based thereon in accordance with other embodiments of the present patent application;
  • FIG. 143 depict an example of a pipeline in accordance with another embodiment of the present patent application.
  • FIG. 144 shows a welding station in accordance with another embodiment of the present patent application.
  • FIG. 145 show a plurality of pipeline welding stations in accordance with another embodiment of the present patent application
  • FIG. 146 is a schematic diagram of a system with a plurality of welding stations in communication with a plurality of control and log collection stations in accordance with another embodiment of the present patent application;
  • FIG. 147 is a schematic diagram of a system with a plurality of welding stations in communication with a plurality of control and log collection stations in accordance with another embodiment of the present patent application;
  • FIG. 148 is a schematic diagram of welding station in communication with a network via a WiFi connection in accordance with another embodiment of the present patent application;
  • FIG. 149 is a schematic diagram of a plurality of job sites in communication with a cloud server via a worldwide network (internet) in accordance with another embodiment of the present patent application;
  • FIG. 150 is a schematic diagram of a plurality of welding stations in communication with intermediate computing devices (lead technicians, inspectors, engineers, etc.) which are in turn in communication with a cloud server through the internet in accordance with another embodiment of the present patent application;
  • FIG. 151 is a schematic diagram of a plurality of welding stations in communication with an intermediate computer system (Engineer, quality and Tech terminals) through a wireless (e.g., WiFi) communication channel in accordance with another embodiment of the present patent application;
  • Engine, quality and Tech terminals e.g., WiFi
  • FIG. 152 is a schematic diagram of a plurality of welding stations in communication with a computer system through a wireless (e.g., WiFi) communication channel in accordance with another embodiment of the present patent application;
  • a wireless e.g., WiFi
  • FIG. 153 is a schematic diagram of a plurality of welding stations in communication with a plurality of intermediate computer systems (Engineer, quality and Tech terminals) which in turn are in communication with a cloud server in accordance with another embodiment of the present patent application;
  • FIG. 154 shows an example graphical user interface ("GUI") for a "Main Screen” of an application for cloud based universal data logging (uLog) implemented by a computer system at the welding station, at the intermediate computer system or at the cloud server in accordance with another embodiment of the present patent application;
  • GUI graphical user interface
  • FIG. 155 shows an example GUI for a "Live Log” screen of the application for cloud based universal data logging (uLog) showing voltages versus time at one welding station in accordance with another embodiment of the present patent application;
  • FIG. 156 shows an example GUI for a "Get Log” screen of the application for cloud based universal data logging (uLog) showing weld data parameters including type of weld event, time, zone, weld travel speed, lead wire travel speed in accordance with another embodiment of the present patent application;
  • FIG. 157 shows an example GUI for a summary report screen of the application for cloud based universal data logging (uLog) displaying various welding parameters including weld time, weld station identification number, weld arc voltage, etc., in accordance with another embodiment of the present patent application;
  • uLog cloud based universal data logging
  • FIG. 158 shows an example GUI for a "Save Data on Log” screen of the application for cloud based universal data logging (uLog) displaying various in accordance with another embodiment of the present patent application;
  • FIG. 159 shows an example GUI for an "Analytics" screen of the application for cloud based universal data logging (uLog) showing two icons for selecting a type of analysis performed (e.g., trends, moving average) in accordance with another embodiment of the present patent application;
  • uLog cloud based universal data logging
  • FIG. 160 shows an example GUI for a "Welding Parameter” screen of the application for cloud based universal data logging (uLog) showing two various for selecting a type of function to be performed in accordance with another embodiment of the present patent application;
  • FIG. 161 A depicts schematically an example of a spool that is configured to carry a weld wire in accordance with another embodiment of the present patent application;
  • FIG. 161B depicts schematically a lateral view of a hub-transducer that is configured to measure a weight of the spool in accordance with another embodiment of the present patent application;
  • FIG. 161C depicts another lateral view of the hub-transducer showing the positioning of transducer elements or strain sensors/gauges for measuring weight strain when the spool is mounted on the hub in accordance with another embodiment of the present patent application;
  • FIG. 162 depicts schematically an arrangement where a weld wire in spool mounted to hub is pulled by a motor assembly for feeding the wire 82 to the weld device (not shown) in accordance with another embodiment of the present patent application;
  • FIG. 163 is a flow chart depicting a process of comparing the measured weight and the theoretical weight determined based on the wire feed speed in accordance with another embodiment of the present patent application;
  • FIGS. 164A and 164B depict enlarged lateral cross-sections of the motor assembly in accordance with another embodiment of the present patent application;
  • FIG. 165 is a diagram of a configuration of the welding system depicting the interconnections of various components of the system in accordance with another embodiment of the present patent application;
  • FIG. 166 shows a non-destructive testing system overview in accordance with another embodiment of the present patent application.
  • FIG. 167 shows a generic embodiment of a non-destructive testing system in accordance with another embodiment of the present patent application.
  • FIG. 168 shows an ultrasonic testing embodiment of a non-destructive testing system in accordance with another embodiment of the present patent application.
  • FIG. 169 shows a radiographic testing embodiment of a non-destructive testing system in accordance with another embodiment of the present patent application.
  • FIGS. 1A and IB show block diagrams of a method 1000 for welding pipe sections or segments 1022 (e.g., 1022a and 1022b as shown in FIG. 2) of a pipeline 1024 (as shown in FIG. 2) together.
  • FIG. 1A shows a high level block diagram of the method 1000
  • FIG. IB shows a more detailed block diagram of the method 1000.
  • FIG. 2 shows a cross-sectional view of a weld joint 1026 connecting the pipe segments 1022 (e.g., 1022a and 1022b) of the pipeline 1024.
  • the pipe segments 1022 e.g., 1022a and 1022b
  • the pipe segments 1022 may interchangeably be referred to herein as pipes or pipe sections.
  • the weld joint 1026 is a complete circumferential weld connecting the pipe segments 1022 (e.g., 1022a and 1022b) end-to-end circumferentially.
  • the weld joint 1026 may be referred to as a girth weld or a butt weld.
  • the pipe segments 1022a and 1022b are welded together at their beveled end portions.
  • the first pipe segment 1022a and the second pipe segment 1022b have a length of at least 30 feet. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have a length of at least 31.5 feet. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have a length of at least 33 feet. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have a length of at least 34.5 feet. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have a length of at least 36 feet. [00217] In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have an exterior diameter of 24 inches or less. In one embodiment, the exterior diameter of the pipe segment may also be referred to as the outer diameter of the pipe segment.
  • first pipe segment 1022a and the second pipe segment 1022b have a nominal exterior diameter of 24 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an exterior diameter of 24.1875 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an exterior diameter of 23.8125 inches or less.
  • first pipe segment 1022a and the second pipe segment 1022b have an exterior diameter of 22.8 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b have an exterior diameter of 21.6 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an exterior diameter of 20.4 inches or less. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b each have an exterior diameter of 19.2 inches or less.
  • first pipe segment 1022a and the second pipe segment 1022b each have an exterior diameter in the range of 26 to 28 inches.
  • the first pipe segment 1022a and the second pipe segment 1022b are made of a metal material. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are made of a carbon steel material. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are made of an alloy steel material. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are made of a low-alloy steel material. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b are made of a stainless steel material.
  • first pipe segment 1022a and the second pipe segment 1022b may be made of a American Petroleum Institute specification (API) 5L grade X52 (i.e., 52000 PSI minimum yield strength and 66000 PSI minimum tensile strength) material.
  • API American Petroleum Institute specification
  • the first pipe segment 1022a and the second pipe segment 1022b may be made of an API 5L grade X60 (i.e., 60000 PSI minimum yield strength and 75000 PSI minimum tensile strength) material.
  • the first pipe segment 1022a and the second pipe segment 1022b may be made completely or in-part from a Corrosion Resistant Alloy (CRA).
  • CRA Corrosion Resistant Alloy
  • the Corrosion Resistant Alloy may include both iron-based alloys such as various grades of stainless steel or nickel-based alloys (i.e., typically known by the trade name, Inconel).
  • some CRA materials may require shield gas on both sides of the weld.
  • a purge and inspection system 7001 (as will be described in detail with respect to FIGS. 86- 100) may be used within the pipes 1022a, 1022b to provide a purge gas chamber inside (at interface region of) the pipes to be welded and an external weld system 7500 (as shown in FIG. 97) may be used outside the pipes 1022a, 1022b.
  • the external weld system 7500 may be configured to provide shield gas outside (e.g., at joint of) the pipes to be welded.
  • first pipe segment 1022a and the second pipe segment 1022b may be made of the same material. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b may be made of the different materials.
  • first pipe segment 1022a and the second pipe segment 1022b may be made of bi-metallic materials where the inner portion of the pipe segment is a CRA material and the outer portion of the pipe segment may be either carbon steel or a different CRA material than the inner portion.
  • the first pipe segment 1022a and the second pipe segment 1022b includes a metal pipe interior 5244 surrounded by an insulator/a coating material 5246.
  • the end portions of the first pipe segment 1022a and the second pipe segment 1022b to be welded have the insulator/coating material 5246 removed and the metal pipe interior 5244 exposed.
  • first pipe segment 1022a and the second pipe segment 1022b may be coated on its external surface with a corrosion resistant material/coating when the first pipe segment 1022a and the second pipe segment 1022b are used in corrosive environments (e.g., sea/salt water/ocean, chemical, etc.).
  • first pipe segment 1022a and the second pipe segment 1022b may be coated on its external surface with a wear resistant material/coating.
  • first pipe segment 1022a and the second pipe segment 1022b may be coated on its external surface with an insulator material/coating.
  • first pipe segment 1022a and the second pipe segment 1022b may be coated on its interior surface with the corrosion resistant material/coating, the wear resistant material/coating, the insulator coating/material or a combination thereof. In one embodiment, the first pipe segment 1022a and the second pipe segment 1022b may be coated on both its interior and exterior surfaces with the corrosion resistant material/coating, the wear resistant material/coating, the insulator coating/material or a combination thereof.
  • an end 1038a of the pipe 1022a is welded to a second end 103 b of the pipe 1022b.
  • the end 1038a of the pipe 1022a has an internal bevel surface 5228 and an external bevel surface 5230.
  • the end 1038b of the pipe 1022b has an internal bevel surface 5232 and an external bevel surface 5234.
  • a root pass weld layer of weld material is disposed in a region IB defined by the first internal bevel surface 5228 and the second internal bevel surface 5232 when an internal weld system 5004 is used to deposit the root pass weld layer from within the pipes 1022a, 1022b.
  • the external bevel surfaces 5230 and 5234 each may include first external bevel surfaces 5230a and 5234a and second bevel surfaces 5230b and 5234b, respectively.
  • the first external bevel surfaces 5230a and 5234a are beveled at an angle EBi with respect to an axis N-N that is perpendicular to a longitudinal axes A-A of the pipe segments 1022a, 1022b.
  • the angle EBi may be 5°.
  • the second external bevel surfaces 5230b and 5234b are beveled at an angle EB 2 with respect to the axis N-N.
  • the angle EB 2 is greater than the angle EBi.
  • the angle EB 2 may be 45°.
  • the external bevel surfaces 5230 and 5234 may each include a single bevel surface. In one embodiment, the external bevel surfaces 5230 and 5234 may each include a single continuous surface having a J-shaped configuration.
  • the internal bevel surfaces 5228 and 5232 are beveled at an angle IB with respect to the axis N-N. In one embodiment, the angle IB may be 37.5°. In one embodiment, the internal bevel surfaces 5228 and 5232 may have a distance B measured along axis N-N from their respective inner pipe surfaces 5130 and 5132. In one embodiment, the distance B measured along axis N-N from their respective inner pipe surfaces 5130 and 5132 is 0.05 inches.
  • the external bevel surfaces 5230 and 5234 and the internal bevel surfaces 5228 and 5232 may be separated from each other by a non-bevel surface.
  • the non-bevel surface may have a distance NB measured along the axis N- N. In one embodiment, the distance NB measured along axis N-N is 0.05 inches.
  • the non-bevel surface is optional and the external bevel surfaces 5230 and 5234 and their corresponding internal bevel surfaces 5228 and 5232 may be next to (and touching) each other.
  • the internal bevel surfaces 5228 and 5232 of the pipe segments 1022a, 1022b may have the same bevel angle.
  • the external bevel surfaces 5230 and 5234 of the pipe segments 1022a, 1022b may have the same bevel angle(s). In another embodiment, the bevel angle of the internal bevel surfaces 5228 and 5232 of the pipe segments 1022a, 1022b may vary. In another embodiment, the bevel angle(s) of external bevel surfaces 5230 and 5234 of the pipe segments 1022a, 1022b may vary.
  • the dimensions B of the internal bevel surfaces, the dimension NB of the non-bevel surface, and the bevel angles IB, EBi and EB 2 inay vary and depend on the thickness T of the pipe segments 1022a, 1022b.
  • the end 1038a of the pipe 1022a and the end 1038b of the pipe 1022b are joined to have a weld groove 5236 formed therebetween.
  • the weld groove 5236 may have a V-shaped cross-section.
  • the end 1038a of the pipe 1022a and the end 1038b of the pipe 1022b are constructed and arranged to have J- shaped configurations such that the weld groove formed by joining the end 1038a of the pipe 1022a and the end 1038b of the pipe 1022b together has a U-shaped configuration.
  • the shape of the weld groove depends on the welding parameters or conditions.
  • a weld material 1034 is configured to connect the first pipe segment 1022a and the second pipe segment 1022b.
  • the weld material 1034 may include Inconel material or Inconel alloy material.
  • the weld material 1034 may include a material that has a higher strength than the material of the pipes.
  • the weld material 1034 may be a different material than the material of the pipes.
  • the weld material may include Inconel material or Inconel alloy material and the material of the first pipe segment 1022a and the second pipe segment 1022b may include a stainless steel material.
  • the weld material 1034 and/or weld joint 1026 includes a plurality of pass weld layers 1014, 1016, 1018 and 1020.
  • the plurality of pass weld layers 1014, 1016, 1018 and 1020 may include the root pass weld layer 1014, the hot pass weld layer 1016, one or more fill pass weld layers 1018 and the cap pass weld layer 1020 as will be explained in detail below.
  • the pass weld layer(s) may interchangeably be referred to herein as pass layer(s).
  • the weld pass (e.g., root pass, hot pass, fill pass(es), cap pass) may be a single advancement of the weld tool or weld system along the weld joint 1026.
  • a weld bead or a weld layer is formed as a result of each weld pass.
  • the method 1000 for welding pipe sections or segments 1022a and 1022b together generally includes a root pass weld procedure 1002, a hot pass weld procedure 1004, a fill and cap pass weld procedure 1006, a weld inspection procedure 1008, a heating procedure 1010 and a coating procedure 1012.
  • the fill and cap pass weld procedure 1006 may include one or more of fill pass weld procedures 1006a and a cap pass weld procedure 1006b.
  • the method 1000 is generally a multi-pass weld or multi-layer weld procedure that includes, for example, the root pass weld procedure 1002, the hot pass weld procedure 1004, and the fill and cap weld procedure 1006.
  • one or more of the weld passes may be performed by the same weld system or tool at different times.
  • the weld passes may be performed sequentially by same weld system or tool.
  • the root and hot pass weld procedures may be performed sequentially by an internal weld system 5004 (as will be described in detail below) from interior of the pipes.
  • the fill and cap pass weld procedures may be performed sequentially by an external weld system 7500 from the exterior of the pipes.
  • the internal weld system 5004 is generally configured to weld the pipe segments 1022a and 1022b from inside the pipeline 1024 and the external weld system 7500 is generally configured to weld the pipe segments 1022a and 1022b from outside the pipeline 1024.
  • the welding performed by the internal weld system 5004 may result in a K-shaped weld bead or layer and the welding performed by the external weld system 7500 may result in a J-shaped weld bead or layer.
  • the hot, fill and cap pass weld procedures may be performed sequentially by the external weld system 7500 from the exterior of the pipes, while only the root pass weld procedure is performed by the internal weld system 5004 (as will be described in detail below) from interior of the pipes.
  • one or more of the weld passes (e.g., root pass, hot pass, fill pass(es), cap pass) of the multi-pass or multi-layer weld method 1000 may be performed by different weld systems or tools at same or different times. In one embodiment, the weld passes may be performed sequentially by different weld systems or tools.
  • each of the hot, fill and cap pass weld procedures may be performed in its corresponding weld shack from the exterior of the pipes.
  • the weld shack is a relatively small enclosure, for example, approximately 12 feet wide, 10 feet long and 8 feet high where an external weld system is mounted and carried from one pipe joint to the next by a back end rig.
  • the weld shack typically is a lightweight metal frame covered with thin sheet metal.
  • the weld shack has a special floor designed to pivot up to allow the weld shack to be lowered onto the pipes and then pivot back down to allow easy access to the pipe.
  • each of the one or more fill pass weld procedures may be performed in different weld shacks each having an external weld system.
  • the root pass weld procedure 1002 is the first welding procedure of the multi-pass or multi-layer weld method 1000. In one embodiment, the root pass weld procedure 1002 is performed by the internal weld system 5004. In one embodiment, the root pass weld procedure 1002 may be performed by a tie-in internal weld system 3001 (as will be described in detail below) having on-board weld power.
  • the root pass weld procedure 1002 when performed with the internal weld system 5004, may take up to 1.03 minutes.
  • the cycle time for the root pass weld procedure is 4 minutes (this timing is calculated from when a reach rod or umbilical 5034 is set on an auto travel).
  • the total cycle time for three cycles of the root pass weld procedure (performed by the internal weld system 5004) is 13.15 minutes (including a 2.30 minutes for the spool/weld wire change procedure), and the average cycle time for the root pass weld procedure (performed by the internal weld system 5004) is 4.42 minutes.
  • the root pass weld procedure 1002 may be performed by an external weld system 7500. In one embodiment, the root pass weld procedure 1002 may be performed by the external weld system 7500 with the purge and inspection system 7001. In one embodiment, the root pass weld procedure 1002 may be performed by the external weld system with tie-in clamps. In one embodiment, the root pass weld procedure 1002 may be performed by the external weld system 7500 with internally disposed clamps 7050, 7052. In one embodiment, the internally disposed clamps may be standard clamps or purge clamps (e.g., the purge and inspection system 7001).
  • the root pass weld procedure 1002 forms the root pass weld layer 1014.
  • the root pass weld layer 1014 is the first weld bead or layer deposited in the multiple pass or a multi-layer welding method 1000.
  • the root pass layer may also be referred to as a root sealer bead or layer.
  • the root pass weld procedure 1002 is performed by Gas Metal Arc Welding (GMAW).
  • GMAW Gas Metal Arc Welding
  • GTAW Gas Tungsten Arc Welding
  • the root pass weld procedure 1002 is performed by Short Circuit Gas Metal Arc Welding (GMAW-S).
  • the root pass weld procedure 1002 is performed by other welding processes as would be appreciated by one skilled in the art.
  • the hot pass weld procedure 1004 is the second welding procedure of the multi-pass or multi-layer weld method 1000. In one embodiment, the hot pass weld procedure 1004 is performed by the internal weld system 5004. In one embodiment, the hot pass weld procedure 1004 may be performed by the tie-in internal weld system 3001 having on-board weld power.
  • the hot pass weld procedure 1004 is performed by the external weld system 7500. In one embodiment, the hot pass weld procedure 1004 is performed by the external weld system with internally disposed clamps. In one embodiment, the internally disposed clamps may be standard clamps or purge and inspection clamps. In another embodiment, the hot pass weld procedure 1004 may be performed by a manual welder. In such an embodiment, the pipe ends are configured to include a 30° bevel angle.
  • the hot pass weld procedure 1004 when performed with the external weld system (in a weld shack) and in a ditch side location, may take up to 1.06 minutes. In one embodiment, the hot pass weld procedure 1004, when performed with the external weld system (in a weld shack) and in a work side location, may take up to 58 seconds. In one embodiment, the cycle time for the hot pass weld procedure is 2.38 minutes (this timing is calculated from when the hot pass weld shack is set on the pipe).
  • the total cycle time for three cycles the hot pass weld procedure performed by the external weld system in a weld shack is 11.35 minutes
  • the average cycle time for the hot pass weld procedure performed by the external weld system in a weld shack is 3.45 minutes.
  • the hot pass weld procedure 1004 forms the hot pass weld layer 1016.
  • the hot pass weld layer 1016 is the second weld bead or layer deposited in the multiple pass or a multi-layer weld method 1000.
  • the hot pass weld procedure 1004 immediately follows the root pass weld procedure 1002.
  • the hot pass weld procedure 1004 is performed by Gas Metal Arc Welding (GMAW).
  • GMAW Gas Metal Arc Welding
  • GTAW Gas Tungsten Arc Welding
  • the hot pass weld procedure 1004 is performed by Short Circuit Gas Metal Arc Welding (GMAW-S).
  • the hot pass weld procedure 1004 is performed by other welding processes as would be appreciated by one skilled in the art.
  • the one or more of fill pass weld procedures 1006a and the cap weld procedure 1006b of the fill and cap pass weld procedure 1006 are performed by the external weld system 7500.
  • the fill and cap pass weld procedure 1006 may be performed at multiple stations.
  • the fill and cap pass weld procedure 1006 may be performed by a manual welder.
  • the pipe ends are configured to include a 30° bevel angle.
  • the one or more fill pass weld procedures 1006a follow (or are performed after) the hot pass weld procedure 1004.
  • the one or more fill pass weld procedures 1006a form the fill pass weld layer(s) 1018.
  • the fill pass weld layer(s) 1018 are configured to fill the weld groove and be substantially flush with the surfaces of the pipe segments 1022a and 1022b of the pipeline 1024.
  • the number of fill pass weld procedures 1006a in the multiple pass or multi-layer weld method 1000 may vaiy. In one embodiment, the number of fill pass weld procedures 1006a in the multiple pass or multi-layer weld method 1000 may depend on the thickness of the pipe segments 1022a and 1022b of the pipeline 1024 being welded together.
  • the fill pass weld procedures 1006a are performed by Gas Metal Arc Welding (GMAW). In one embodiment, the fill pass weld procedures 1006a are performed by Gas Tungsten Arc Welding (GTAW). In one embodiment, the fill pass weld procedures 1006a are performed by Pulsed Gas Metal Arc Welding (GMAW-P). In another embodiment, the fill pass weld procedures 1006a are performed by other welding processes as would be appreciated by one skilled in the art.
  • GMAW Gas Metal Arc Welding
  • GTAW Gas Tungsten Arc Welding
  • GMAW-P Pulsed Gas Metal Arc Welding
  • the fill pass weld procedures 1006a are performed by other welding processes as would be appreciated by one skilled in the art.
  • the cap pass weld procedure 1006b is the last or final weld procedure of the multi-pass or multi-layer weld method 1000. In one embodiment, the cap pass weld procedure 1006b follows (or is performed after) the fill pass weld procedure(s) 1006a. In one embodiment, as shown in FIG. 2, the cap pass weld layer 1020 is the weld bead or layer deposited subsequent the fill pass weld procedures 1006a. In one embodiment, the cap pass weld procedure 1006b may also be referred to as a cover pass weld procedure. In one embodiment, the cap pass weld procedure 1006b forms the cap pass weld layer 1020. In one embodiment, as shown in FIG.
  • the cap pass weld layer 1020 is the last or final weld bead deposited in the multiple pass or a multi-layer weld method 1000.
  • the cap pass weld layer 1020 is configured to be substantially higher than the surfaces of the pipe segments 1022a and 1022b of the pipeline 1024.
  • the cap pass weld procedure 1006b is performed by Gas Metal Art Welding (GMAW). In one embodiment, the cap pass weld procedure 1006b is performed by Gas Tungsten Art Welding (GTAW). In one embodiment, the cap pass weld procedure 1006b is performed by Pulsed Gas Metal Arc Welding (GMAW-P). In another embodiment, the cap pass weld procedure 1006b is performed by other welding processes as would be appreciated by one skilled in the art.
  • GMAW Gas Metal Art Welding
  • GTAW Gas Tungsten Art Welding
  • GMAW-P Pulsed Gas Metal Arc Welding
  • the cap pass weld procedure 1006b is performed by other welding processes as would be appreciated by one skilled in the art.
  • the root pass weld procedure 1002 may be the only pass weld procedure of the multi-pass or multi-layer weld method 1000 that is performed by the internal weld system 5004, while the hot pass weld procedure 1004 and the fill and cap pass weld procedure 1006 are all performed using the external weld system 7500.
  • both the root pass weld procedure 1002 and the hot pass weld procedure 1004 of the multi-pass or multi-layer weld method 1000 are performed by the internal weld system 5004, while the fill and cap pass weld procedure 1006 is performed using the external weld system 7500.
  • the root pass weld procedure 1002, the hot pass weld procedure 1004 and the fill and cap pass weld procedure 1006 are performed using the external weld system 7500.
  • the purge and inspection clamps are used inside the pipes 1022a, 1022b, while the external weld system 7500 performs the root pass weld procedure 1002, the hot pass weld procedure 1004 and the fill and cap pass weld procedure 1006.
  • FIGS. 2G-2I show cross-sectional views of pipelines 1024 with weld joints 1026 formed therebetween.
  • FIG. 2G shows a cross-sectional view of the pipeline 1024 with the weld joint 1026 formed therebetween.
  • the weld joint 1026 of FIG. 2G includes the root pass weld layer 1014 and the hot pass weld layer 1016 formed by the internal weld system 5004 from interior of the pipes 1022a, 1022b, while the one or more fill pass weld layers 1018 and the cap pass weld layer 1020 are formed by the external weld system 7500 from the exterior of the pipes 1022a, 1022b.
  • the individual weld pass layers may also be clearly seen in FIG. 2.
  • the border 1032 between the weld material 1034 and pipe material 1036 may be easily and clearly distinguished in FIG. 2.
  • the shape of the border 1032 is unique to the pipeline 1024 that is welded (e.g., the root pass weld procedure 1002 and/or the hot pass weld procedure 1004) from the inside the pipeline 1024.
  • the locations of the root pass weld layer 1014 and hot pass weld layer 1016 will swap (e.g., when compared to the weld joint in which the root pass weld procedure is performed by the internal weld system 5004 from inside the pipeline 1024 and the hot pass weld procedure 1004 is performed by the external weld system from outside the pipeline 1024).
  • the hot pass weld layer 1016 is positioned closer to an interior longitudinal axis A-A of the welded first and second pipes 1022a and 1022b than the root pass weld layer 1014.
  • the hot pass weld layer 1016 of the weld material 1034 has at least a portion 5238 thereof disposed closer to the longitudinal axis A-A than interior surfaces 5130, 5132 of the welded pipes 1022a and 1022b in regions 5240 and 5242 of the welded pipes 1022a and 1022b immediately adjacent to the weld material 1034 on opposite sides of the weld material 1034.
  • the root pass weld layer 1014 is disposed in the internal bevel surfaces 5228, 5232 of the first and second pipe 1022a and 1022b and the hot pass weld layer 1016 is disposed on top of the root pass weld layer 1014 (i.e., closer to the interior longitudinal axis A-A).
  • the internal weld system 5004 is constructed and arranged to perform more than one welding pass from inside the pipeline 1024.
  • the internal weld system 5004 is constructed and arranged to be actuated in the radial direction so that the internal weld system 5004 can adjust the height of the weld torch 5502 between the two passes (e.g., the root pass weld procedure 1002 and the hot pass weld procedure 1004).
  • additional weld pass layer(s) may be disposed on top of the hot pass layer 1016 and positioned closer to the interior longitudinal axis A-A of the welded first and second pipes 1022a, 1022b than the hot pass layer 1016.
  • the one or more fill pass weld layers 1018 may be performed by the internal weld system 5004 such that the one or more fill pass weld layers 1018 are disposed on top of the hot pass layer 1016 and positioned closer to the interior longitudinal axis A-A of the welded first and second pipes 1022a, 1022b than the hot pass layer 1016.
  • the one or more fill pass weld layers 1018 and the cap pass weld layers 1020 may be performed by the internal weld system 5004 such that the one or more fill pass weld layers 1018 and the cap pass weld layers 1020 are disposed on top of the hot pass layer 1016 and positioned closer to the interior longitudinal axis A-A of the welded first and second pipes 1022a, 1022b than the hot pass layer 1016.
  • the one or more fill pass weld layers 1018 and the cap pass weld layer 1020 are disposed in the external bevel surfaces 5230, 5234 of the first and second pipe 1022a and 1022b and may be performed by the external weld system 7500 from outside the pipeline 1024.
  • FIG. 2H shows a cross-sectional view of the pipeline 1024 with the weld joint 1026 formed therebetween.
  • the weld joint 1026 of FIG. 2H includes the root pass weld layer 1014 formed by the internal weld system 5004 from interior of the pipes 1022a, 1022b, while the hot pass weld layer 1016, the one or more fill pass weld layers 1018, and the cap pass layer 1020 are formed by the external weld system 7500 from the exterior of the pipes 1022a, 1022b.
  • the root pass weld layer 1014 is disposed in the internal bevel 5228, 5232 of the first and second pipe 1022a and 1022b.
  • the hot pass weld layer 1016, the one or more fill pass weld layers 1018 and the cap pass weld layer 1020 are disposed in the external bevel surfaces 5230, 5234 of the first and second pipe 1022a and 1022b.
  • FIG. 21 shows a cross-sectional view of the pipeline 1024 with the weld joint 1026 formed therebetween.
  • the weld joint 1026 of FIG. 21 includes the root pass weld layer 1014, the hot pass weld layer 1016, the one or more fill pass weld layers 1018 and 1020 formed by the external weld system 7500 from the exterior of the pipes 1022a, 1022b.
  • the root pass weld layer 1014, the hot pass weld layer 1016, the one or more fill pass weld layers 1018 and the cap pass weld layer 1020 are all disposed in the external bevel surfaces 5230, 5234 of the first and second pipe 1022a and 1022b.
  • the weld joint 1026 may be inspected during the weld inspection procedure 1008.
  • the weld inspection procedure 1008 is performed after the fill and cap pass weld procedure 1006.
  • the weld joint 1026 may be cleaned before the weld inspection procedure 1008.
  • a significant amount of heat may be generated during the welding procedures (e.g., procedures 1002, 1004, and 1006).
  • the weld inspection procedure 1008 is carried out at an operating temperature that is less than at the higher weld temperature.
  • the weld joint 1026 may be cooled before the weld inspection procedure 1008 by an internal cooling system 2010 or 6500 (as described in detail below).
  • the weld inspection procedure 1008 may include any type of nondestructive testing/inspection of the weld joint 1026.
  • the weld inspection procedure 1008 may include an Automated Ultrasound Testing (AUT).
  • AUT Automated Ultrasound Testing
  • the Automated Ultrasound Testing of the weld joint 1026 may be used for both onshore and offshore pipeline weld applications.
  • the AUT is configured to be used in high-production environments.
  • the AUT is configured to be used for detecting and sizing weld flaws.
  • the Automated Ultrasound Testing is performed by an AUT scanner system (e.g., 6801 as shown in FIG. 136A).
  • the AUT scanner system includes an ultrasonic sensor system.
  • the AUT scanner system may be portable.
  • the AUT scanner system may also include a data acquisition system that is operatively connected to the ultrasonic sensor system.
  • the ultrasonic sensor system may include an emitter that is configured to send, for example, ultrasonic signals (e.g., wave pulses) into the pipe segments 1022a and 1022b and/or the girth weld 1026 therebetween.
  • the ultrasonic signals or pulses may be sent at a rate from 1 Hz to 20,000 Hz.
  • the frequency of the ultrasonic sound wave may vary from 0.5 MHz to 23 MHz.
  • the ultrasonic signals or pulses, sent by the emitter are configured to reflect off the boundaries where the density of the girth weld 1026 changes.
  • the ultrasonic sensor system may include a receiver that is configured to receive/detect the reflected pulses.
  • the receiver is configured to measure the intensity of the reflected pulse and produce an electronic signal proportional to the intensity of the reflected pulse.
  • the emitter and receiver of the ultrasonic sensor system may have multiple elements or components.
  • the emitter of the ultrasonic sensor system may be selectively activated to target the ultrasonic pulse at a specific location.
  • a range of Automated Ultrasonic Testing may include Time of Flight Diffraction (ToFD), Phased Array (PA), corrosion mapping, and/or complete weld inspection.
  • ToFD Time of Flight Diffraction
  • PA Phased Array
  • corrosion mapping corrosion mapping
  • complete weld inspection may be used when multiple weld bevels are to be evaluated.
  • the AUT weld inspection procedure may include a full- coverage pulse-echo ultrasonic weld inspection.
  • the pulse-echo ultrasonic inspection techniques use Phased Array (PA) probes coupled with ToFD inspection to provide very accurate weld flaw measurements.
  • PA Phased Array
  • the welds may be divided into zones (zonal discrimination) that are evaluated individually, with the results being reassembled into a comprehensive weld analysis.
  • a linear and sectorial scanning may provide superior weld examination.
  • the ToFD ultrasonic weld inspection may be used to supplement the full-coverage pulse-echo ultrasonic weld inspection.
  • the weld inspection procedure 1008 may include an X- ray radiography Testing.
  • the X-ray radiography Testing is performed by an X-ray radiography system.
  • the X-ray radiography system includes an emitter that is configured to send an X-ray radiation into the pipe segments 1022a and 1022b and the girth weld 1026 therebetween.
  • the intensity of the X-ray radiation may be attenuated by the material of the pipe segments 1022a and 1022b and girth weld 1026 therebetween.
  • the X-ray radiography system includes a receiver that is configured to measure the intensity of the X-ray radiation that passes through the material of the pipe segments 1022a and 1022b and girth weld 1026 therebetween.
  • the weld inspection procedure 1008 may include Gamma and close proximity radiography inspection.
  • the weld inspection procedure 1008 may include Magnetic Particle Inspection (MPI) or Dye Penetrant Inspection (DPI).
  • the weld inspection procedure 1008 may include any other Non-Destructive Testing (NDT), for example, but not limited to, Guided Wave Ultrasonic testing, eddy current testing, hardness testing, Tank Floor Testing (MFL), Positive Material Identification, Corrosion Mapping Surveys, etc.
  • NDT Non-Destructive Testing
  • NDT Non-Destructive Testing
  • the Non-Destructive Testing may generally refer to any testing configured to identify weld defects without damaging the pipes and/or the weld formed therebetween.
  • each pipe segment 1022a, 1022b includes the metal pipe interior 5244 surrounded by external protective coatings (e.g., an insulator material) 5246.
  • external protective coatings e.g., an insulator material
  • end portions 5248 and 5250 of the pipe segments 1022a, 1022b to be welded have the metal pipe interior exposed.
  • external protective coatings are applied back to the weld joint 1026.
  • an insulator is applied to the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b such that the insulator 5246A (as shown in FIG. 118) is adhered to an exterior surface 5254 of the metal pipe interior 5244, thus insulating the formerly exposed end portions 5248, 5250 of the pipes 1022a, 1022b.
  • the weld joint 1026 and the surrounding portions of the pipe segments 1022a and 1022b of the pipeline 1024 are heated to a predetermined coating temperature.
  • the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b are heated.
  • the predetermined coating temperature is the temperature that is required for the application of the external protective coatings or the insulator. In one embodiment, the predetermined coating temperature is configured to provide a good adhesion or bonding between the external protective coatings or the insulator and the pipeline 1024.
  • the heating procedure 1010 is performed after the weld inspection procedure 1008.
  • an induction pre-heating procedure may be used to heat the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the pipeline 1024 in preparation for application of the coating material(s) or the insulator.
  • the heating procedure 1010 is performed by a heating system 5304 (shown and explained with respect to FIGS. 1 15A and 115B).
  • the heating system may include an electrical heating system.
  • the heating system may include Ultra high frequency (UHF) induction coils that are configured to rapidly heat the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the pipeline 1024 up to the required coating temperature.
  • the heating system is also configured to regulate the temperature of the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the pipeline 1024 to maintain a suitable coating application temperature.
  • UHF Ultra high frequency
  • the heating system may include a heating feedback system configured to enable the heating system to achieve and maintain the required coating temperature and a temperature sensor operatively coupled to the feedback system.
  • the temperature sensor may be a contact or a non-contact temperature sensor.
  • the heating feedback system may include one or more sensors that are configured to sense other parameters of the heating procedure - heating time, etc.
  • the coating procedure 1012 is performed immediately after the heating procedure 1010.
  • the coating procedure 1012 is performed in a coating shack (i.e., similar in construction to the weld shack) having a coating head that is constructed and arranged to apply/spray/provide insulator/coating/epoxy mixture to the exposed end portions 5248, 5250 of the welded pipes 1022a, 1022b of the pipeline 1024.
  • the coating head completes the coating procedure in less than a minute. In one embodiment, the coating head completes the coating procedure in 50 seconds.
  • an insulator/coating is applied to the heated exposed end portions 5248, 5250 of the welded pipes such that the insulator/coating 5246A (as shown in FIG. 1 18) is adhered to the exterior surface 5254 of the metal pipe interior, thus insulating the formerly exposed end portions 5248, 5250 of the pipes 1022a, 1022b.
  • the coatings are applied to external surfaces or areas of the pipe segments 1022a and 1022b surrounding the weld joint 1026 to provide an insulation barrier in order to prevent or minimize corrosion at weld areas.
  • the coatings may include polypropylene coatings.
  • the coatings may include polyethylene coatings.
  • the coatings may include polyurathane coatings.
  • the coatings may include insulation (e.g., heat loss) coatings.
  • the coatings may include anti- corrosion coatings.
  • the coatings may include wear-resistant coatings.
  • the coatings may include fusion bonded epoxy (FBE).
  • the coatings may include fusion bonded epoxy (FBE) plus chemically modified polypropylene (CMPP) or polyethylene (CMPE) dual powder base layers.
  • the chemically modified polypropylene (CMPP) or polyethylene (CMPE) layer is then followed immediately by the polypropylene (PP) or polyethylene (PE) tape.
  • the coatings may include Multi-Component Liquid coatings (MCL) (e.g., urethane and epoxy based MCL coatings).
  • MCL Multi-Component Liquid coatings
  • the coatings may include a field joint coating (FJC).
  • the coatings may include an Injection Molded polypropylene.
  • the pipeline 1024 is pre-heated to a temperature of 180 °C to receive the Injection Molded polypropylene coating.
  • an automated equipment may be used to apply coating materials at the weld joint 1026.
  • the coating delivery system may include Injection Molded Coating System as shown and described in detail with respect to FIGS. 117A and 1 17B.
  • the coating delivery system may include a flame-spray coating system.
  • the insulation/coatings may be applied to the exposed regions of the weld joint using a nozzle device.
  • the nozzle device is configured to spray insulation materials onto the exposed region of pipe at the region of the welds.
  • the nozzle device is shown and described with respect to FIGS. 1 16A-116B.
  • an abrasive blasting procedure may be used to prepare the pipeline 1024 for the coatings.
  • the abrasive blasting procedure may be performed prior to the heating procedure 1010.
  • the oxidized pipe weld joint is sandblasted to remove all contaminants.
  • the coating system may include a coating feedback system configured to enable the coating system to achieve the desired coatings on the pipeline 1024 and one or more sensors operatively connected to the coating feedback system.
  • the one or more sensors are configured to sense the following parameters of the coating procedure - heating time, heating temperature, coating material temperature, coating material volume, etc.
  • the method 1000 may include other procedures that are not shown in FIG. 1A. In one embodiment, these other procedures of the method 1000 are shown in and explained with respect to FIG. IB.
  • the method 1000 may include a pipe preparation procedure 1040, a pipe alignment procedure 1042, an optional weld inspection procedure 1044, a repair procedure 1046, a cooling procedure 1048, and a pipeline deployment procedure 1050. In one embodiment, each of these procedures is optional.
  • the pipe preparation procedure 1040 is performed prior to the root pass weld procedure 1002. In one embodiment, the pipe preparation procedure 1040 is performed prior to the pipe alignment procedure 1042.
  • the pipe preparation procedure 1040 may include a cutting procedure 1040a.
  • the cutting procedure 1040a is performed for preparation of the edge or end portions of the pipe segments 1022a, 1022b for welding.
  • the pipe segments 1022a and 1022b that are to be welded together are cut into the desired dimensions.
  • the cutting procedure 1040a may be performed at the manufacturer's location.
  • the method may include a stringing procedure in which the pipes are distributed according to a design plan (before the pipe joining/welding procedure).
  • each joint of the pipe segment has a specific place in the pipeline.
  • the stringing crew ensures that each piece of pipe is placed where it belongs. Inspectors check the pipe's designated numbers to ensure that the joints are in the correct order.
  • the method may include a bending procedure in which the pipes are bent to fit the right-of-way's topography.
  • the pipe is inserted into a bender and a mandrel is then positioned in the pipe.
  • the mandrel is constructed and arranged to apply pressure inside the pipe to prevent buckling while bending.
  • the operator positions the pipe and makes the bend.
  • the pipe is removed from the bender after the bend is made. After the bending procedure, each piece of pipe is set in place.
  • the pipe preparation procedure 1040 may include a beveling procedure 1040b.
  • the beveling procedure 1040b is performed for preparation of the edge or end portions of the pipe segments 1022a and 1022b for welding.
  • the end portions of the pipe sections or segments 1022a and 1022b that are to be welded together are beveled into the desired dimensions.
  • the desired bevels may be machined into the end portions of the pipe segments 1022.
  • a pipe facing machine is inserted in the pipe and is anchored to the pipe (by raising its internal clamp shoes).
  • the beveling procedure 1040b may take 10 seconds.
  • the operator may manually check the formed bevel using a bevel gage 5801 shown in FIGS. 2C-2F.
  • FIGS. 2C-2E show a front view, a perspective view and a side view of the bevel gage 5801, respectively, while FIG. 2F shows a detailed view of detail A in FIG. 2C.
  • the beveling procedures 1040a, 1040b may be performed at the manufacturer's location.
  • the standard bevel depth for field welding from the inside of the pipe is .050 inches.
  • the weld bead is about 3 millimeters tall so that the weld bead protrudes from the surface by 0.05 to 0.07 inches.
  • the bevel may be cut to a depth of 0.150 to 0.170 inches.
  • the pipe alignment procedure 1042 is performed prior to the root pass weld procedure 1002. In one embodiment, the pipe alignment procedure 1042 is performed between the pipe preparation procedure 1040 and the root pass weld procedure 1002. In one embodiment, a preheat procedure may be performed, prior to the welding procedure (i.e., root pass weld procedure), to heat the pipe to over 100 °C so as to evaporate all moisture from the surface of the pipe.
  • a preheat procedure may be performed, prior to the welding procedure (i.e., root pass weld procedure), to heat the pipe to over 100 °C so as to evaporate all moisture from the surface of the pipe.
  • the pipe alignment procedure 1042 may include providing a second pipe 1022a at the second end 1038b of the first pipe 1022b, and aligning the ends 1038a, 1038b of the first and second pipes 1022a, 1022b that are to be welded.
  • the internal weld system 5004 may include a feedback system (e.g., using inspection detector 5056, one or more processors 5140, orientation motors 5030, 5074, external cradle 5330, 6010A, 6010B, internal clamps 5144, 5144, 7050, 7052 as will be explained in detail below) that is configured to sense whether the ends 1038a, 1038b of the first and second pipes 1022a, 1022b are properly aligned.
  • a feedback system e.g., using inspection detector 5056, one or more processors 5140, orientation motors 5030, 5074, external cradle 5330, 6010A, 6010B, internal clamps 5144, 5144, 7050, 7052 as will be explained in detail below
  • the term "motor” as used herein broadly refers to any type of electromechanical motor, such as an electric motor, hydraulic motor, pneumatic motor, just for example.
  • the optional weld inspection procedure 1044 may be performed between the hot pass weld procedure 1004 and the fill and cap weld procedure 1006.
  • the optional weld inspection procedure 1044 may include X-ray radiography inspection.
  • the X-ray radiography inspection is performed by an X-ray radiography system.
  • the X-ray radiography system includes an emitter that is configured to send an x-ray radiation into the pipe segments 1022a and 1022b and the root and hot pass weld layers formed therebetween.
  • the intensity of the X-ray radiation may be attenuated by the material of the pipe segments 1022a and 1022b and the root and hot pass weld layers 1014, 1016 formed therebetween.
  • the X-ray radiography system includes a receiver that is configured to measure the intensity of the x-ray radiation that passes through the material of the pipe segments 1022a and 1022b and the root and hot pass weld layers 1014, 1016 formed therebetween.
  • the weld inspection procedure 1044 may include Gamma and close proximity radiography inspection.
  • the repair procedure 1046 is performed after the weld inspection procedure 1008 and before the heating and coating procedures 1010 and 1012. In one embodiment, the repair procedure 1046 is configured to repair any weld defects that are detected during the weld inspection procedure 1008.
  • the weld repair procedure noted herein can be one of a variety of types.
  • an additional welding operation is performed on top of the previous weld to remedy any weld defect.
  • the defective weld may be ground down or optionally entirely cut out (manually or automatically) before any subsequent repair welding operation is conducted.
  • the pipeline 1024 is allowed to cool to a suitable temperature before further processing steps can occur (e.g., before spooling of the connected pipe segments or handling /placement of the pipe segments in water or at some other suitable location on land).
  • the cooling procedure 1048 is performed after the coating procedure 1012.
  • the cooling procedure 1048 is performed by a cooling system 2010, 21 10, 2210, 6500 (as shown in and described with respect to FIGS. 104-1 12B and 1 19-136) that is configured to remove heat from the welded pipes so as to reduce their temperature to an acceptable temperature for effective spooling.
  • the pipeline should be below a predetermined temperature (e.g., 50 to 70 C) to carry out the spooling procedure, the S-lay procedure, etc.
  • the cooling system may be an internal cooling system that is configured to cool the welded pipes from inside the pipeline 1024.
  • the welded pipes may also be allowed to air cool over time.
  • the welded pipes may be cooled by spraying or pouring water on the outside of the insulation/coatings on the pipeline.
  • the water spraying or pouring procedure may be carried out in one or more stations.
  • the cooling procedure 1048 is performed, for example, for a barge welding procedure, a spool base Tie-in welding procedure, and a spool base main line welding procedure.
  • the onshore main line welding procedure and the onshore tie-in welding procedure may not have a separate cooling procedure.
  • the pipeline deployment/lowering procedure 1050 is performed after the coating procedure 1012. In one embodiment, the pipeline deployment/lowering procedure 1050 is performed after the cooling procedure 1048.
  • the pipeline deployment procedure 1050 may include a spooling procedure 1050a, a S-lay procedure 1050b, or a pipeline lowering procedure 1050c.
  • the spooling procedure 1050a is configured to spool the pipeline onto the vessel, which transports the pipeline to its final destination or location.
  • the pipeline should be below a predetermined temperature (e.g., 50 to 70 °C) to carry out the spooling procedure 1050a.
  • the predetermined temperature e.g., 50 to 70 °C
  • the predetermined temperature is configured to avoid any damage during the spooling procedure 1050a.
  • the S-lay procedure is an offshore pipe-lay procedure in which the pipeline is lowered to the sea in a horizontal position.
  • the pipeline is pushed off the end of the vessel in an S-shaped curve.
  • the pipeline should be below a predetermined temperature (e.g., 50 to 70 °C) to cany out the S-lay procedure 1050b.
  • the predetermined temperature e.g., 50 to 70 °C
  • the predetermined temperature is configured to avoid any damage during the S-lay procedure 1050b.
  • the pipeline lowering procedure 1050c is configured to position/lower the pipeline into a pre-dug ditch.
  • the pipeline weld condition/situations may be classified into five categories, namely, onshore main line weld procedure, onshore tie-in weld procedure, spool base main line weld procedure, spool base tie-in weld procedure, and barge weld procedure.
  • the onshore main line welding procedure is shown in FIG. 3.
  • the onshore main line welding procedure is generally performed at a ground level and adjacent to a pre-dug ditch in which the pipeline will be disposed.
  • the onshore pipelines are welded together in sections, for example, up to 1 mile long.
  • the welding stations of the onshore welding are near each other.
  • the before welding procedures and after welding procedures of the onshore welding process are decoupled from the actual welding procedure itself so that the before and after welding procedures can occur at their own pace. After the segments of pipeline are welded together, they are lowered into the pre-dug ditch.
  • the onshore tie-in weld procedure is shown in FIG. 4.
  • the onshore tie-in weld procedure generally occurs in a pre-dug ditch in which the pipeline will be disposed. That is, the sections or segments are cut to length and welded together in the pre-dug ditch.
  • the spool base main line weld procedure is shown in FIG. 5.
  • the spool base main line weld procedure is generally performed in a factory-like setting. All procedures of the spool base main line weld procedure happen within the factory-like setting and in a coordinated, assembly line process.
  • the pipes are welded, inspected and coated along a firing line to form a pipe stalk (e.g., sometimes as long as 7 kilometers).
  • the pipe stalks are stored until they can be spooled onto a vessel for transport to their final location. That is, when the ship/barge is away from the spool base, the welded pipe is stored in long sections.
  • the pipe stalks are reeled onto big spools on barges (typically J-lay) and unspooled when the barge arrives at the job location.
  • barges typically J-lay
  • the spool base tie-in weld procedure is shown in FIG. 6.
  • the spool base tie-in weld procedure is used to join the pre-assembled pipeline sections or segments together as they are being spooled onto the vessel/ship, which generally transports the pipeline to its final location. It is the cooling of this joint after coating that limits the spooling rate. All procedures of the spool base Tie-in weld are performed at the same station.
  • Barge weld procedure is shown in FIG. 7.
  • the barge weld procedure is generally performed in a factory-like setting on-board a floating vessel. All procedures of the barge weld procedure are generally performed within the factory-like setting and in a coordinated, assembly line process.
  • the pipeline is deployed in its final location as it comes off the vessel.
  • Each of these pipeline weld situations may have one or more weld procedures described with respect to FIGS. 1A and IB.
  • One or more systems described in this patent application e.g., the internal weld system 5004, the tie-in internal weld system 3001, purge and inspection system 7001, the external weld system 7500, and the internal cooling system 2010
  • the internal weld system 5004 may be used in the operational procedures of these pipeline weld situations.
  • the onshore main line weld procedure begins the with pipe preparation procedure in which an automated weld-friendly bevel is machined into each end of the pipes. This may be done by an advance crew that is working a short distance ahead of the welding crew.
  • a root pass weld procedure is performed.
  • the root pass weld procedure may be performed by the internal weld system 5004.
  • the root pass weld procedure may be performed by an external weld system 7500 with internal positioned clamp(s) 7050, 7052.
  • the hot pass weld procedure is performed. The hot pass weld procedure may be performed either by the external weld system or by the internal weld system 5004.
  • both the hot and root pass weld procedures are performed by the internal weld system 5004.
  • only the root pass weld procedure is performed by the internal weld system 5004, while the hot pass weld procedure is performed by the external weld system 7500.
  • the fill and cap pass weld procedure is performed after the hot pass weld procedure.
  • the fill and cap pass weld procedure may be performed by the external weld system 7500.
  • the fill and cap pass weld procedure may be performed at multiple stations.
  • the weld inspection procedure is performed. For example, Ultrasonic, x-ray radiography or Magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection procedure are repaired during the weld repair procedure.
  • the welded pipe is coated with Fusion Bonded Epoxy coating.
  • the Fusion Bonded Epoxy coating is applied to the (heated) exposed end portions of the welded pipes such that the Fusion Bonded Epoxy coating is adhered to an exterior surface of the pipe interior.
  • the coating procedure may be done by an autonomous crew that is working behind the repair crew.
  • the pipeline is then lowered into the pre-dug ditch.
  • the pipeline lowering procedure may be done by an autonomous crew that is working behind the coating crew.
  • the onshore tie-in weld procedure begins with the pipe preparation procedure.
  • the exact pipe lengths are not known in advance, so overlap is designed into the onshore tie-in weld procedure.
  • a root pass weld procedure is performed.
  • the root pass weld procedure may be performed by the tie-in internal weld system 3001. In another embodiment, the root pass weld procedure may be performed by the tie-in clamp system with an external weld system 7500. In another embodiment, the root pass weld procedure may be performed by a manual welder with externally positioned clamps.
  • the hot pass weld procedure is performed.
  • the hot pass weld procedure may be performed by the tie-in internal weld system 3001.
  • the hot pass weld procedure may be performed by the external weld system 7500.
  • the hot pass weld procedure may be performed by a manual welder.
  • both the hot and root pass weld procedures are performed by the tie-in internal weld system 3001.
  • only the root pass weld procedure is performed by the tie-in internal weld system 3001
  • the hot pass weld procedure is performed by the external weld system 7500.
  • the fill and cap pass weld procedure is performed after the hot pass weld procedure.
  • the fill and cap pass weld procedure may be performed by the external weld system 7500.
  • the fill and cap pass weld procedure may be performed by the manual welder.
  • the fill and cap pass weld procedure is done from the exterior of the pipes.
  • the weld inspection procedure is performed. For example, Ultrasonic, x-ray radiography or Magnetic inspection may be used to inspect the weld area.
  • the weld inspection procedure is done by an autonomous crew that is working behind the welding crew. Any weld defects detected during the weld inspection procedure are repaired during the weld repair procedure.
  • the repair procedure is performed by an autonomous crew that is working behind the inspection crew.
  • the welded pipe is coated with Fusion Bonded Epoxy coating.
  • the Fusion Bonded Epoxy coating is applied to the (heated) exposed end portions of the welded pipes such that the Fusion Bonded Epoxy coating is adhered to an exterior surface of the pipe interior.
  • the coating procedure may be done by an autonomous crew that is working behind the repair crew.
  • the spool base main line weld procedure begins with the pipe preparation procedure in which an appropriate bevel is machined into the ends of the pipe.
  • a root pass weld procedure is performed.
  • the root pass weld procedure may be performed by the internal weld system 5004.
  • the root pass weld procedure may be performed by the purge and inspection system 7001 with the external weld system 7500.
  • the root pass weld procedure may be performed by the internal clamps with the external weld system.
  • the hot pass weld procedure is performed.
  • the hot pass weld procedure may be performed by the internal weld system 5004.
  • the hot pass weld procedure may be performed by the external weld system 7500.
  • both the hot and root pass weld procedures are performed by the internal weld system 5004.
  • only the root pass weld procedure is performed by the internal weld system 5004, while the hot pass weld procedure is performed by the external weld system 7500.
  • the root pass weld procedure is performed by the external weld system 7500 with internal purge clamps 7001, while the hot pass weld procedure is performed by the external weld system 7500.
  • the X-ray radiography weld inspection procedure is performed after the hot pass weld procedure.
  • the X-ray radiography weld inspection procedure is optional.
  • the fill and cap pass weld procedure is performed after the hot pass weld procedure and X-ray radiography weld inspection procedure.
  • the fill and cap pass weld procedure may be performed by the external weld system.
  • the fill and cap pass weld procedure may be performed at multiple stations.
  • the weld inspection procedure is performed to perform the weld inspection of the weld joint.
  • Ultrasonic, x-ray radiography or Magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection procedure are repaired during the weld repair procedure.
  • the welded pipe is coated with the Injection Molded Polypropylene coating.
  • the Injection Molded Polypropylene coating is applied to the (pre-heated to 180°C) exposed end portions of the welded pipes such that the Injection Molded Polypropylene coating is adhered to an exterior surface of the pipe interior. Cooling procedure is performed after the coating procedure.
  • the pipes may be allowed to air cool over time.
  • the spool base tie-in weld procedure begins with the pipe preparation procedure in which an appropriate bevel is machined into the ends of the pipe.
  • a root pass weld procedure is performed.
  • the root pass weld procedure may be performed by the tie-in internal weld system 3001.
  • the root pass weld procedure may be performed by the purge clamp system 7001 with an external weld system 7500.
  • the root pass weld procedure may be performed by the internal clamps with the external weld system.
  • the hot pass weld procedure is performed.
  • the hot pass weld procedure may be performed by the tie-in internal weld system 3001. In another embodiment, the hot pass weld procedure may be performed by the external weld system.
  • both the hot and root pass weld procedures are performed by the tie-in internal weld system 3001.
  • only the root pass weld procedure is performed by the tie-in internal weld system 3001.
  • the X-ray radiography weld inspection procedure is performed after the hot pass weld procedure.
  • the X-ray radiography weld inspection procedure is optional.
  • the fill and cap pass weld procedure is performed after the hot pass weld procedure.
  • the fill and cap pass weld procedure may be performed by the external weld system.
  • the fill and cap pass weld procedure may be performed at multiple stations.
  • the weld inspection procedure is performed to perform the weld inspection of the weld joint.
  • Ultrasonic, x-ray radiography or Magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection procedure are repaired during the weld repair procedure.
  • the welded pipe is coated with the Injection Molded Polypropylene coating.
  • the Injection Molded Polypropylene coating is applied to the (pre-heated to 180°C) exposed end portions of the welded pipes such that the Injection Molded Polypropylene coating is adhered to an exterior surface of the pipe interior. Cooling procedure is performed after the coating procedure.
  • the pipes may be cooled by pouring or spraying water on the outside surfaces of the insulation. In another embodiment, the pipes may be cooled by an internal cooling system. In one embodiment, the pipes may be spooled onto the vessel after the cooling procedure. In one embodiment, the pipes should be below a temperature of between 50 and 70 °C during the spooling procedure so as to avoid any damage during the spooling process. In one embodiment, all the procedures of the spool base tie-in weld sequence may occur at the same location.
  • the barge weld procedure begins with the pipe preparation procedure in which an appropriate bevel is machined into the ends of the pipe.
  • a root pass weld procedure is performed.
  • the root pass weld procedure may be performed by the internal weld system 5004.
  • the root pass weld procedure may be performed by the purge clamp system 7001 with an external weld system 7500.
  • the root pass weld procedure may be performed by the internal clamps with the external weld system 7500.
  • the hot pass weld procedure is performed.
  • the pipes advance to the hot pass weld procedure after the root pass weld procedure is complete.
  • the hot pass weld procedure may be performed by the internal weld system 5004. In another embodiment, the hot pass weld procedure may be performed by the external weld system.
  • both the hot and root pass weld procedures are performed by the internal weld system 5004.
  • only the root pass weld procedure is performed by the internal weld system 5004.
  • the X-ray radiography weld inspection procedure is performed after the hot pass weld procedure.
  • the X-ray radiography weld inspection procedure is optional.
  • the fill and cap pass weld procedure is performed after the hot pass weld procedure and X-ray radiography weld inspection procedure.
  • the fill and cap pass weld procedure may be performed by the external weld system.
  • the fill and cap pass weld procedure may be performed at multiple stations.
  • the weld inspection procedure is performed to perform the weld inspection.
  • Ultrasonic, x-ray radiography or Magnetic inspection may be used to inspect the weld area. Any weld defects detected during the weld inspection procedure are repaired during the weld repair procedure.
  • the welded pipe is coated with the Injection Molded Polypropylene coating.
  • the Injection Molded Polypropylene coating is applied to the (pre-heated to 180°C) exposed end portions of the welded pipes such that the Injection Molded Polypropylene coating is adhered to an exterior surface of the pipe interior.
  • the cooling procedure is performed after the coating procedure.
  • the pipes may be cooled by pouring or spraying water on the outside surfaces of the insulation. In one embodiment, the cooling procedure may be performed at multiple stations. In another embodiment, the pipes may be cooled by an internal cooling system. In one embodiment, the pipes may be pushed off the end of the vessel in a S-shaped configuration. In one embodiment, the pipes should be below a temperature of between 50 and 70 °C during the S-lay procedure so as to avoid any damage during the S-lay procedure. [00347] In one embodiment, a field system 5000 for welding two pipes 1022a, 1022b is provided. The term "field system" as used herein is a generic term intended to refer to the system(s) disclosed herein as a whole, and/or any of the subsystems by themselves.
  • the "field system” can refer to the combination of the internal inspection system, external welder, internal pipe cooler, and ultrasound non-destructive testing system, together with the remote uLog processing system (e.g., remote computer system 13704).
  • the "field system” can refer to the internal weld system alone, the internal inspection system alone, the internal cooling system alone, the tie-in welder alone, for example. That is, the "field system” can refer to the internal weld system 5004 alone, the internal inspection system 7001 alone, the internal cooling system 6500 alone, the tie-in welder 3001 alone, for example.
  • each pipe segment 1022a or 1022b has the longitudinal axis as shown by arrow A-A.
  • the field system 5000 is configured to support multiple pipe segments 1022a, 1022b and adjust their positions and/or orientations until the pipe segments 1022a, 1022b are both aligned such that their longitudinal axes A-A are collinear and one end of each of the pipe segments 1022a, 1022b abuts at interface edges.
  • FIG. 9 illustrates an enlarged detailed view of the field system 5000 of FIG. 8 in which the edges form a pipe interface 5002 (also known as a "fit up" joint).
  • the field system 5000 includes an internal weld system 5004 that applies a weld to the interior of the interface 5002 from inside the fitted up pipe segments 1022a, 1022b.
  • the internal weld system 5004 is rolled into an end of one of the pipe segments 1022b as shown in FIG. 10-1.
  • the second pipe segment 1022a is then placed and manipulated until both pipe segments 1022a, 1022b are satisfactorily aligned.
  • the internal weld system 5004 applies a weld (e.g., a gas metal arc weld "GMAW”) from inside the pipe segments 1022a, 1022b to a face or edge joint of the pipe segment 1022a, 1022b and into a v- shaped opening formed by chamfered/beveled edges of the two pipe segments 1022a, 1022b (other cross-sectional shapes other than a v-shaped opening may also be used).
  • GMAW gas metal arc weld
  • FIG. 9 A shows a partial cross-sectional view of the pipeline 1024 displaying an ideal alignment of a weld torch 5502 of the internal weld system 5004 to the internal bevel surfaces 5228 and 5232 (along longitudinal axes A-A of the pipes 1022a, 1022b).
  • the pipes 1022a, 1022b are perfectly aligned with each other and do not have any Hi-Lo (i.e., a height difference between the bevel edges of the pipes 1022a, 1022b after the pipe alignment).
  • the field system 5000 may include external clamps 5302 that are used to clamp pipes together from the outside (external to the pipes).
  • the external clamps 5302 have bars across the weld joint and welding may be done manually.
  • the external clamps 5302 may be hydraulically operated or may be mechanically operated (e.g., using a hand lever).
  • the external clamps 5302 may be a tipton clamp as shown in FIGS. 7A and 7B.
  • the internal weld system 5004 is connected to an external structure/system (i.e., external to the pipes 1022a, 1022b being welded) by an umbilical 5034 (as shown in FIG. 10-1).
  • the external system is the remote uLog processing system.
  • the umbilical 5034 may be between 40 and 80 feet long (e.g., for a pipe that is 40 or 80 feet long).
  • the umbilical 5034 may be referred to as a reach rod.
  • the reach rod/umbilical 5034 may be fixedly connected to the internal weld system 5004. That is, the reach rod/umbilical 5034 is a permanent piece of the internal weld system 5004.
  • the umbilical 5034 includes a structural tubular member that protects all of the cables, wiring and hoses (e.g., that connect the external structure/system and the internal weld system 5004) from damage.
  • the umbilical 5034 is disconnected at a disconnection point, DP (as shown in FIG. 10-2).
  • This disconnection facilitates the new/incoming pipe segment 1022a to be placed in position with respect to the first pipe 1022b.
  • FIG. 10-2 shows that the cables, hoses and wires (e.g., that connect the external structure/system and the internal weld system 5004) at the end of the reach rod/umbilical 5034 are disconnected and that the new/incoming pipe segment 1022a is being placed in position with respect to the first pipe 1022b.
  • the umbilical 5034 may hang/extend out of the incoming pipe 1002a by a distance, HD.
  • the distance, HD that the umbilical 5034 may hang/extend out of the incoming pipe 1002a is in between 1 and 5 feet.
  • the umbilical 5034 is generally used to convey fluids (compressed air), send electrical signals and/or send communication signals between the external structure/system and the internal weld system 5004.
  • the tie-in internal weld system 3001 does not include the reach rod or the umbilical.
  • the umbilical 5034 may include weld power lines configured to deliver power to the weld torches.
  • the umbilical 5034 includes three weld power lines to independently deliver power to the three associated weld torches in the internal weld system 5004.
  • the number of weld power lines in the umbilical 5034 may vary and depend on the number of weld torches in the internal weld system 5004.
  • the umbilical 5034 may include communication lines configured to communicate with the inspection detector 5056, the inspection camera 51 12, and/or other electronic modules (e.g., to start or stop welding) of the internal weld system 5004.
  • the communications to the internal weld system 5004, including to the inspection detector 5056, to the inspection camera 5112, and/or to other electronic modules of the internal weld system 5004, may be performed wirelessly. It should be appreciated that where a plurality of weld torches are provided, a plurality of inspection detectors/lasers 5056 may also be provided.
  • the umbilical 5034 may include a fluid communication line configured to supply compressed air to the internal weld system 5004.
  • the umbilical 5034 may include another (separate) power line configured to deliver power to the batteries 51 16 to recharge them.
  • the separate power line to recharge the batteries 51 16 is optional.
  • the umbilical 5034 may include a separate power line configured to deliver power to one or more electronic modules and/or the motors of the internal weld system 5004. In another embodiment, this separate power line is optional.
  • the internal weld system 5004 is used for pipes having an internal diameter of 26 to 28 inches with 0 to 1 inch pipe wall thickness. Therefore, the internal weld system 5004 is configured to fit in holes between 24 and 28 inches. In one embodiment, the internal weld system 5004 is used for pipes having an internal diameter of 24 inches or less with pipe wall thickness of 0 to 1 inch. In one embodiment, the internal weld system 5004 is used for pipes having an external diameter of 24 inches or less. In one embodiment, the internal weld system 5004 is used for pipes having an external diameter of 26 to 28 inches.
  • FIG. 10A shows the internal weld system 5004 being constructed, sized and positioned in pipes having an internal diameter of 26 inches with 1 inch pipe wall thickness.
  • the external diameter of the frame structure of the internal weld system 5004 is 23.32 inches in relation to the internal diameter of 26 inches (with 1 inch pipe wall thickness) of the pipes.
  • the outer diameter of the frame structure (not including its wheels) of the internal weld system 5004 is 23.32 inches.
  • FIG. 10B shows the internal weld system 5004 being constructed, sized and positioned in pipes having an internal diameter of 24 inches with 1 inch pipe wall thickness.
  • the external diameter of the frame structure of the internal weld system 5004 is 21.32 inches in relation to the internal diameter of 24 inches (with 1 inch pipe wall thickness) of the pipes.
  • the outer diameter of the frame structure (not including its wheels) of the internal weld system 5004 is 21.32 inches.
  • the diameter of the frame of the internal weld system 5004 may be a function of the internal weld system's ability to fit through the pipe bends.
  • the standard minimum bend radius of the pipe is 30 times D, where D is the external or outer diameter of the pipe. That is, the radius of the centerline of the pipe is 30 times the outer or external diameter of the pipe. For example, for a 26" outer or external diameter pipe, the minimum bend radius the internal weld system 5004 needs to traverse is 780 inches (i.e., (26 inches) x 30).
  • the minimum bend radius the internal weld system 5004 needs to traverse is 720 inches (i.e., (24 inches) x 30).
  • the field system 5000 may include a cradle 5330 for carrying and moving the first pipe 1022a and the second pipe 1022b.
  • the cradle 5330 is configured to provide the second pipe 1022a at the second end 1038b of the first pipe 1022b after the frame assembly of the internal weld system 5004 is positioned at the second end of the first pipe 1022b.
  • the cradle 5330 may be referred to as a Line Up Module (LUM).
  • LUM Line Up Module
  • the pipe 1022a or 1022b is small and flexible, there may be as many as four cradles spaced along the length of the pipe 1022a or 1022b. If the pipe 1022a or 1022b is large and stiff, there may be as few as two cradles along the length of the pipe 1022a or 1022b.
  • two cradles may be used for carrying and moving the pipe such that each cradle is positioned at an end of the pipe.
  • three cradles may be used for carrying and moving the pipe such that two cradles are positioned at the ends of the pipe and one cradle is positioned at the center section of the pipe.
  • the centrally positioned cradle is configured to simply provide support and is not configured to be articulated.
  • the cradles 5330 used for incoming pipe 1022a may all be configured to be actuatable to carry, move, and provide the incoming pipe 1022a at the second end of the first pipe 1022b (after the frame assembly of the internal weld system 5004 is positioned at the second end of the first pipe 1022b) and re-align the incoming pipe 1022a in the event the pre-weld profile data determines adjustment is required.
  • the cradle 5330 may include a set of actuated rollers 5332 external to the pipes 1022a, 1022b.
  • the rollers 5332 of the cradle 5330 may be referred to as the exterior rotatable members.
  • an exterior surface 5346 and/or 5348 (as shown in FIG. 2G) of the first pipe 1022a and/or the second pipe 1022b is movably engaged by the exterior rotatable member(s) 5332 to facilitate adjustment of the relative positioning of the pipes 1022a, 1022b based on the instructions from the one or more processors 5140.
  • the cradle 5330 includes a fixed frame 5334 that is configured to be fixedly connected to a surface (e.g., ground), a first moveable frame 5336 that is configured to be moveable to position the pipe horizontally, and a second moveable frame 5338 that is configured to be moveable to position the pipe vertically.
  • a fixed frame 5334 that is configured to be fixedly connected to a surface (e.g., ground)
  • a first moveable frame 5336 that is configured to be moveable to position the pipe horizontally
  • a second moveable frame 5338 that is configured to be moveable to position the pipe vertically.
  • the cradle 5330 may be hydraulically operated.
  • hydraulic cylinders 5340 positioned on the sides of the cradle 5330 may be configured to move the second moveable frame 5338.
  • the hydraulic cylinder(s) 5342 positioned under the cradle 5330 may be configured to move the first moveable frame 5336.
  • the motion of the cradles 5330 (positioned at both ends of the pipes) may be coordinated to adjust the linear movement of the pipe 1022a or 1022b in all three directions (up-down, left-right, forward-back) and adjust the angular movement of the pipe 1022a or 1022b in in two directions (pitch, yaw)).
  • the cradle 5330 is operatively associated with to the one or more processors 5140.
  • the cradle 5330 is connected wirelessly or using a wired connection to the one or more processors 5140 such that, in the event the pre-weld profile data determines adjustment is required, the hydraulic cylinders 5340 and 5342 are adjusted to move and re-align the incoming pipe 1022a based on the pre-weld profile data.
  • the externally positioned rollers 5332 may be operatively connected to and controlled by the one or more processors 5140 via the first moveable frame 5336 and/or the second moveable frame 5338.
  • the cradle 5300 may be electrically operated.
  • FIG. 73 shows electrically operated cradles 6010A and 6010B.
  • the rollers of the cradles 6010A and 6010B may be driven by motors to move the pipe 1022a or 1022b linearly and/or angularly.
  • the cradles 601 OA and 6010B may include motors operatively connected to lead screw arrangements that enable the movement of the first moveable frame and/or the second moveable frame.
  • the angular alignment error causes a gap 5344 on one side of the pipe.
  • the positional alignment error causes opposite Hi-Lo, i.e. high on one side (e.g., 1022b), low on the other side (e.g., 1022a).
  • the cradles 5330 or the cradles 6010A and 6010B may be used in the offshore pipeline alignment and welding procedures.
  • both angular and positional pipe alignment errors may be corrected by sending the control signals from the one or more processors 5140 to the cradles 5330 or the cradles 6010A and 6010B (to control the associated rollers 5332).
  • the one or more processors 5140 are configured to adjust the relative positioning between the pipes (to correct their alignment errors) by controlling the cradles 5330 or the cradles 601 OA and 6010B.
  • the one or more processors 5140 are configured to operate the cradle 5330 to enable relative movement between the first pipe 1022a and the second pipe 1002b based on the pre-weld profile data to alter an interface region 5136 between the pipes 1022a, 1022b prior to the welding operation based on the instructions from the one or more processors 5140.
  • the pipes 1022a, 1002b may be aligned by a crane and the clamp (internal or external).
  • the clamp may be constructed and arranged to align the two pipes 1022a, 1002b both horizontally and vertically.
  • the crane is configured to control axial position and the two angles (pitch and yaw).
  • the internal weld system 5004 includes a forward-most section 5006, a center section 5008 and a drive section 5010.
  • frame members of the forward-most section 5006, the center section 5008 and the drive section 5010 may be together may be referred to as a frame assembly or as the frame of the internal weld system 5004.
  • the frame or frame assembly of the internal weld system 5004 may be configured to support all of the components of each of the forward-most section 5006, the center section 5008 and the drive section 5010.
  • the frame or frame assembly of the internal weld system 5004 may include forward-most section frame 5026 (as shown in FIG. 12), center section frame 5068 (as shown in FIG. 23), and drive section frame 5278 (as shown in FIG. 32A).
  • the frame or frame assembly of the internal weld system 5004 is configured to be placed within the pipes 1022a, 1022b.
  • the forward-most section 5006 is the section where external cables, wiring and hoses from the external system/structure (external to the pipes to be welded) connect. In one embodiment, the forward-most section 5006 is configured to house all of the weld support components as described in detail below. In one embodiment, the center section 5008 is configured to align the pipe segments 1022a, 1022b and perform the welding procedures. In one embodiment, the drive section 5010 is configured to move the internal weld system 5004 from one pipe joint to the next pipe joint. In one embodiment, the drive section 5010 is also configured to house batteries, compressed air and shield gas that the rest of the internal weld system 5004 needs to operate.
  • some components of the internal weld system 5004 are positioned such that half of the component is positioned in the forward-most section 5006 and the remaining half of the component is positioned in the center section 5008. In one embodiment, some components of the internal weld system 5004 are positioned in the one of the three sections of the internal weld system 5004 but are connected to another of the three sections of the internal weld system 5004. For example, a component of the internal weld system 5004 is positioned in the forward-most section 5006 of the internal weld system 5004 and is connected to only the center section 5008 of the internal weld system 5004.
  • FIG. 12 shows a detailed view of the forward-most section 5006 of the internal weld system 5004.
  • the forward-most section 5006 of the internal weld system 5004 includes a tow hitch 5012, a forward-most electronics module 5014, a front slip ring 5016, a front clamp control valve 5018, a wire feed assembly 5020, a front position sensor 5022, adjustable ramps 5024, a forward-most section frame 5026, guide wheels 5028, a front rotation motor 5030, and a front rotary union 5032.
  • the forward- most electronics module 5014 may include the one or more processors 5014.
  • the front clamp control valve 5018, the front position sensor 5022, and the front rotation motor 5030 may be operatively connected to the one or more processors 5140.
  • FIGS. 13-22 show views of various components of the forward-most section 5006 of the internal weld system 5004.
  • FIG. 13 shows the tow hitch 5012
  • FIG. 14 shows the front rotary union 5032
  • FIG. 15 shows the front slip ring 5016
  • FIG. 16 shows the forward-most section frame 5026
  • FIG. 17 shows the adjustable ramps 5024
  • FIG. 18 shows the guide wheels 5028
  • FIG. 19 shows the front rotation motor 5030
  • FIG. 20 shows the front clamp control valve 5018
  • FIG. 21 shows the front position sensor 5022
  • FIG. 22 shows the wire feed assembly 5020, respectively.
  • FIG. 11A shows a view of the umbilical 5034 in which the internal weld system 5004 is configured to attached at a first end 5035 of the umbilical 5034 and an operator control system 5039 is configured to be attached to a second end 5037 of the umbilical 5034.
  • the first end 5035 of the umbilical 5034 is connected to the tow hitch 5012 of the forward- most section 5006 of the internal weld system 5004.
  • the communications (of the internal weld system 5004) with the Ulog system are configured to happen through one or more processors or modules in the operator control system 5039.
  • the operator control system 5039 is positioned external to the pipes 1022a, 1022b being welded.
  • the forward-most section frame 5026 is constructed and arranged to house/support all of the components of the forward-most section 5006 of the internal weld system 5004. In one embodiment, the forward-most section frame 5026 is constructed and arranged to provide mounting points for all of the components at the front of the internal weld system 5004 and protect these components from damage. In one embodiment, the forward-most section frame 5026 is constructed and arranged to guide new pipe segments into alignment with the old/existing pipe segments. In one embodiment, the forward-most section frame 5026 may be made from steel or any other material as would be appreciated by one skilled in the art.
  • the forward-most frame 5026 is constructed and arranged to have a nose cone shaped configuration to enable the internal weld system 5004 to easily move into the new pipe segment when joining/welding the new pipe segment with the old/existing pipe segment.
  • the nose cone shaped configuration of the forward-most frame 5026 may function as an alignment structure that is configured to facilitate alignment of the second pipe 1022b with the first pipe 1022a.
  • the nose cone shaped alignment structure is configured to project outwardly from the second end of the first pipe 1022a to facilitate alignment of the second pipe 1022b with the first pipe 1022a.
  • the forward-most section frame 5026 includes a sensor 5352 configured to sense an end of the pipe when the frame of the internal weld system 5004 returns to pipe opening after welding a preceding pipe.
  • the sensor 5352 may be configured to be moveable with the frame of the internal weld system 5004.
  • the sensor 5352 is operatively connected to or associated with the one or more processors 5140.
  • the senor 5352 may be a rotary switch.
  • the rotary switch may have a downwardly projecting prod or wire biased into the interior pipe surface and configured to slidingly engage the interior pipe surface until it reaches the pipe and extends downwardly after reaching the pipe end to actuate the rotary switch, thus detecting the end of the pipe.
  • the wire is configured to extend outwardly from its normal position to detect the end of the pipe.
  • the senor 5352 may be a linear encoder that is configured to be operatively connected to the wheels/rollers of the internal weld system 5004 to determine the distance traveled by the internal weld system 5004 and use that information to sense/detect the end of the known pipe length.
  • the sensor 5352 is configured to detect the interface region 5136 between the pipes 1022a, 1022b.
  • the one or more processors 5140 are configured to operate drive motors 5124 to move the frame of the internal weld system 5004 through at least one of the pipes 1022a, 1022b until the sensor 5352 detects the interface region 5136.
  • the sensor 5352 is configured to detect when the frame of the internal weld system 5004 is positioned at the interface region between the pipes 1002a, 1022b.
  • the sensor 5352 may be the inspection sensor 5056.
  • the sensor 5352 may be a laser.
  • the sensor 5352 may be the inspection camera 5112.
  • the inspection detector 5056 and/or the inspection camera 51 12 are configured to also perform the sensing function of the sensor 5352.
  • an end portion 5208 of the forward-most section frame 5026 is configured to be connected to a flange portion 5210 (as shown in FIG. 23) of a front clamp 5142 of the center section 5008.
  • the end portion 5208 of the forward-most section frame 5026 is configured to be connected to the flange portion 5210 of the front clamp 5142 of the center section 5008 using fastening members, for example, bolts 5212 (as shown in FIG. 23).
  • a rotary union is generally a union or a coupling that is constructed and arranged to allow for rotation of two combined/united members.
  • the rotary union is constructed and arranged to provide a seal between a stationary supply passage (pipe or tubing) and a rotating member (drum, cylinder or spindle) to permit the flow of a fluid into and/or out of the rotating member.
  • Fluids generally used with the rotary unions include compressed air and purge gas.
  • the rotary union generally includes a housing, a shaft, a seal and a bearing. The bearings and seal are assembled around the shaft.
  • the bearings are used to allow a member of the rotary joint, either the shaft or the housing, to rotate.
  • the seal is constructed and arranged to prevent the fluid medium (e.g., compressed air or purge gas) from leaking outside the rotary union while in operation.
  • a rotary union locks onto an input valve while rotating to meet an outlet valve. During this time the fluid flows into the rotary union from its source and is held within the rotary union during its movement. This fluid leaves the rotary union when the valve openings meet during rotation and more fluid flows into the rotary union again for the next rotation.
  • the front rotary union 5032 is configured to allow for the flow of compressed air therethrough.
  • the front rotary union 5032 (e.g., described in connection with FIG. 25, for example) is constructed and arranged to receive the compressed air from a rear rotary union 5072 (via, e.g., a rear slip ring 5080, a rotatable hub 5078 and the front slip ring 5016).
  • the rear rotary union has essentially the same components and operates in essentially the same way as the front rotaiy union 5032 and hence not illustrated in the same detail as front rotary union 5032.
  • the front rotary union 5032 is constructed and arranged to send a portion of the received compressed air to the front clamp control valve 5018 (to actuate and operate the front clamp 5142) via the valve 5204.
  • the front rotary union 5032 is constructed and arranged to send the remaining portion of the received compressed air to a compressor or an external air supply tank 5029 (as shown in FIG. 70) to recharge the system (e.g., fill the tank with compressed air) via the valve 5204.
  • the remaining portion of the received compressed air sent to the compressor or external air supply tank 5029 passes through the front rotary union 5032.
  • two valves 51 15 and 51 17 are configured to be closed until the start of the refill procedure.
  • the compressed air from the external air supply tank 5029 travels through the valve 51 15, 51 17, and 5204 to the front rotary union 5032, from the front rotary union 5032 to the rear rotary union 5072, and then through the valves 5198, 5196, 5194 and 51 13 to the compressed air tank 5128 to refill the compressed air tank 5128 with the compressed air.
  • the entire fluid communication path (or the supply fluid communication line) between the external air supply tank 5029 and the compressed air tank 5128 is maintained at tank pressure during the refill procedure.
  • the front rotary union 5032 in the forward-most section 5006 is also configured to allow the compressed air from the umbilical 5034 to be connected to the wire feed assembly 5020 which is rotatably mounted on a rotatable hub 5078 of the center section 5008.
  • a slip ring is an electromechanical device (electrical connector) that is constructed and arranged to allow the transmission of power and communication signals from a stationary structure to a rotating structure.
  • a slip ring can be used in any electromechanical system that requires unrestrained, continuous rotation while transmitting power and/or data signals.
  • the slip ring includes a stationary structure (brush) which rubs on the outside diameter of a rotating structure. As the rotating structure turns, the electric current or signal is conducted through the stationaiy structure to the rotating structure making the connection.
  • the stationary structure may be a graphite or metal contact (brush) and the rotating structure may be a metal ring. Additional ring/brush assemblies are stacked along the rotating axis if more than one electrical circuit is needed. Either the brushes or the rings are stationary and the other component rotates.
  • the front slip ring 5016 is configured to allow the transmission of communication signals from the forward-most electronics module 5014 to a wire feed electronics module 5046 of the wire feed assembly 5020. In one embodiment, the front slip ring 5016 is also configured to allow the transmission of (welding) power and the transmission of communication signals from the umbilical 5034 to the internal weld system 5004.
  • the adjustable ramps 5024 are constructed and arranged to improve the alignment of the pipe segments 1022a, 1022b.
  • the adjustable ramps 5024 are constructed and arranged to be adjustable to accommodate different pipe sizes.
  • the adjustable ramps 5024 are constructed and arranged to also protect the center section 5008 from being hit by the incoming pipe segment 1022b.
  • the adjustable ramps 5024 of the internal weld system 5004 are constructed and arranged to be adjustable to extend a little more than the retracted clamp shoes (i.e., the clamp shoes 5157 in their retracted positions) but extend less than the extended clamp shoes (i.e., the clamp shoes 5157 in their extended positions).
  • the guide wheels 5028 are constructed and arranged to prevent the incoming pipe segment 1022b from scraping the sides of the forward-most section 5006.
  • the guide wheels 5028 are constructed and arranged to be adjustable to accommodate different pipe sizes.
  • the guide wheels 5028 are passive members.
  • the forward-most electronics module 5014 includes communication connections to the umbilical 1034 and to the front slip ring 5016.
  • the forward-most electronics module 5014 is configured to communicate power and communication signals to and from the umbilical 5034 and is configured to communicate power and communication signals to and from the front slip ring 5016.
  • the forward-most electronics module 5014 is also configured to control the operation of the front rotation motor 5030 and the front clamp control valve 5018. In one embodiment, the forward-most electronics module 5014 is further configured to receive signals from the front position sensor 5022.
  • the front rotation motor 5030 in the forward-most section 5006 is shown in FIGS. 12 and 19.
  • the front rotation motor 5030 is electronically synchronized with a rear rotation motor 5074 positioned in the center section 5008 (described below).
  • the two rotation motors 5030 and 5074 are configured to rotate the rotatable hub 5078 of the center section 5008 while maintaining the front and rear clamps 5142 and 5144 stationary.
  • the front rotation motor 5030 may include an offset gear drive (due to packaging constraints).
  • the front rotation motor 5030 has an electric motor having a rotor, a rotary shaft rotated by the rotor, and an external gear 5021a supported by the rotary motor shaft and having external teeth thereon.
  • the external gear 5021 may engage an offset gear 5021b, also having external teeth.
  • An opposite end of the offset gear 5021b also has external teeth 5021c.
  • the external teeth 5021c of the external/driver gear are constructed and arranged to engage with internal teeth 5023 (as shown in FIG.
  • the external teeth 5021c of the external/driver gear are constructed and arranged to engage with the internal teeth 5023 formed on the driven (annulus) gear member 5021 of the wire feed assembly 5020 using a gear train arrangement (see FIG. 19) to transmit torque from the front rotation motor 5030 to the wire feed assembly 5020.
  • the front clamp control valve 5018 is configured to receive the compressed air from the stationary side of the front rotary union 5032.
  • the front clamp control valve 5018 is operatively connected to receive control signals from the forward electronics module 5014. In one embodiment, the front clamp control valve 5018 is configured to supply the compressed air to actuate and operate the front clamp 5142, when it receives signals from the forward-most electronics module 5014.
  • the front position sensor 5022 may be a proximity sensor and specially profiled encoder wheel.
  • the encoder wheel is constructed and arranged to be rotatably mounted on the wire feed assembly 5020 so as to be rotated with the rotatable hub 5078.
  • the front position sensor 5022 is operatively connected to send control signals to the forward electronics module 5014.
  • the proximity sensor of the front position sensor 5022 may be configured to send control signals to the forward-most electronics module 5014 when the sensor is at a high point on the encoder wheel.
  • the forward-most electronics module 5014 is configured to use the signals received from the front position sensor 5022 to determine the orientation of the forward-most section 5006 relative to the rest of the internal weld system 5004 (e.g., rotatable hub 5078).
  • the wire feed assembly 5020 includes a wire spool holder 5036, a wire straightener 5038, a weld wire bowden (guide) tube 5040, a shield gas control valve 5042, a wire feed system 5044, the wire feed electronics module 5046, and a wire feed assembly frame 5048.
  • an exemplary weld wire spool 5272 is shown in FIG. 22A.
  • the wire straightener 5038, the shield gas control valve 5042, and the wire feed system 5044 may be operatively connected to one or more processors 5140.
  • the wire feed electronics module 5046 may include one or more processors 140.
  • the wire feed assembly 5020 is constructed and arranged to house the wire spools 5272, the wire spool holders, the wire straighteners, the wire feed system, and the shield gas control valves for each of three illustrated weld torches 5502 in the center section 5008 of the internal weld system 5004.
  • the wire feed assembly 5020 includes three wire spool holders 5036, three wire straighteners 5038, three weld wire bowden (guide) tubes 5040, three shield gas control valves 5042, and three wire feed systems 5044 associated with three illustrated weld torches 5502 in the center section 5008 of the internal weld system 5004.
  • the number of the wire spool holders, the wire straighteners, the weld wire bowden (guide) tubes, the shield gas control valves, the weld wire/electrode spools and the wire feed systems in the internal weld system 5004 may vary and depend on the number of the weld torches.
  • the weld wire spool 5272 has a size of 7 (7/8) inches and a weight of 10 pounds. In one embodiment, the size of the electrode or weld wire is 0.03 inches. In one embodiment, the electrode or weld wire is made of a carbon steel material. In one embodiment, the electrode or weld wire is a ER70S-6 carbon steel MIG weld wire manufactured, for example, by Chicago Electric Welding Systems. In one embodiment, the electrode or weld wire is designed for use with various shield gas mixtures such as 100% Carbon dioxide (CO ), a mixture of 75 % Argon and 25% C0 2 , or a mixture of 98 % Argon and 2% O 2 ⁇
  • CO Carbon dioxide
  • a mixture of 75 % Argon and 25% C0 2 or a mixture of 98 % Argon and 2% O 2 ⁇
  • the wire feed assembly 5020 is constructed and arranged to be connected to the rotatable hub 5078 of the center section 5008, so that rotation of the wire feed module 5020 via the front rotation motor is directly translated to the rotatable hub 5078.
  • the wire feed assembly 5020 is constructed and arranged to be fastened (e.g., using fastening members) to the rotatable hub 5078 of the center section 5008.
  • the wire feed assembly 5020 is also constructed and arranged to house electronics for operating all of the motors in the wire feed assembly 5020 and the rotatable hub 5078.
  • the wire feed assembly frame 5048 is constructed and arranged to be hollow so as to allow power, communication signals, shield gas, weld wire/electrode, motor control signals, and compressed air to pass into, out of, and through it.
  • the wire spool holder 5036 is constructed and arranged to receive and hold weld wire/electrode spools (not shown) for use by the internal weld system 5004.
  • the wire spool holder 5036 may include a retainer member 5220 configured to retain the weld wire/electrode spool therein.
  • the retainer member 5220 may be removable positioned on a shaft 5226 of the wire spool holder 5036 using a lock member 5222 attached to the retainer member 5220.
  • the lock member 5222 may include a smaller diameter region and a larger diameter region.
  • a lock member receiving opening may be formed on the shaft 5226 as having a cross-sectional shape of a generally enclosed circle, with a side opening 5224 extending outwardly from the shaft 5226. With such a configuration, the lock member 5222 may slidably be positioned such that either the larger diameter region or the smaller diameter region is within the generally enclosed circular cross-sectional shape of the lock member receiving opening.
  • the shaft 5226 When the larger diameter region is positioned in the lock member receiving opening, the shaft 5226 surrounds the larger diameter region, which is unable to pass through the side opening 5224, locking the retainer member 5220 to the shaft 5226 due to the engagement between the lock member 5222 and the lock member receiving opening.
  • the retainer member 5220 may freely be removed from the shaft 5226, as the smaller diameter region may pass through the side opening 5224.
  • the retainer member 5220 may be removable attached to the shaft 5226 of the wire spool holder 5036 using a retaining screw.
  • the weld wire or electrode that comes off of the weld wire/electrode spool may have a permanent bend to it.
  • the wire straightener 5038 is configured to remove the permanent bend and make the weld wire straight (e.g., by bending the weld wire in the other direction).
  • the straight configuration of the weld wire helps the weld wire to pass through the weld wire bowden (guide) tube 5040 more easily. Also, providing straight weld wire to the weld torch 5502 results in more consistent welds.
  • the wire straightener 5038 is optional.
  • the weld wire bowden (guide) tube 5040 is constructed and arranged to guide the weld wire/electrode from the wire feed system 5044 to the weld torch 5502. In one embodiment, the weld wire bowden (guide) tube 5040 attached at both its ends. In one embodiment, the weld wire is sheathed by the weld wire bowden (guide) tube 5040.
  • the wire feed system 5044 is constructed and arranged to pull the weld wire through the wire straightener 5038 from the weld wire spool 5272 and push the weld wire through the weld wire bowden (guide) tube 5040 to the weld torch 5502.
  • the wire feed system 5044 is configured to be automatically controlled to deliver the appropriate amount of wire to the weld torch 5502.
  • the wire feed system 5044 may include motor and two serrated wheels that are configured pull weld wire through the wire straightener 5038 from the weld wire spool 5272 and push the weld wire through the weld wire bowden (guide) tube 5040 to the weld torch 5502.
  • the motor(s) of the wire feed system 5004 may include an encoder that is configured to measure the revolutions of the motor.
  • the motor(s) of the wire feed system 5004 are operatively connected to the one or more processors 5140.
  • This information may be used by the one or more processors 5140 to determine how much wire is fed to the weld torch 5502 and to regulate the amount of the weld wire is being fed to the weld torch 5502.
  • the weld wire/electrode is fed to the torch 5502 by the wire feed assembly 5020.
  • the shield gas control valve 5042 is configured to control the flow of the shield gas to the weld torch through a shield gas line.
  • each weld torch 5502 has a corresponding shield gas control valve 5042 connected to it.
  • the shield gas is stored in the drive section 5010 and is brought to the wire feed assembly 5020 by a hose/shield gas line for distribution to the one or more weld torches 5502.
  • the shield gas control valve 5042 is configured to receive the shield gas from the rear rotary union 5072 (e.g., via the rear slip ring 5080 and the rotatable hub 5078).
  • the shield gas control valve 5042 is operatively connected to receive control signals from the wire feed electronics module 5046. In one embodiment, the shield gas control valve 5042 is configured to supply the shield gas to the corresponding weld torch, when it receives signals from the wire feed electronics module 5046.
  • the wire feed electronics module 5046 is configured to send and receive power and communication signals upstream through the front slip ring 5016 to the forward-most electronics module 5014. In one embodiment, the wire feed electronics module 5046 is configured to send and receive power and communication signals downstream through the rear slip ring 5080 to a center section electronics module 5064.
  • the wire feed electronics module 5046 is configured to control all of the motors and valves attached to the rotatable hub 5078 of the center section 5008.
  • the wire feed electronics module 5046 is configured to control the wire feed system, axial motion of the weld torch 5502, radial motion of the weld torch 5502, tilt motion of the weld torch 5502, and/or flow and delivery of the shield gas. That is, the wire feed electronics module 5046 is operatively connected to the shield gas control valve(s) 5042 to control the flow and delivery of the shield gas to the weld torch (es) 5502.
  • the wire feed electronics module 5046 is operatively connected to the axial weld torch motor 5550 to control the axial motion of the weld torch 5502. In one embodiment, the wire feed electronics module 5046 is operatively connected to the radial weld torch motor 5512 to control the radial motion of the weld torch 5502. In one embodiment, the wire feed electronics module 5046 is operatively connected to the tilt weld torch motor 5588 to control the tilt motion of the weld torch 5502. In one embodiment, the axial weld torch motor 5550, the radial weld torch motor and the tilt weld torch motor 5588 may either individually or together be referred to as "weld torch motor(s)".
  • the wire feed electronics module 5046 is configured to communicate with and control an inspection detector 5056 and an inspection camera 5112 both rotatably mounted on the rotatable hub 5078.
  • the inspection detector 5056 is carried by the frame assembly of the internal weld system 5004.
  • the inspection camera 51 12 is carried by the frame assembly of the internal weld system 5004.
  • the inspection detector 5056 may include an inspection laser, a three dimensional inspection camera, an inspection ultrasound sensor system, an inspection electrical capacitive probe, and any other inspection detectors as would be appreciated by one skilled in the art.
  • FIGS. 23 and 24 show a front view and a cross-sectional view of the center section 5008 of the internal weld system 5004.
  • the forward- most frame 5026 of the forward-most section 5006 is connected to the front clamp 5142 of the center section 5008, and the wire feed assembly 5020 is rotatably connected to the rotatable hub 5078.
  • the center section 5008 of the internal weld system 5004 includes the front clamp 5142 (or first pipe engagement structure 5052), the inspection detector 5056, a weld head assembly or torch module 5500, a rear clamp 5144 (and second pipe engagement structure 5054), a rear clamp control valve 5062, the center section electronics module 5064, toe wheels 5066, a center section frame 5068, adjustable ramps 5070, the rear rotary union 5072, the rear rotation motor 5074, a rear position sensor 5076, the rotation module 5078, and the rear slip ring 5080.
  • the front clamp 5142 (or first pipe engagement structure 5052), the inspection detector 5056, the weld head assembly or torch assembly 5500, the rear clamp 5144 (and second pipe engagement structure 5054), the rear clamp control valve 5062, the rear rotation motor 5074, the rear position sensor 5076 are operatively connected to the one or more processors 5140.
  • the inspection camera 51 12 is operatively connected to the one or more processors 5140.
  • the center section electronics module 5064 may include the one or more processors 5140.
  • the term "pipe engagement structure” as used herein can refer to a clamp for fixedly securing to a pipe surface, or an interior seal that is configured to create a gas seal against the pipe interior surface, or the combination of both the aforementioned clamp and seal.
  • the first pipe engagement structure 5052 may be the first clamp 5142, the first seal 5146 or a combination thereof.
  • the second pipe engagement structure 5054 may be the second clamp 5144, the second seal 5148 or a combination thereof.
  • the first and second pipe engagement structures 5052 and 5054 are carried by the frame assembly of the internal weld system 5004.
  • FIGS. 25-31 show views of various components of the center section 5008 of the internal weld system 5004.
  • FIG. 25 shows the rear rotary union 5072
  • FIG. 26 shows the rear slip ring 5080
  • FIG. 27 shows the center section frame 5068 and the adjustable ramps 5070
  • FIG. 28 shows the toe wheels 5066
  • FIG. 29 shows the rear clamp control valve 5062
  • FIG. 30 shows the front clamp 5142
  • FIG. 31 shows the rotation module 5078, respectively.
  • the rear rotary union 5072 in the center section 5008 is shown in FIGS. 23, 24 and 25.
  • the structure and operation of the rear rotary union 5072 is similar to the front rotary union 5032, and hence the structure and operation of the rear rotary union 5072 will not be described in detail here, except for the differences noted below.
  • the rear rotary union 5072 is configured to allow for the flow of compressed air and the flow of shield gas (or purge gas) therethrough.
  • the rear rotary union 5072 in the center section 5008 is configured to allow the compressed air from a compressed air tank 5128 (as shown in FIGS. 32A and B) of the drive section 5010 to be connected through the rotatable hub 5078 of the center section 5008 to the front rotary union 5032.
  • the rear rotary union 5072 in the center section 5008 is also configured to connect shield gas tanks 51 14 (as shown in FIGS. 32A and 32B) in the drive section 5010 to the shield gas control valves 5042 in the wire feed assembly 5020 of the forward-most section 5006.
  • the rear rotary union 5072 is constructed and arranged to send a portion of the received compressed air to the rear clamp control valve 5062 (to operate the rear clamp 5144). In one embodiment, the rear rotary union 5072 is constructed and arranged to send the remaining portion of the received compressed air to the front rotary union 5032 (e.g., via the rear slip ring 5080, the rotatable hub 5078 and the front slip ring 5016). In one embodiment, the remaining portion of the received compressed air sent to the front rotary union 5032 passes through the rear rotary union 5072.
  • the front and rear rotary unions 5032 and 5072 of the present patent application may be of the type which is available commercially under the name Series 012 2 Pass Threaded Shaft Unions, manufactured by the Rotary Systems, Inc.
  • the front and rear rotary unions of the present patent application may be any rotary union that would be appreciated by one skilled in the art.
  • the structure and operation of the rear slip ring 5080 is similar to the front slip ring 5016, and hence the structure and operation of the rear slip ring 5080 will not be described in detail here, except for the differences noted below.
  • the rear slip ring 5080 in the center section 5008 is configured to allow the transmission of communication signals between the wire feed electronics module 5046 and the center section electronics module
  • the front and rear slip rings 5016 and 5080 of the present patent application may be of the type which is available commercially under the name AC6275, manufactured by the Moog, Inc.
  • the front and rear slip rings 5016 and 5080 of the present patent application may be rated 50 amps.
  • the front and rear slip rings of the present patent application may be any rotaiy union that would be appreciated by one skilled in the art.
  • the center section electronics module 5064 in the center section 5008 includes communication cables to the wire feed assembly 5020 through the rear slip ring 5080 and communication cables to the drive section 5010.
  • 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.
  • the center section electronics module 5064 in the center section 5008 is also configured to control the rear clamp control valve 5062.
  • the center section frame 5068 is constructed and arranged to house/support all of the components of the center section 5008 of the internal weld system 5004.
  • the center section frame 5068 is constructed and arranged to provide mounting points for all of the components located in the center section 5008 and protects these components from damage.
  • the center section frame 5068 is also constructed and arranged to connect to the drive section 5010 through a U-joint that allows the internal weld system 5004 to bend in curved pipes.
  • the center section frame 5068 may be made from steel or any other material as would be appreciated by one skilled in the art.
  • an end portion 5214 of the center section frame 5068 is configured to be connected to a flange portion 5216 of the rear clamp 5144.
  • the end portion 5214 of the center section frame 5068 is configured to be connected to the flange portion 5216 of the rear clamp 5144 using fastening members, for example, bolts 5218.
  • the adjustable ramps 5070 are constructed and arranged to help center the internal weld system 5004 when the internal weld system 5004 is being placed into a pipe. In one embodiment, the adjustable ramps 5070 are also constructed and arranged to protect the center section 5008 from being hit by the end of the pipe segment. In one embodiment, the adjustable ramps 5070 are constructed and arranged to be adjustable to accommodate different pipe sizes.
  • the toe wheels 5066 are constructed and arranged to support the weight of the center section 5008.
  • the toe wheels 5066 are constructed and arranged to be sprung to protect the internal weld system 5004 from jarring shocks when the internal weld system 5004 crosses over a weld bead.
  • the toe wheels 5066 are constructed and arranged to have an adjustable toe angle to help the internal weld system 5004 run straight in the pipe.
  • the toe wheels 5066 are constructed and arranged to be adjustable in height for different pipe sizes.
  • the toe wheels 5066 are passive members.
  • the rear clamp control valve 5062 is constructed and arranged to receive the compressed air from the stationary side of the rear rotary union 5072.
  • the rear clamp control valve 5062 is operatively connected to receive control signals from the center section electronics module 5064. In one embodiment, the rear clamp control valve 5062 is configured to supply the compressed air to actuate and operate the rear clamp 5144, when it receives signals from the center section electronics module 5064.
  • the rear position sensor 5076 may be a proximity sensor and specially profiled encoder wheel.
  • the encoder wheel is constructed and arranged to be rotatably mounted on the rotatable hub 5078.
  • the rear position sensor 5076 is operatively connected to send control signals to the center section electronics module 5064.
  • the proximity sensor of the rear position sensor 5076 may be configured to send control signals to the center section electronics module 5064 when the sensor is at a high point on the encoder wheel.
  • the center section electronics module 5064 is configured to use the signals received from the rear position sensor 5076 to determine the orientation of the center section 5008 relative to the rest of the internal weld system 5004 (e.g., rotatable hub 5078).
  • the rear rotation motor 5074 in the center section 5008 is shown in FIG. 24.
  • the rear rotation motor 5074 is electronically synchronized with the front rotation motor 5030 such that the rotation motors 5030 and 5074 together are configured to rotate the rotatable hub 5078 of the center section 5008 while maintaining the front and rear clamps 5142, 5144 stationary.
  • the rotation motors 5030 and 5074 are configured to rotate the weld torch 5502 circumferentially (360° rotation) along an interface region 5136.
  • the rotation motors 5030 and 5074 configured to direct the inspection beam of radiation, are also configured to drive the weld torch 5502 at least 360° relative to the pipe axis A-A so as to complete a rotationally continuous, root pass weld.
  • the front rotation motor 5030 and the rear rotation motor 5074 may be referred to as the orientation motors. In one embodiment, the front rotation motor 5030 and the rear rotation motor 5074 are operatively associated with the one or more processors 5140.
  • the rear rotation motor 5074 has an electric motor having a rotor, a rotary shaft rotated by the rotor, and a driver gear supported by the rotary shaft and having teeth thereon.
  • the teeth of the driver gear are constructed and arranged to engage with teeth formed on a driven gear member 5079 of the rotatable hub 5078 to transmit torque from the rear rotation motor 5074 to the rotatable hub 5078.
  • the rotatable hub 5078 is constructed and arranged to rotate during welding, pre-weld scan and post-weld scan procedures.
  • the rotatable hub 5078 is positioned between the first and second clamps 5142 and 5144. Since the first and second clamps 5142 and 5144 are not physically linked to each other, the front rotation motor 5030 and the rear rotation motor 5074 at each end of the rotatable hub 5078 are synchronized to keep the two pipes 1022a, 1022b from moving relative to each other.
  • the two pipe engagement structures 5142, 5144 may be rotated relative to each other by turning the front rotation motor 5030 and the rear rotation motor 5074, for example, at different speeds and/or different directions.
  • a central portion 5077 of the rotatable hub 5078 includes slots/openings through which the shield gas hoses, the bowden tubes, the weld power cables, the motor cables, the inspection detector cables, and the camera cables are configured to pass.
  • the front clamp 5142 has a hollow configuration.
  • an opening 5082 through the center of the front clamp 5142 is constructed and arranged to be large enough to allow all of the required cables and hoses to pass therethrough.
  • the opening 5082 of the front clamp 5142 is also constructed and arranged to allow for a structural member that is required to support the weight of the front half of the internal weld system 5004 as well as to maintain alignment of the two halves/pipe segments 1022a, 1022b of the weld joint.
  • the front and rear clamps 5142, 5144 are constructed and arranged to be mounted to the rotatable hub 5078, for example, by angular contact ball bearings 5108, 5098 that are preloaded to provide stiffness.
  • the interior surface 5130, 5132 of the first pipe 1022a and/or the second pipe 1022b is engaged and manipulated by the first clamp 5142 and the second clamp 5144, respectively to adjust the relative positioning of the pipes based on the instructions from the one or more processors 5140.
  • the adjustment of the relative positioning of the pipes 1022a, 1022b is achieved without disengaging the first pipe engagement structure 5144 from the interior surface 5132 of the first pipe 1022b and without disengaging the second pipe engaging structure 5142 from the interior surface 5130 of the second pipe 1022a. This can be done because the rotation motors 5030 and 5074 are configured to rotate the pipes 1022a, 1022b without disengaging the pipe engagement structures 5144, 5142 as described in this application.
  • the front clamp 5142 generally includes a piston 5084, a cylinder 5086, a bushing 5088, clamp shoe pin members 5090, link members 5092, a shaft 5094, a hub 5096, a front bearing 5098, a spider member 5100, a bell housing 5102, a front plate 5104, a rear plate 5106, a rear bearing 5108, and a sleeve 51 10.
  • the rear bearing 5108 and the front bearing 5098 are configured to support the rotatable hub 5078.
  • the rear clamp 5144 has the same structure, configuration and operation as described above with respect to the front clamp 5142 and hence the structure, configuration and operation of the rear clamp 5144 will not be described in detail here.
  • the front clamp 5142 is configured to clamp one of the pipes 1022a, 1022b and the second clamp 5144 is configured to clamp the other of the pipes 1022a, 1022b.
  • one of the clamps 5142, 5144 may be referred to as a first clamp and the other of the clamps 5142, 5144 may be referred to as the second clamp.
  • the clamps 5142, 5144 of the internal weld system 5004 may either individually or together be referred to as the brake system of the internal weld system 5004 that secures the frame of the internal weld system 5004 at a desired location within the pipes 1022a, 1022b.
  • the front and rear clamps 5142, 5144 are radially extending clamps that engage the interior surface 5130, 5132 of the pipes 1022a, 1022b, respectively to secure the frame of the internal weld system 5004 from movement. The operation of the front and rear clamps 5142 and 144 will be discussed in detail below.
  • the internal weld system 5004 includes the first pipe engagement structure 5052, the second pipe engagement structure 5054, the inspection detector 5056, the one or more processors 5140; and the weld torch 5502.
  • the inspection detector 5056, the inspection camera 51 12, the weld torch 5502 and the weld head assembly 5500 are rotatably mounted on the rotatable hub 5078.
  • the structure, configuration and operation of each of the first pipe engagement structure 5052, the second pipe engagement structure 5054, the inspection detector 5056, the inspection camera 5112, the weld torch 5502 and the weld head assembly 5500 are described in detail with respect to the FIGS. 30 and 33-59 and their related descriptions.
  • FIGS. 32A and 32B show detailed side and top views of the drive section 5010 of the internal weld system 5004.
  • the drive section 5010 of the internal weld system 5004 includes the shield gas tanks 51 14, batteries 51 16, drive section electronics module 5118, pneumatic valves 5120, drive wheels or rollers 5122, drive motors 5124, brakes 5126 and the compressed air tank 5128.
  • the pneumatic valves 5120 include a brake valve 5190 and a drive wheel valve 5192 (both shown in FIG. 70).
  • the drive section 5010 of the internal weld system 5004 includes drive section frame 5278.
  • the drive section frame 5278 may be made from steel or any other material as would be appreciated by one skilled in the art.
  • the drive section electronics module 5118 may include the one or more processors 140.
  • the pneumatic valves 5120 (the brake valve 5190 and the drive wheel valve 5192), and the drive motors 5124 may be operatively connected to the one or more processors 140.
  • the drive section 5010 may be connected to the center section 5008 via a universal joint 5123 and spring members 5125.
  • the shield gas tanks 5114 are constructed and arranged to hold the shield gas required for the weld torches 5502.
  • the hoses are constructed and arranged to connect the shield gas tanks 5114 to the rear rotary union 5072 in the center section 5008.
  • the batteries 51 16 are Lithium ion batteries. In one embodiment, the batteries 51 16 are configured to power all of the electronics as well as the electric drive motors 5124 of the internal weld system 5004. For example, in one embodiment, the batteries 51 16 are configured to power the center section electronics module 5064, the forward-most section electronics module 5014, the drive section electronics module 51 18 and the weed feed electronics module 5046. In one embodiment, the batteries 51 16 may be operatively connected to the one or more processors 114.
  • the batteries 51 16 are also configured to power the radial weld torch motor 5512, the tilt weld torch motor 5588, the axial weld torch motor 5550, the motors of the wire feed systems 5044, the front and rear rotation motors 5030 and 5074, and the drive motors 5124.
  • the batteries 5116 are not configured to supply to weld power.
  • the batteries 51 16 are configured to deliver power to just the drive section electronics module 51 1 and the drive motors 5124, while the power to the rest of the motors and the electronic modules of the internal weld system 5004, including the radial weld torch motor 5512, the tilt weld torch motor 5588, the axial weld torch motor 5550, the motors of the wire feed systems 5044, the front and rear rotation motors 5030 and 5074, the center section electronics module 5064, the forward-most section electronics module 5014, and the weed feed electronics module 5046, is supplied from an external power source via the reach rod/umbilical 5034.
  • the drive motors 5124 are configured to drive the rollers or wheels 5122 to move the frame assembly (including the first pipe engagement structure 5052, the second pipe engagement structure 5054, the weld torch(es) 5502 and the inspection detector 5056) of the internal weld system 5004, from the first end of the pipe 1022a, 1022b to the second end of the pipe 1022a, 1022b along an interior 5130, 5132 of the pipe 1022a, 1022b.
  • the drive motors 5124 of the drive section 5010 are configured to move the frame of the internal weld system 5004 down the pipeline 1004 after each weld is completed.
  • the drive motors 5124 of the drive section 5010 are configured to both accelerate and decelerate the internal weld system 5004 in the pipeline 1004.
  • the power source is carried by the frame assembly of the internal weld system 5004 and is configured to power the drive motors 5124.
  • the drive motors 5124 of the drive section 5010 are electrically powered. In one embodiment, the drive motors 5124 of the drive section 5010 are powered by the batteries 51 16.
  • the drive rollers 5122 are configured to engage the interior surfaces 5130, 5132 of one or more of the pipes 1022a, 1022b. In one embodiment, the drive rollers 5122 are operatively connected to the drive motors 5124 of the drive section 5010. In one embodiment, the drive rollers 5122 is configured to be actuated by a pneumatic cylinder 5137 that is operatively associated with the pneumatic valves 5120 to receive the compressed air from the compressed air tank 5128. In one embodiment, the drive rollers 5122 are made of an elastomeric material or a rubber material.
  • the drive rollers 5122 are configured to enable the movement of the internal weld system 5004 down the pipeline 1004 after each weld is completed.
  • the internal weld system 5004 may include a plurality of drive rollers 5122 that are configured to rotatably support the frame or frame assembly of the internal weld system 5004.
  • the internal weld system 5004 includes four active drive wheels. That is, two drive wheels on each side that are 180° apart. In one embodiment, the number of drive wheels may vary.
  • the drive rollers 5122 may include treads thereon to increase their traction when the internal weld system 5004 is driving through the pipeline.
  • two of the four drive rollers 5122 may be directly connected to and driven by their respective drive motors 124.
  • the other two drive rollers 5122 may be connected to the motor driven drive wheels by chains 51 1 1 and are driven by the motor driven drive wheels.
  • the drive rollers 5122 are constructed and arranged for driving the weld system 5004 inside the pipes 1022a, 1022b until the weld system 5004 is at the desired location.
  • the drive rollers 5122 are constructed and arranged to be pressed against the inside of the pipe by a pneumatic cylinder.
  • the brake 5126 is configured to be actuated by a pneumatic cylinder 5133 that is operatively associated with the pneumatic valves 5120 to receive the compressed air from the compressed air tank 5128.
  • the brake 5126 of the internal weld system 5004 is for emergency use.
  • the brake 5126 can be used in case the drive motors 5124 of the drive section 5010 fail to decelerate the internal weld system 5004 for some reason.
  • the brake 5126 may be applied on hillsides to keep the internal weld system 5004 from rolling deep into the pipeline 1004 or falling out of the pipe depending on slope direction.
  • the brake 5126 is configured to be either manually or automatically controlled.
  • the brake 5126 may also be used to secure the frame of the internal weld system 5004 in place within the pipes during the welding procedure, the pre- weld scan procedure and/or the post weld scan procedure.
  • the brake 126 may be configured to secure the frame of the internal weld system 5004 from movement at a desired location within the pipes during the welding procedure, the pre-weld scan procedure and/or the post weld scan procedure.
  • the compressed air tank 5128 is constructed and arranged to hold the air for operating the brake 5126, the drive rollers 5122, and the front and the rear clamps 5142, 5144.
  • the compressed air tank 5128 is constructed and arranged to be connected to the umbilical 5034 through both the front and rear rotary unions 5032, 5072 so that compressed air tank 5128 may be refilled as needed.
  • the pneumatic valves 5120 are constructed and arranged to control air to the two pneumatic cylinders that are configured to engage and operate the brake 5126 and the drive rollers 5122, respectively.
  • the drive section electronics module 51 18 is configured to allow the transmission of the communication signals upstream to the center section electronics module 5064. In one embodiment, the drive section electronics module 51 18 is also configured to control the drive motors 5124 and the two pneumatic valves 5120.
  • the one or more processors 5140 are configured to operate the drive motors 5124 to move the frame of the internal weld system 5004 through at least one of the pipes 1022a, 1022b until the sensor 5352 detects the interface region 5136 between the pipes 1022a, 1022b.
  • the one or more processors 5140 are configured to operate the brake system of the internal weld system 5004 to secure the frame of the internal weld system 5004 from movement at a location within the pipes 1022a, 1022b that positions the inspection detector 5056 in relation to the interface region 5136 to enable the inspection detector 5056 to detect the profile of the interface region 5136 between the pipes 1022a, 1022b.
  • FIG. 33 shows a view of the center section 5008 of the internal weld system 5004 being positioned inside the pipe segments 1022a, 1022b, where some components of the center section 5008 are not shown for sake of clarity.
  • the front and rear clamps 5142, 5144, the rotatable hub 5078, the weld head assembly 5500, the inspection detector 5056 and the inspection camera 51 12 are shown in FIG. 33.
  • the field system 5000 for welding two pipes includes a computer system 5138 for facilitating pipe welding.
  • the computer system 5138 includes the one or more processors 5140 that are communicatively connected to the weld system 5004.
  • the computer system 5138 and its one or more processors 5140 may be communicatively connected to the weld system 5004 (and one or more components thereof) via one or more wired or wireless communication links.
  • the wired communication links may comprise one or more Ethernet links, coaxial communication links, Fiber Optic communication links, or other wired communication links.
  • the wireless communication links may comprise one or more Wi-Fi communication links, Bluetooth communication links, near-field communication (NFC) communication links, cellular communication links, or other wireless communication links.
  • one or more components of the weld system 5004 may be communicatively connected to one another via one or more of the foregoing wired or wireless communication links.
  • reducing the number of communication cables in the weld system 5004 in some embodiments may reduce potential entanglement of the cables during rotation of an inspection device (e.g., inspection laser, inspection camera, or other inspection device), a weld torch, or other component of the weld system 5004.
  • an inspection device e.g., inspection laser, inspection camera, or other inspection device
  • a weld torch or other component of the weld system 5004.
  • the computer system 5138 and its one or more processors 5140 may be positioned in the field system 5000. In another embodiment, the computer system 5138 and its one or more processors 5140 may be positioned remotely from the field system 5000. In one embodiment, the one or more processors 5140 may include a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information. [00473] It should be appreciated that the "one or more processors" as disclosed herein may constitute a single processor that is located on-board and local to the particular system or component being discussed, off-board and local to the particular system or component being discussed, or remotely located to the particular system or component being discussed.
  • connection with the one or more processors can be wired or wireless.
  • the "one or more processors” may also refer to a plurality of processors that are on-board and local, a plurality of processors that are off-board and local, a plurality of processors that are remote, or any combination of on-board (and local), off-board (and local), and remote processors.
  • on-board processors such processors refer to processors that are carried physically (i.e., physically connected, and move with) by the particular system or component.
  • off-board processors these refer to processors that are local to a job-site and communicate wirelessly with on-board electronics.
  • Off-board processors can also refer to electronics that are tethered to the on-board system (e.g., through a reach rod), and are local to the job site. Seen in another light, if the processor moves with the reach rod, it may also be considered an "on-board" processor.
  • the first pipe engagement structure 5052 is configured to engage an interior surface 5130 of the first pipe 1022a to enable the first pipe engagement structure 5052 to be fixed relative to the first pipe 1022a.
  • the second pipe engagement structure 5054 is configured to engage an interior surface 5132 of the second pipe 1022b to enable the second pipe engagement structure 5054 to be fixed relative to the second pipe 1022b.
  • the inspection detector 5056 is positioned between the first pipe engagement structure 5052 and the second pipe engagement structure 5054 and is configured to emit an inspection beam of radiation.
  • an inspection detector motor is operatively associated with the inspection detector 5056 to direct the inspection beam of radiation along the interface region 136 between the pipes 1022a, 1022b.
  • the front and rear rotation motors 5030 and 5074 may individually or together be referred to as the inspection detector motor.
  • the front and rear rotation motors 5030 and 5074 are configured to rotationally move the inspection detector 5056 along the interface region 5136.
  • the inspection detector 5056 is configured to generate signals based upon a profile of the interface region 5136 between the pipes 1022a, 1022b.
  • the interface region 5136 is an annular interface region. In one embodiment, the interface region 5136 is in the interior of the pipes 1022a, 1022b at regions of the pipes 1022a, 1022b adjacent to where the weld would go. [00476]
  • the term "interface region” as used herein refers to the interior surfaces of the pipes to be welded in the area, and optionally in the adjacent vicinity, where the weld material is to be deposited.
  • the interface region includes at least a portion, or optionally the entirety, of the internal bevel of both pipes to be welded, if such bevels are provided.
  • the interface region includes the entirety of the beveled surfaces and also extends beyond the beveled surface, if bevels are provided.
  • the wheels 5028 on the forward-most section 5006 of the internal weld system are constructed and arranged to keep the clamps from dragging on the inner surfaces of the pipe. The less the wheels 5028 extend out, the easier the internal weld system fits through the pipe bends.
  • the wheels 5028 may be adjustable. In one embodiment, the wheels 5028 may not be adjustable.
  • the sprung or toe wheels 5066 (as shown in FIG. 23) at the rear clamp 5144 and the adjustable wheels 5276 (as shown in FIG. 32 A) at the back of the drive section 5008 are constructed and arranged so that the clamp centerline is about 0.25 inches below the pipe centerline. With this configuration, when the clamps expand against the inner surfaces of the pipe, the expander picks the clamp up off of the wheels rather than compress the wheels into the pipe's inner walls
  • the "pipe engagement structure” comprises a clamp that securely engages a pipe surface.
  • the clamp for example, can include one or more shoes or other support structure configured to fixedly engage with a pipe surface so as to prevent movement thereof.
  • the "pipe engagement structure” comprises a seal that sealingly engages the interior surface of a pipe so as to inhibit gas from passing therethrough.
  • Such seal may comprise, for example, an inflatable bladder, a resilient structure, or other engineered structure that engages the interior pipe surface to inhibit gas from passing therethrough.
  • Such seal can be used in a purging operator to remove oxygen from a region in the pipe to be welded, so as to prevent or reduce oxidation as a result of the welding process.
  • the pipe engagement structure comprises a combination of a clamp and a seal, or one or more clamps and/or one or more seals.
  • the first pipe engagement structure 5052 includes the first clamp 5142 and the second pipe engagement structure 5054 includes the second clamp 5144.
  • the first pipe engagement structure 5052 includes a first seal 5146 and the second pipe engagement structure 5054 includes a second seal 5148.
  • the second seal 5148 and the second clamp 5144 may be referred to as the rear seal 5148 and the rear clamp 5144, respectively.
  • the first seal 5146 and the first clamp 5142 may be referred to as the front seal 5146 and the front clamp 5142, respectively.
  • the first pipe engagement structure 5052 includes the clamp 5142 and the second pipe engagement structure 5054 includes the seal 5148. In one embodiment, the first pipe engagement structure 5052 includes the seal 5146 and the second pipe engagement structure 5054 includes the clamp 5144.
  • the first pipe engagement structure 5052 includes the clamp 5142 and the seal 5146 and the second pipe engagement structure 5054 includes the clamp 5144 and the seal 5148. In one embodiment, the first pipe engagement structure 5052 includes the clamp 5142 and the seal 5146 and the second pipe engagement structure 5054 includes the clamp 5144. In one embodiment, the first pipe engagement structure 5052 includes the clamp 5142 and the seal 5146 and the second pipe engagement structure 5054 includes the seal 5148. In one embodiment, the first pipe engagement structure 5052 includes the clamp 5142 and the second pipe engagement structure 5054 includes the clamp 5144 and the seal 5148. In one embodiment, the first pipe engagement structure 5052 includes the seal 5146 and the second pipe engagement structure 5054 includes the clamp 5144 and the seal 5148.
  • a high pressure purge gas is sent into a region between the clamp and the seal.
  • the purge gas from the region between the clamp and the seal may leak through the slight gap between the pipes about to be welded and may also be exhausted from the pipes on the side of the inspection detector 5056 and the inspection camera 51 12 where there is no seal and has just the clamp.
  • This optional configuration prevents the over pressurization of the region between the clamp and the seal (e.g., in comparison with arrangements having two seals, one on either side of the inspection detector 5056 and the camera 5112), without the provision of a regulator to regulate pressure with the purge gas region, and/or a separate over pressurization relief valve for the region between the clamp and the seal.
  • the continuous supply of the high pressure purge gas into the region between the clamp and the seal is configured to reduce the oxygen in a region in the vicinity of the weld torch during a welding operation.
  • first and the second seals may optionally have openings therethrough to prevent over pressurization of the purge gas chamber formed between the first and the second seals.
  • one or both of the seals, where an inflatable seal bladder is provided for the seal may be partially inflated to provide a predefined or calculated gap therearound to allow flow out of the purge area at a desired rate.
  • inert gas is introduced into the purge chamber therebetween. It should be understood, however, that the purge seals 5146, 5148 need not (and typically do not) create a perfect seal. Inert gas is leaked, for example, through the gap between the two pipes 1022a, 1022b being welded. The inert purge gas may also leak around the seals 5146, 5148, which need not be perfect. Of course, during the welding operation, the gap between the pipes 1022a, 1022b is slowly closed and sealed. As a result, the pressure within the purge chamber between the pipes 1022a, 1022b may rise as the weld between the pipes 1022a, 1022b is created.
  • the pressure sensor provided within the purge chamber detects the pressure within the purge chamber and generates signals to the one or more processors 5140, which in turn communicates with one or more valves and/ or one or more regulators, so as to control or regulate the purge gas pressure within the purge chamber to prevent over-pressurization.
  • Over-pressurization within the purge chamber would apply a greater than desired outwardly directed gas force through the gap between the pipes to be welded and potentially alter a desired outcome of the weld.
  • only a single seal 5146, 5148 is provided to create a purge chamber that is sealed on only one side. This arrangement still provides a reasonable purge chamber, which is largely devoid of oxygen, and also prevents any possibility of over-pressurization.
  • inert purge gas will leak not only from the gap between the pipes, but also through an end of the pipe that is not sealed, and hence may consume more gas in comparison with the double sealed embodiment.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first clamp 5142 and the second seal 5148. That is, the first clamp 142 and the second seal 5148 are each positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first seal 5146 and the second clamp 5144. That is, the first seal 5146 and the second clamp 5144 are each positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first clamp 5142 and the second clamp 5144. That is, the first clamp 5142 and the second clamp 5144 are each positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first seal 5146 and the second seal 5148. That is, the first seal 5146 and the second seal 5148 are each positioned on axially opposite sides of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first seal 5146, the first clamp 5142, the second clamp 5144 and the second seal 5148. That is, the first seal 5146 and the first clamp 5142 are positioned axially on one side of the inspection detector 5056 and the inspection camera 51 12 and the second clamp 5144 and the second seal 5148 are positioned axially on the other side of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first seal 5146, the first clamp 5142 and the second seal 5148. That is, the first seal 5146 and the first clamp 5142 are positioned axially on one side of the inspection detector 5056 and the inspection camera 5112 and the second seal 5148 is positioned axially on the other (opposite) side of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first seal 5146, the second seal 148 and the second clamp 5144. That is, the second seal 5 148 and the second clamp 5144 are positioned axially on one side of the inspection detector 5056 and the inspection camera 51 12 and the first seal 5146 is positioned axially on the other (opposite) side of the inspection detector 5056 and the inspection camera 5112.
  • the inspection detector 5056 and the inspection camera 51 12 are configured to be positioned axially (with respect to the pipe axis) between the first seal 5146, the first clamp 5142 and the second clamp 5144. That is, the first seal 5146 and the first clamp 5142 are positioned axially on one side of the inspection detector 5056 and the inspection camera 5112 and the second clamp 5144 is positioned axially on the other (opposite) side of the inspection detector 5056 and the inspection camera 51 12. [00495] In one embodiment, the inspection detector 5056 and the inspection camera 5112 are configured to be positioned axially (with respect to the pipe axis) between the first clamp 5142, the second seal 5148 and the second clamp 5144.
  • the second seal 5148 and the second clamp 5144 are positioned axially on one side of the inspection detector 5056 and the inspection camera 51 12 and the first clamp 5142 is positioned axially on the other (opposite) side of the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 is positioned between the clamps 5142, 5144, it is able to extract profile data from between the clamps 5142, 5144 after the clamps 5142, 5144 have been clamped in place. As such the inspection detector 5056 can continue to scan and detect the profile of the interface region 5136 during a welding operation. This is beneficial for some applications, as the interface region 5136 may change slightly as the two pipes 1022a, 1022b are being welded, as the welded connection itself may change the interface region 5136 in other areas that have not been welded yet.
  • the inspection detector 5056 allows for a detection and determination of any change in one or more characteristics of the interface region 5136 on-the-fly, or in "real time" at regions of the interface region 5136 about to be welded.
  • the inspection detector 5056 is positioned between the clamps 5142, 5144, it is able to extract pre-weld profile data from the interface region 5136 after the clamping force is applied by the clamps 5142, 5144.
  • the clamping force of the clamps 5142, 5144 themselves may alter the interface region 5136.
  • the clamping force may slightly alter the distance between the pipe ends and/a relative height displacement between the pipe ends at certain (or all) regions of the interface region 5136.
  • the clamping force applied by the clamps 5142, 5144 may change a roundness of one or both of the pipes (e.g., the first clamp may alter the roundness of the first pipe to be welded and/or the second clamp may alter the roundness of the second pipe to be welded.
  • the clamp shoes for any one of the clamps 5142, 5144 are symmetrically provided and evenly circumferentially spaced about the interior of the pipe being engaged.
  • the outermost surface of each clamp shoe may be equally spaced from the central axis of the clamp. The spacing of each clamp shoe can be set to be slightly larger than the inner diameter of the pipe.
  • the clamping force of the clamp 5142, 5144 can be used to change the shape of a slightly out of round pipe to one that is more rounded.
  • the profile of the interface region 5136 is not yet fully determined because of the shape changing possibility.
  • the inspection detector 5136 describe herein can be used to determine the profile after clamping has been applied.
  • the inspection detector 5056 and/or camera 51 12 are able to extract profile data from between the seals 5146, 5148 after the seals 5146, 5148 have been engaged with the interior surfaces 5130, 5132 of the pipes 1022a, 1022b to be welded. As such the inspection detector 5056 can continue to scan and detect the profile of the interface region 5136 before, during and/or after a welding operation in which the regions between the seals 5146, 5148 have been provided or filled with a purge gas.
  • the interface region 5136 may be inspected by the inspection detector 5056 and/or camera 1 12, before, during, and/or after a welding operation without breaking the seal 5146, 5148. If, for example, the inspection detector 5056 and/or camera 51 12 (together with the one or more processors 5140) determine(s) that a slight modification to the weld, or an additional welding operation is desired, such modification or additional welding operation can be accomplished without the need to reestablish the purge chamber (for example, in comparison to a contemplated arrangement in which a post-weld inspection detector and/or camera are located outside the purge chamber, and introducing the inspection detector 5056 and/or camera 51 12 to inspect the welded interface region 5136 only after the purge chamber has been broken).
  • the inspection detector 5056 can be used to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 between the pipes 1022a, 1022b subsequent to a welding operation and generate post-weld profile data based on the scan, and this post-weld profile data can be obtained, and optionally a corrective or other additional weld can be achieved based on the post-weld profile data, without releasing the clamps 5142, 5144 and/or seals 5146, 5148.
  • the clamps 5142, 5144 are configured to rotate. In one embodiment, the clamps 5142, 5144 are configured to rotate in opposite directions to one another.
  • the present system enables relative rotation between the first clamp and the second clamp 5142, 5144, after they have been clamped to the first and second pipe interiors 5130, 5132 respectively.
  • This can be accomplished by the one or more orientation motors 5030, 5074 operating one or both of the clamps 5142, 5144 as described herein.
  • Such relative rotation of the pipes 1022a, 1022b can be conducted in response to pre-weld profile data determining that a better rotational match between the pipe ends is available and can be accomplished by relative rotation of one or both of the clamps 142, 5144.
  • Such relative rotation is accomplished without the need to unclamp the first and second clamps 5142, 5144, and while the inspection detector 5056 remains axially positioned between the clamps 5142, 5144.
  • the inspection detector 5056 can be again used to scan the interface region 5136 to obtain new pre- weld profile data. It should be appreciated that because neither clamp 5142, 5144 needs to be released to obtain the new pre- weld profile data, unnecessary downtime can be avoided.
  • rollers 5332 of the external cradle 5330 can be used (as instructed by the one or more processors 5140) to work in conjunction with the one or more clamps 5142, 5144 to effect such relative rotation.
  • the clamps 5142, 5144 and the seals 5146, 5148 are positioned inside the pipes 1022a, 1022b to form an internal sealed region/area. In one embodiment, the clamps 5142, 5144 and the seals 5146, 5148 are configured to seal opposite sides of a seam to be welded.
  • clamp 5142 and the seal 5146 are activated together and the clamp 5144 and the seal 5148 are activated together.
  • the clamps 5142, 5144 and the seals 5146, 5148 are controlled by the same valve.
  • the seals 5146, 5148 are activated with the clamp 5142. In one embodiment, the seals 5146, 5148 are activated with the clamp 5144. In one embodiment, the clamp 5142 and the seal 5146 are activated independently and the clamp 5144 and the seal 5148 are activated independently. In one embodiment, a separate seal control system may be configured to operate both the seals 5146, 5148 that is independent (and separate from) of a clamp control system that is configured to operate both the clamps 142, 5144.
  • the clamp 5144 is positioned relative to the end of the pipe 1022b. In one embodiment, the clamp 5142 and the seal 5146 are then activated together. In one embodiment, when the pipe 1022a is positioned relative to the pipe 1022b, the clamp 5144 and the seal 5148 are activated together.
  • the clamps 5142, 5144 are configured to be moveable between a retracted position (as shown in FIGS. 35B) where the clamps 5142, 5144 are not in contact with the inner surfaces 5130, 5132 of the pipes 1022a, 1022b and an extended position (as shown in FIGS. 35A) where the clamps 5142, 5144 are configured to apply clamp forces on the inner surfaces 5130, 5132 of the pipes 1022a, 1022b.
  • the clamps 5142, 5144 are constructed and arranged to engage (make contact) with the pipes 1022a, 1022b and transmit forces that grip and shape the pipes 1022a, 1022b.
  • FIGS. 30, and 33-42 show a perspective and a cross-sectional of the center section 5008 of the internal weld system 5004 being positioned inside the pipe segments 1022a, 1022b, where both clamps 5142, 5144 and seals 5146, 5148 are engaging the inner surfaces 5130 and 5132 of the pipes segments 1022a, 1022b and where some components of the center section 5008 are not shown for sake of clarity;
  • FIG. 33 and 34 show a perspective and a cross-sectional of the center section 5008 of the internal weld system 5004 being positioned inside the pipe segments 1022a, 1022b, where both clamps 5142, 5144 and seals 5146, 5148 are engaging the inner surfaces 5130 and 5132 of the pipes segments 1022a, 1022b and where some components of the center section 5008 are not shown for sake of clarity;
  • FIG. 33 and 34 show a perspective and a cross-sectional of the center section 5008 of the internal weld system 5004 being positioned inside the pipe segments 1022a, 10
  • FIG. 35 shows a view of the center section 5008 of the internal weld system 5004 being positioned inside the pipe segments 1022a, 1022b, where only clamps 5142, 5144 (no seals) are engaging the inner surfaces 5130 and 5132 of the pipes segments 1022a, 1022b and where some components of the center section are not shown for sake of clarity;
  • FIG. 36 shows a perspective view of the clamp shoe 5157 attached to the clamp shoe pin member 5090 positioned in the spider member 5100;
  • FIG. 37 shows a perspective view of the spider member 5100;
  • FIG. 38 shows a perspective view of the clamp shoe pin member 5090;
  • FIGS. 39 and 40 show perspective views of the hub 5096 of the clamps 5142 or 5144 with the clamp shoe pin members 5090 and the link members 5092 connected thereto.
  • the clamps 5142, 5144 are shown in retracted position to show how the ramps 5026, 5070 extend slightly higher.
  • the weld torches 5502 are shown in their extended positions. Typically, the weld torches 5502 would only be extended after the clamps 5142, 5144 are extended.
  • the weld system 5004 may include a plurality of first clamp shoes 5157 circumferentially, equally spaced apart from each other on its respective spider member 5100 and a plurality of second clamp shoes 5157 circumferentially, equally spaced apart from each other on its respective spider member 5100.
  • the clamp shoes 5157 may have different heights for different size pipes and may be fine-tuned, for example, with shims or any other adjustment members. In one embodiment, the clamps shoes 5157 may be self-centering members. In one embodiment, the clamp shoes 5157 of the internal weld system 5004 are constructed and arranged to have a radial clearance of about 1 inch to the inner surfaces of the pipe.
  • each clamp shoe 5157 includes pipe surface contact members (or surfaces) 5156.
  • the pipe surface contact members 5156 are constructed and arranged to frictionally engage, when the clamps 5152, 5154 are extended, the inner surfaces 5130, 5132 of the pipes 1022a, 1022b on either side of the interface region 5136.
  • each clamp shoe 5157 is constructed and arranged to be connected to and positioned on its associated clamp shoe pin member 5090.
  • the clamp shoe pin member 5090 is constructed and arranged to extend through its corresponding opening 5158 in the spider member 5100.
  • the openings 5158 in the spider member 5100 are constructed and arranged to generally extend radially in the spider member 5100 so as to enable a radial movement (e.g., up and down radial movement) of the clamp shoe pin member 5090 in the corresponding opening 5158 in the spider member 5100.
  • the spider member 5100 may be any member that is constructed and arranged to facilitate movement of the clamp shoe pin members 5090 such that the clamps 5142, 5144 apply clamping forces on the inner surfaces 5130, 5132 of the pipes 1022a, 1022b .
  • one end 5164 of the clamp shoe pin member 5090 is attached to the clamp shoe 5157 and the other end 5166 of the clamp shoe pin member 5090 is connected to the link member 5092.
  • the end 5166 of the clamp shoe pin member 5090 includes a notch 5168 that is constructed and arranged to receive the link member 5092 therein.
  • the end 5166 of the clamp shoe pin member 5090 also includes openings 5170 that constructed and arranged to receive fastening members 5172 to connect the link member 5092 to the end 5166 of the clamp shoe pin member 5090.
  • the spider member 5100 may include openings 5162 that are constructed and arranged to enable the connection between the clamp shoe pin members 5090 and the link members 5092.
  • the openings 5162 of the spider member 5100 are also constructed and arranged to enable the movement of the link member 5092 when the clamps 5142, 5144 are moved between their retracted and extended positions.
  • the spider member 5100 is attached to the respective clamps 5142 or 5144.
  • the link member 5092 is an elongated member with openings formed at its end portions.
  • the end portions of the link member have generally rounded configurations to enable the movement of the link member 5092 when the clamps 5142, 5144 are moved between their retracted and extended positions
  • the hub 5096 may include notches 5174 (as shown in FIG. 40) that are constructed and arranged to enable the connections between the link members 5092 and the hub 5096.
  • the notches 174 of the hub 5096 are also constructed and arranged to enable the movement of the link members 5092 in the notches 5174 when the clamps are moved between their retracted and extended positions.
  • the clamp 5152 or 5154 includes the cylinder 5086, the piston 5084 and the shaft 5094.
  • the piston 5084 is configured to be movable axially in the cylinder 5086, and the shaft 5094 is secured to the piston 5084.
  • the shaft 5094 is movable with the piston 5084.
  • the hub 5096 is constructed and arranged to be connected to the shaft 5094 that is longitudinally moved by the axially, reciprocating piston 5084, for example, driven by fluid (hydraulic or pneumatic) pressure inside the cylinder 5086.
  • the clamps 5142, 5144 are moved from the retracted position (as shown in FIGS. 35B) where the clamps 5142, 5144 are not in contact with the inner surfaces 5130, 5132 of the pipes 1022a, 1022b to the extended position (as shown in FIGS. 3 A) where the clamps 5142, 5144 are configured to apply clamp forces on the inner surfaces 5130, 5132 of the pipes 1022a, 1022b, by activating the cylinder 5086 so that the piston 5084 is axially moved in the cylinder 5086.
  • the compressed air from the front rotary union 5032 through the front clamp control valve 5018 enter a port 5031 (as shown in FIG. 30). The compressed air entering the port 5031 pushes the piston 5084 forward to move the clamps 5142, 5144 to their extended position.
  • the axial movement of the piston 5084 causes an axial movement of the shaft 5094 connected to the piston 5084.
  • the axial movement of the shaft 5094 in turn causes an axial movement of the hub 5096.
  • the axial movement of the hub 5096 is translated to a radial movement of the clamp shoe pin members 5090 via their link members 5092.
  • the radial clamp forces are generated by fluid pressure of the compressed air acting on the piston 5084 that drives the link members 5092 that convert the axial movement of the piston 5084 (via the shaft 5094 and the hub 5096) to a radial movement of the clamps shoes 5157.
  • the size of the cylinder, the applied fluid pressure, and the sizes of various components of the clamps 5142 and 5144 may be changed to control the clamp forces being applied by the clamps on the inner surfaces 5130, 5132 of the pipes 1022a, 1022b.
  • the seals 5146, 5148 have a generally donut or annular shaped configuration to allow a portion of the center section (e.g., the front clamp 5142 or the rear clamp 5144) to pass therethrough.
  • the seals 5146, 5148 are constructed and arranged to be radially expandable members.
  • the seals 5146, 5148 are constructed and arranged to be connected to a pneumatic or a hydraulic line that conveys fluid to the seals 5146, 5148 to inflate them. As the seals 5146, 5148 inflate, they are constructed and arranged to engage the inner surfaces 5130, 5132 of the pipes 1022a, 1022b, respectively forming a chamber 5150 therebetween. In one embodiment, the seal 5146, when inflated, engaged the inner surface 5130 of the pipe 1022a and the seal 5148, when inflated, engaged the inner surface 5132 of the pipe 1022b. In one embodiment, the seals 5146, 5148, when inflated, engage on opposite sides of the interface region 5136. In one embodiment, the chamber 5150 is a closed volume that may be referred to as a purge gas chamber. In one embodiment, the chamber 5150 is constructed and arranged to receive a purge gas therein.
  • the internal weld system 5004 may include the purge gas tank configured to provide purge gas between the inflated first seal 5146 and the inflated second seal 5148 to reduce oxygen from between the inflated first and the second seals 5146 and 5148 during a welding operation.
  • the purge tank may be positioned in the drive section 5010 of the internal weld system 5004.
  • the purge gas is configured to prevent oxidation during a welding procedure.
  • the purge gas is an inert gas.
  • the purge gas may include argon, helium, nitrogen, or a combination thereof.
  • the purge gas may include a combination of argon and C0 2 .
  • the purge gas is pumped into the internal sealed region that is formed between the inflated first and the second seals 5146, 5148.
  • the sealed, internal region free of oxygen, oxidation that may result from the extreme heats that take place during the welding procedure may be prevented.
  • the internal weld system 5004 may include an oxygen sensor 5176 and a pressure sensor 5178.
  • the oxygen and pressure sensors 5176 and 5178 are operatively connected to the one or more processors 5140.
  • the oxygen and pressure sensors 5176 and 5178 are constructed and arranged to be positioned on the rotatable hub 5078.
  • the oxygen and pressure sensors 5176 and 5178 are constructed and arranged to be positioned on the spider member 5100 (e.g., between the clamps).
  • the oxygen sensor 5176 is configured to measure oxygen content of the gas in the purge chamber 5150 and send an oxygen content data, which is indicative of the oxygen content of the gas in the purge chamber 5150, to the one or more processors 5140.
  • the one or more processors 5140 are configured to receive the oxygen content data, compare the received oxygen content data to its predetermined oxygen content value, and generate an excess oxygen gas signal if the oxygen content data is greater than the predetermined oxygen content value.
  • the internal weld system 5004 may be configured to open a valve structure to allow purge gas (from the purge gas source/tank) to flow into the purge chamber 5150 until the measured oxygen content falls below the predetermined oxygen content value.
  • the internal weld system 5004 may be configured to stop the welding procedure.
  • the pressure sensor 5178 is configured to measure pressure of the inert gas in the purge chamber 5150 and send pressure data, which is indicative of the pressure of the inert gas in the purge chamber 5150, to the one or more processors 5140.
  • the one or more processors 5140 are configured to receive the pressure data, compare the received pressure data to its predetermined pressure value, and generate an overpressure signal if the pressure data is greater than the predetermined pressure value.
  • the internal weld system 5004 may be configured to open an exhaust valve structure to release the pressure in the purge chamber 5150 until the measured pressure falls below the predetermined pressure value.
  • the internal weld system 5004 may be configured to stop the welding procedure.
  • the seals 5146, 5148, the purge gas tank, the purge gas chamber 5150 formed between the seals 5146, 5148, the oxygen and pressure sensors 5176 and 5178 that monitor the gas in the purge gas chamber 5150 are all optional.
  • the internal weld system 5004 includes the inspection camera 51 12 configured to be positioned between the first pipe engagement structure 5052 and the second pipe engagement structure 5054.
  • the inspection camera 51 12 is constructed and arranged to be rotatably mounted on and connected to the rotatable hub 5078.
  • the inspection camera 51 12 is operatively connected to the one or more processors 5140. In one embodiment, the inspection camera 51 12 is configured to send camera inspection data prior to, subsequent to, or during a weld operation to the one or more processors 5140.
  • the camera inspection data may generally include image(s), captured by the inspection camera 5112, of the weld joint.
  • the inspection camera 51 12 is configured to capture image(s) of weld joint during or subsequent to the weld operation.
  • the camera inspection data may generally include image(s), captured by the inspection camera 5112, of the interface region 5136 between the pipes 1022a, 1022b.
  • the inspection camera 5112 is configured to capture image(s) of the interface region 5136 between the pipes 1022a, 1022b prior to or during the weld operation.
  • the inspection camera 51 12 may be any device that is configured for capturing/viewing the weld joint or the interface region 5136 between the pipes 1022a, 1022b.
  • the camera device 51 12 may be a two-dimensional (2D) camera for visual inspection of the weld joint or the interface region 5136 between the pipes 1022a, 1022b.
  • the inspection camera 51 12 may be a two-dimensional (2D) charge-coupled device (CCD) color camera.
  • the one or more processors 5140 that are associated with the inspection camera 51 12 may be configured to analyze the image(s) captured by the inspection camera 5112 to detect any defects present in the weld joint.
  • a visual signal may be delivered to an external operator display based on the analysis.
  • the 2D camera may be a color camera and a change in coloration may indicate a weld defect to the operator.
  • a perceived change in profile may also indicate a weld defect.
  • the inspection camera 5112 is configured to obtain a thermal image of (e.g., various color regions of the metal) of the weld joint/region. This thermal image is then analyzed to determine what temperatures the different regions of the weld joint/region have reached.
  • the images provided by the inspection camera 51 12 may be color images.
  • the one or more processors 5140 that are associated with the inspection camera 51 12 may be configured to analyze the color of each pixel of the received image to determine the temperature associated with that pixel.
  • the images provided by the inspection camera 51 12 may be grayscale images.
  • the one or more processors 5140 that are associated with the inspection camera 5112 may be configured to analyze the intensity or brightness of each pixel of the received image to determine the temperature associated with that pixel.
  • the one or more processors 5140 that are associated with the inspection camera 51 12 may be configured to analyze the properties of the pixels of the received image to determine if the temperature is outside the threshold or predetermined temperature range (and is a relatively veiy high or relatively very low) and or if there is a large temperature difference between adjacent pixels.
  • the abnormal temperature(s) or temperature differences may be an indication of the occurrence of a weld defect.
  • the image may be analyzed to determine whether a region or regions of the weld joint/region have reached a relatively very high or relatively very low temperature. In one embodiment, the image may be analyzed to determine whether a region or regions of the weld joint/region have temperature differential/changes. In one embodiment, a temperature of each region of the weld joint/region is determined, and the determined temperature of each region of the weld joint/region is compared with a threshold or predetermined temperature range to determine whether a region or regions of the weld joint/region have reached a relatively very high temperature, and/or a region or regions of the weld joint/region have temperature differential/changes.
  • the inspection camera 51 12 is configured to follow the weld torch 5502 so that an operator can inspect the weld as soon as the weld is created by the weld torch 5502.
  • the inspection detector comprises a laser, 3D camera, ultrasound, and an electric capacitive probe.
  • the type of laser can be a Laser Displacement Sensor.
  • the laser can be LK-G5000 series Ultra High-Speed/High-Accuracy Laser Displacement Sensor manufactured by Keyence.
  • the laser can be a smart laser sensor, such as, Smart Laser Sensor SLS-050 manufactured by Meta Vision Systems Inc.
  • the inspection detector may include an emitter for emitting the inspection beam of radiation, and a receiver for receiving inspection signals from reflected radiation.
  • the detector's receiver comprises a sensor that detects the reflected radiation and generates signals based upon the reflected radiation.
  • the signals are received by the one or more processors.
  • the signals contain data and information corresponding to the three dimensional profile of the interface region between pipes to be welded and can be used to detect, for example, the relative heights of the adjacent pipe surfaces at the regions to be welded, the relative spacing between the pipes, any non- uniformities in the adjacent surfaces to be welded (e.g., at the bevels thereof).
  • the inspector detector is scanned along the entire interface between the pipes, it can determine the specific interface profile at any particular region of the scan. This information can be used by the one or more processors to control the operation of the weld torch to provide a customized/tailored weld that is tailored specifically to the structural profile of the pipes to be welded at the interface region thereof.
  • the system 5000 may include housings 5852, 5854 (as shown in FIG. 31) that are configured to house and protect the inspection detector 5056 and the inspection camera 5112, respectively from flying hot weld sparks (spatter) and/or other debris that may fly towards the inspection detector 5056 and/or the inspection camera 51 12 during a welding operation.
  • the housings 5852, 5854 of the inspection detector 5056 and/or the inspection camera 51 12 may be made of polycarbonate material.
  • portions of the housings 5852, 5854 may be configured to be removable to facilitate cleaning (e.g., removal of the weld spatter or other weld debris therefrom) or repair.
  • the portions of the housings 5852, 5854 may include camera lens shield or inspection detector lens shield.
  • portions of the housings 5852, 5854 of the inspection detector 5056 and/or the inspection camera 51 12 may be configured to be disposable so that portions of the housings 5852, 5854 may be easily replaced when they are clogged with the weld spatter or other weld debris.
  • the inspection camera 51 12 may include a (rectangular) polycarbonate member in front of its lens that may be replaced when obstructed/blocked by the weld spatter or other weld debris.
  • the pre-weld inspection, the on-the-fly inspection and the post- weld inspection may be performed by the inspection detector 5056. In one embodiment, the pre-weld inspection, the on-the-fly inspection and the post-weld inspection may be performed by the inspection detector 5056 and the inspection camera 51 12.
  • the inspection detector 5056 includes an emitter 5180 for emitting the beam of radiation, and a receiver 5182 for receiving inspection signals from reflected radiation. In one embodiment, the inspection detector 5056 transmits radiation towards the interface region 5136. In one embodiment, the received 5182 of the inspection detector 5136 is configured for receiving radiation reflected from the surfaces of the interface region 5136 and generating electronic signals based thereon. In one embodiment, the receiver or sensor 5182 of the inspection detector 5056 is configured to sense the reflected signal to detect 3D topography of the weld joint/region.
  • the inspection detector 5056 may interchangeably be referred to herein as the inspection laser.
  • the inspection detector 5136 includes a plurality of inspection detectors that transmit radiation towards the interface region 5136.
  • each inspection detector may include a receiver for receiving radiation reflected from the surfaces of the interface region 136 and generating electronic signals based thereon.
  • the inspection detector 5056 may include a Laser Displacement Sensor. In one embodiment, the inspection detector 5056 may include a Complementary metal-oxide-semiconductor (CMOS) sensor. In one embodiment, the inspection detector 5056 may include High Definition Ernostar type lens. In one embodiment, the one or more processors 5140 that are associated with the inspection detector 5056 are configured to use triangulation to detect the position of the reflected light on the RS-CMOS sensor.
  • CMOS Complementary metal-oxide-semiconductor
  • the inspection detector 5056 may include High Definition Ernostar type lens.
  • the one or more processors 5140 that are associated with the inspection detector 5056 are configured to use triangulation to detect the position of the reflected light on the RS-CMOS sensor.
  • the inspection detector 5056 may receive its power from the wire feed electronics module 5046.
  • the wire feed electronics module 5046 is configured to receive its power from the batteries 51 16 in the drive section 5010 via the rear slip ring 5080.
  • the inspection detector 5056 receives its power from the batteries 51 16 in the drive section 5010 via the rear slip ring 5080 and the wire feed electronics module 5046. This may be the case when the cables, hoses, and/or wires to the reach rod/umbilical 5034 are disconnected from the system 5004, for example, when the system 5004 is traveling from one weld joint to the next weld joint.
  • the inspection detector 5056 may receive its power directly from the umbilical/reach rod 5034.
  • the inspection detector 5056 may receive its power directly from the umbilical/reach rod 5034.
  • power to and communication from the inspection detector 5056 and/or camera 51 12 may be desired.
  • Such power and/or communication of the inspection detector 5056 and/or camera 51 12 may take place with components, such as the one or more processors 5140 and/or a power source, that are outside of the pipe engagement structures (e.g., outside of the clamps 5142, 5144 and/or seals 5146, 5148).
  • the power and/or communication takes place through a hardwired (as opposed to wireless) communication and/or power line
  • such hardwired line may take into account rotation by the rotatable hub 5078, for example, to reduce or prevent twisting and/or tangling of the hardwired line.
  • the hardwired line (which can transmit information and/or power) can be provided with (i) a movable portion that moves with inspection detector 5056 while the inspection detector 5056 directs the inspection beam along the interface region under the rotational force of the one or more orientation motors, and (ii) a stationary portion that remains fixed during movement of the movable portion.
  • the stationary and rotational portions of the hardwired line can be connected via the described slip ring that provides the interface between the movable and fixed portions of the hardwired line to enable the signals to pass from the movable portion to the stationary portion.
  • a single hardwired line e.g., with multiple, discreet wires
  • a plurality of hardwired lines discretate lines for power and communication.
  • on-board power is provided to the inspection detector, then only a communication line may pass through the slip ring. If wireless communication with the inspection detector is provided, then only a power line may pass through the slip ring. If on-board power and wireless communication is provided, then a hardwired communication need not be provided.
  • the inert gas may also be desirable to provide the inert gas to an axial location between the pipe engagement structures (e.g., between clamps and/or seals) through a pneumatic line or tube for carrying pressurized inert gas.
  • a pneumatic line or tube for carrying pressurized inert gas.
  • the pneumatic line can be provided with the stationary portion connected with the inert gas source and the movable portion that extends into the rotatable hub , the movable portion being coupled to the stationaiy portion through the rotary union.
  • the rotary union permits relative rotation between the stationary and movable pneumatic portions.
  • the inspection detector 5056 may be operatively associated with the inspection motor to direct a beam of radiation along the interface region 5136 between the pipes 1022a and 1022b.
  • the inspection detector 5056 and the inspection motor may be operatively associated with one or more processors 5140.
  • the first and second rotation motors 5030 and 5074 together may be interchangeably referred to as the inspection motor.
  • the inspection detector 5056 is configured to detect a characteristic of the interface region 5136 between the pipes 1022a, 1022b.
  • the characteristic of the interface region 5136 may include a gap between the pipes 1022a, 1022b.
  • the characteristic of the interface region 5136 may include a radial offset (e.g., high/low) between the pipes 1022a, 1022b.
  • the characteristic of the interface region 5136 may include geometry at each weld location.
  • the characteristic of the interface region 136 may include chips, gauges, or any irregularities in the pipes 1022a, 1022b.
  • the characteristic of the interface region 5136 may include roundness of the pipes 1022a, 1022b.
  • the characteristic of the interface region 5136 may include contours of bevels of the pipes 1022a, 1022b (after pipe alignment). In one embodiment, the characteristic of the interface region 5136 may include various color regions of the metal of the weld joint/region. For example, these color regions are analyzed to determine what temperatures the different regions of the weld joint/region have reached.
  • the inspection detector 5056 may be configured to detect the characteristic of the interface region 5136 between the pipes 1022a, 1022b, for example, before the weld torch 5502 has been activated to commence securing/welding the pipes 1022a, 1022b to one another.
  • the characteristic of the interface region 5136 may include a pipe bevel geometry, a gap between internal adjoining ends of the pipes 1022a, 1022b (after pipe alignment), a gap between bevels of the pipes 1022a, 1022b (after pipe alignment), etc.
  • the inspection detector 5056 may be configured to detect the characteristic of the interface region 136 between the pipes 1022a, 1022b, for example, 1022b during a welding operation, at a region of the interface prior to weld material being deposited thereon.
  • the characteristic of the interface region 5136 may include a height difference between the bevel edges of the pipes after their alignment.
  • the characteristic of the interface region 5136 may include high-low differences between the adjacent edges of the pipes (e.g., at the interior beveled portions thereof).
  • the inspection detector 5056 may be configured to detect the characteristic of the interface region 5136 between the pipes 1022a, 1022b, for example, subsequent to a welding operation.
  • the characteristic of the interface region 5136 may include a characteristic of the formed weld beads, weld shape parameters such as mismatch, bead concavity, the re-entrant angle.
  • the one or more processors 140 are configured to operate the inspection detector 5056 and the motor 5030, 5074 to scan the interface region 5136 between the pipes 1022a, 1022b.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 between the pipes 1022a and 1022b to determine a profile of the interface region 5136 between the pipes 1022a and 1022b prior to a welding procedure and generate pre-weld profile data based thereon.
  • profile is a generic term in referring to physical attributes of the interface region to be welded between the pipes.
  • profile data refers to data, corresponding to the profile, that can be derived from the interface region. For example, such data can be obtained by scanning the interface region with an inspection detector, such as a laser.
  • the profile data can contain numerous types of information about the profile, such different types of information are referred to herein as "characteristics.”
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 between the pipes 1022a and 1022b during a welding procedure, at a region of the interface 5136 prior to weld material being deposited thereon, and generate on-the-fly profile data.
  • the one or more processors 5140 are configured to generate weld signals to control the weld torch 5502 based on the on-the-fly profile data. The on-the-fly profile data is described in detail below.
  • on-the-fly also means or refers to "real-time,” meaning that the sensing or detection is used by the one or more processors during a current welding operation to control the welder.
  • weld torch trails the inspection detector/inspection laser be a defined amount, some buffering (or slight time delay) takes place between the receipt of the profile data, and the use of such by the one or more processors to control the weld torch.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 between the pipes 1022a and 1022b subsequent to a welding procedure and generate post-weld profile data based thereon.
  • the post-weld profile data is described in detail below.
  • the inspection detector 5056 is configured to work in conjunction with the weld torch 5502 of the weld system 5004 to sense interface joint profile or/and weld material profile to apply weld material to the edge joint in the appropriate location and amount.
  • the inspection detector 5056 is configured to survey the weld and send a signal to the one or more processors 5140 of the articulating weld head 5502 to control movement of the weld head 5502 around the entire edge joint.
  • the weld torch 5502 is configured to follow the inspection detector as the weld head control system continuously receives weld profile information from the edge joint. The information is then used to continuously adjust the weld torch 5502 to achieve the desired weld structure/profile.
  • the internal weld system 5004 may include one inspection detector per weld torch 5502. In one embodiment, the internal weld system 5004 includes three weld torches 5502 and three associated inspection detectors 5056. In another embodiment, the internal weld system 5004 may include two inspection detectors per weld torch 5502. In one embodiment, the number of inspection detectors used in the internal weld system 5004 may vary.
  • the field system 5000 of the present patent application is an intelligent internal inspection system that places the internal automation, including the inspection camera 51 12, the inspection detector 5056, and the weld head or torch 5502 between the spaced clamps 5142, 5144 and the sealed structure 5146, 5148.
  • the field system 5000 of the present patent application is an intelligent internal inspection system that places the inspection camera 51 12 and the inspection detector 5056 between the spaced clamps 5142, 5144 and the sealed structure 5146, 5148.
  • the field system 5000 of the present patent application is an intelligent internal inspection system that places the internal automation, including the inspection camera 5112, the inspection detector 5056, and the weld head or torch 5502 between the spaced clamps 5142, 5144.
  • the weld system is attached to the rear of the line-up clamp, becoming an inline analytical tool that minimizes the downtime associated with using a third- party tool.
  • both the inspection camera 5112 and the inspection detector 5056 are used for inspecting the weld.
  • the inspection camera 51 12 is configured to capture a two-dimensional image of the weld and analyze the color of the weld. Since the color of the weld is indicative of what temperature the material was raised to during the welding procedure, the information obtained by the inspection camera 51 12 helps determine whether the weld was done correctly.
  • the inspection detector 5056 is configured to analyze the profile of the weld.
  • the inspection detector 5056 in conjunction with the two-dimensional (2D) charge-coupled device (CCD) color camera 5112 is configured to perform a root inspection directly after the root and hot pass weld procedures.
  • the weld system 5004 is configured to provide the root pass weld layer profile and the 2D raw color image that show the discoloration and any geometrical defects of the root pass weld layer.
  • the weld system 5004 is configured to create a permanent record of the root pass weld layer profile and visual image that can be stored and replayed in the user's electronic device (e.g., laptop).
  • the inspection performed by the inspection detector 5056 in conjunction with the color camera 51 12 may be used as a reference for the AUT weld inspection. In one embodiment, the inspection performed by the inspection detector 5056 in conjunction with the color camera 51 12 may be used as a "go, no-go" (pass/fail test (or check)) for the root and hot pass welds. In one embodiment, if a root defect is found, the weld joint can be cut and prepped in the same station, far before the defect callout would happen after all the passes had been deposited, so a significant waste of production time can be avoided.
  • the internal weld system 5004 includes a feedback system that is configured to be operatively connected to a plurality of sensors and the one or more processors 5140.
  • the one or more processors 140 are configured to analyze the data provided by the plurality of sensors.
  • one of the plurality of sensors include a temperature sensor that is configured to provide an indication of the temperature(s) of the weld joint and/or monitor the temperature during the welding procedure.
  • one of the plurality of sensors includes a weld material sensor that is configured to monitor the weld material usage during the welding procedure.
  • one of the plurality of sensors may include sensors that are configured to monitor speed and time of the welding procedure.
  • FIG. 41 shows a front perspective view of the weld head assembly 5500
  • FIGS 42 and 43 show rear perspective view of the weld head assembly 5500
  • FIGS. 44-46 show a left side perspective view, a right side perspective view and a cross-sectional view of the weld head assembly 5500, where some components of the weld head assembly 5500 are not shown for sake of clarity.
  • the center section 5008 may have three weld torches 5502. In another embodiment, the center section 5008 may have two weld torches 5502. In yet another embodiment, the center section 5008 may have only one weld torch 5502. In one embodiment, the number of weld torches may vary.
  • the weld head assembly 5500 includes the weld torch 5502 and a weld torch housing assembly 5504.
  • the weld torch 5502 includes a weld tip 5503.
  • the weld head assembly 5500 (the weld torch 5502 and the weld torch housing assembly 5504) is carried by the frame or frame assembly of the internal weld system 5004.
  • the weld torch 5502 is constructed and arranged to feed or guide a consumable electrode wire 5507 into the weld area/zone.
  • the consumable electrode wire 5507 is supplied from a source (e.g., a wire reel or spool) through the wire feed system 5044.
  • the weld torch 5502 is constructed and arranged to be connected to a power supply (e.g., a constant voltage power supply).
  • a power supply e.g., a constant voltage power supply
  • an electric arc forms between a consumable electrode wire 5507 and the pipes 1022a, 1022b, which heats the pipes 1022a, 1022b, causing them to melt, and join.
  • a shield gas is fed through the weld torch 5502, which shields the weld procedure from contaminants in the air.
  • the shield gas is fed to the weld area/zone through the weld torch nozzle that may include a gas cup 5505.
  • the electrode 5507 may extend beyond the end of the gas cup 5505.
  • the shield gas stored in the drive section 5010 is brought to the wire feed assembly 5020 by a hose/shield gas line for distribution to the one or more weld torches 5502.
  • the shield gas control valve 5042 is configured to receive the shield gas from the rear rotary union 5072 (e.g., via the rear slip ring 5080, the rotatable hub 5078 and the front slip ring 5016).
  • the shield gas control valve 5042 is configured to control the flow of the shield gas to the weld torch 5502 through a shield gas line.
  • each weld torch 5502 has a corresponding shield gas control valve 5042 connected to it.
  • the shield gas control valve 5042 is configured to supply the shield gas to the corresponding weld torch 5502, when it receives signals from the wire feed electronics module 5046.
  • the weld torch 5502 is configured to be carried by the frame assembly of the internal weld system 5004 and configured to create a weld at the end of the second end of the first pipe 1022a.
  • the weld torch 5502 is configured to be positioned internally within to the first pipe 1022a and/or second pipe 1022b to provide an internal welding operation.
  • the internally positioned weld torch 5502 is mounted to (positioned on) and connected to the rotatable hub 5078.
  • the weld torch 5502 may have at least three degrees of freedom. In one embodiment, the degrees of freedom of articulation allow the weld torch 5502 to be very effective and efficient in filling in interface profiles optimally and where necessary.
  • the degree of freedom generally refers to the freedom of movement of the weld torch 5502 in the three-dimensional space.
  • the translational movement or displacement generally refers to linear movement or displacement along the three mutually peipendicular X, Y and Z axes.
  • position as used herein generally refers to the translational movement or displacement. In one embodiment, position may be relative or absolute.
  • the coordinate system may include: a Y axis, which is aligned substantially parallel to the longitudinal axis A-A (as shown in FIG. 8) of the pipes 1022a, 1022b; a X axis, which is perpendicular to the Y axis; and a Z axis, which is perpendicular to the Y axis and is aligned substantially parallel to a radial axis R-R (as shown in FIG. 8) of the pipes 1022a, 1022b.
  • the translational movement along the X axis generally refers to a forward and backward movement.
  • the translational movement along the Y axis generally refers to a left to right side movement.
  • the translational movement along the Z axis generally refers to an up and down movement.
  • the rotational movement or displacement generally refers to rotation about these same three mutually perpendicular X, Y and Z axes.
  • the rotation about the three mutually perpendicular X, Y and Z axes is generally referred to as yaw (Z-axis), pitch (Y-axis) and roll (X-axis).
  • the rotational movement about the X axis generally refers to a left or right side tilting movement.
  • the rotational movement about the Y axis generally refers to a forward or (rearward) backward tilting movement.
  • the rotational movement about the Z axis generally refers to a left or right turning movement.
  • orientation as used herein generally refers to the rotational movement or displacement. In one embodiment, orientation may be relative or absolute.
  • the at least three degrees of freedom may include two translational movements of the weld torch 5502 along two of the three mutually perpendicular X, Y and Z axes and one rotational movement of the weld torch 5502 about one of the same three mutually peipendicular X, Y and Z axes.
  • the two translational movements of the weld torch 5502 along two of the three mutually peipendicular X, Y and Z axes may include an up and down movement of the weld torch 5502 and a side to side (e.g., left to right) movement of the weld torch 5502.
  • the up and down movement of the weld torch 5502 may be referred to as a radial movement (i.e., substantially parallel to the radial axis R-R of the pipes 1022a, 1022b) of the weld torch 5502, and the side to side (left to right) movement of the weld torch 5502 may be referred to as an axial movement (i.e., substantially parallel to the longitudinal axis A-A of the pipes 1022a, 1022b) of the weld torch 5502.
  • the one rotational movement of the weld torch 5502 about one of the same three mutually perpendicular X, Y and Z axes may include a forward or (rearward) backward tilting movement of the weld torch 5502.
  • the weld torch 5502 is mounted for movement about a pivot point P (as shown in the FIGS. 54, 56 and 58) at or adjacent to the weld tip 5503 of the weld torch 5502 such that a weld pool created at the weld tip 5503 generally coincides with the pivot point P.
  • the pivot point P is positioned forwardly of the weld tip 5503.
  • the weld torch 5502 has been designed to pivot about the pivot point P (as shown in the FIGS. 54, 56 and 58) where the electrode wire 5507 makes contact with the pipe 1022a, 1022b.
  • the weld torch 5502 is mounted for movement such that it articulates about an axis that is proximate to the weld torch tip 5503.
  • the axis passes through the pivot point P and is substantially parallel to the longitudinal axis A-A of the pipes 1022a, 1022b.
  • the weld torch 5502 is operatively connected to one or more weld torch motors 5596.
  • the one or more weld torch motors 5596 and the weld torch 5502 are configured to be positioned within an interior of the first and/or second pipes 1022a, 1022b.
  • one or more weld torch motors 5596 are configured to move the weld torch 5502 relative to the first and second pipe engagement structures 5052, 5054 after they are fixed relative to the first pipe and second pipe 1022a, 1022b respectively.
  • the one or more processors 5140 are configured to control the one or more weld torch motors 5596 to control a position and orientation of the weld torch 5502.
  • the one or more weld torch motors 5596 may include the radial weld torch motor 5512 that is configured to control the radial position and orientation of the weld torch 5502, the axial weld torch motor 5550 that is configured to control the axial position and orientation of the weld torch 5502 and the tilt weld torch motor 5588 that is configured to control the tilt position and orientation of the weld torch 5502.
  • the motors 5030 and 5074 are configured for moving the weld torch 5502 circumferentially about the interface region 5136 and also to move the inspection detector 5056 about the interface region 5136 simultaneously with the weld torch 5502.
  • the weld torch 5502 is trailing the inspection detector 5056.
  • the front and rear rotation motors 5030 and 5074 are configured to rotate the rotatable hub 5078 and to rotate the weld torches 5502, the inspection detector 5056 and the inspection camera 51 12 all positioned on and connected to the rotatable hub 5078.
  • the front and rear rotation motors 5030 and 5074 may be interchangeably referred to as the circumferential weld torch motors.
  • the one or more processors 5140 are operatively connected with the one or more orientation motors 5030 and 5074 to rotate the first clamp 5142 relative to the second clamp 5144, so as to rotate the first pipe 1022a relative to the second pipe 1022b, based on the instructions from the one or more processors 5140.
  • the motors 5030 and 5074 are configured to move the weld torch 5502 circumferentially about the interface region 136 and are also configured to move the inspection camera 51 12 about the interface region 5136 simultaneously with the weld torch 5502.
  • the weld torch 5502 is trailing the inspection camera 5112.
  • the inspection camera 5112 is trailing the weld torch 5502.
  • the motors 5030 and 5074 are configured to move the weld torch 5502 circumferentially about the interface region 136 and are also configured to move both the inspection camera 51 12 and the inspection detector 5056 about the interface region 5136 simultaneously with the weld torch 5502.
  • the weld torch 5502 is trailing both the inspection detector 5056 and the inspection camera 5112.
  • the weld torch 5502 is trailing the inspection detector 5056 and is leading the inspection camera 51 12.
  • the motors 5030 and 5074 are configured to drive the weld torch 5502 in a first rotational direction during the root pass weld and to drive the weld torch 5502 in a second direction, opposite the first direction, during the hot pass weld.
  • the motors 5030 and 5074 are configured to drive the weld torch 5502 at least 360° relative to the pipe axis A-A (as shown in FIG. 8) so as to complete a rotationally continuous root pass weld.
  • 360° rotation of the weld torch 5502 relative to the pipe axis A-A (around the interior surface of the pipe) is possible because the weld torch 5502 is mounted on the rotatable hub 5078 (i.e., configured to be axial rotation).
  • one or more weld torch motors 5596 are configured to move the weld torch 5502 longitudinally (as shown in FIGS. 48 and 49) within the pipes 1022a, 1022b, toward and away from the inner surface 5130, 5132 (as shown in FIG. 33) of the pipes 1022a, 1022b.
  • one or more weld torch motors 5596 are configured to move the weld torch 5502 angularly relative to the weld (as shown in FIGS. 56 and 58).
  • the motors 5030 and 5074 are configured to move the weld torch 5502 circumferentially along the interface region 5136.
  • the weld head assembly 5500 includes a radial positioning system 5506 that is configured to enable the radial movement of the weld torch 5502, an axial positioning system 5508 that is configured to enable the axial movement of the weld torch 5502. and a tilt positioning system 5510 that is configured to enable the tilt movement of the weld torch 5502.
  • the torch housing assembly 5504 is constructed and arranged to enclose the weld torch 5502, the radial positioning system 5506, the axial positioning system 5508 and the tilt positioning system 5510 therein. In one embodiment, the torch housing assembly 5504 is configured to protect the components of the weld torch 5502 and various components of its positioning systems 5506, 5508, and 5510 from the welding heat and spatter.
  • the torch housing assembly 5504 may include a base member 5509 and two side housing members 551 1 and 5513.
  • the base member 5509 may be connected to the side housing members 551 1 and 5513 using any suitable fastening mechanism (e.g., fastener members 5527).
  • the torch housing assembly 5504 may include a first transverse housing member 5522 and an opposing, second transverse housing member 5523 that are constructed and arranged to connect the side housing members 5511 and 5513 to each other at their top end portions.
  • the first and second transverse housing members 5522, 5523 may be connected to the side housing members 5511 and 5513 using any suitable fastening mechanism (e.g., fastener members 5525).
  • the weld torch 5502 is mounted for movement, by the radial positioning system 5506, such that the weld tip 5503 is configured to move towards and away from the weld surface 5130, 5132 of the pipes 1022a, 1022b.
  • the one or more processors 5140 are configured to control the one or more weld torch motors 5512 to adjust a radial distance of the weld tip 5503 from within the pipes 1022a, 1022b to the interface region 5136.
  • the one or more processors 5140 are configured to control the one or more weld torch motors 5512 to move the weld tip 5503 radially away from the interface region 5136 after the root pass weld so as to accommodate the weld material deposited in the root pass weld and provide a hot pass weld on top of the root pass weld from within the pipes 1022a, 1022b (closer to the longitudinal axis A-A).
  • the one or more processors 5140 that are configured to control the one or more weld torch motors may be part of the wire feed electronics module 5046.
  • the radial positioning system 5506 is configured to enable the weld torch 5502 to move radially to track variations in the pipe shape, to adjust the weld tip- to-work piece (e.g., pipe) distance for multiple passes (e.g., root and hot pass weld procedures), and to retract away from the pipes 1022a, 1022b when the internal weld system is travelling.
  • the weld tip- to-work piece e.g., pipe
  • the radial positioning system 5506 is configured to provide the weld torch 5502 with a 1.25 inch radial travel.
  • the weld torch 5502 is moveable by the radial positioning system 5506 between a normal, non-raised configuration and a raised configuration. As shown in FIG. 43, the weld torch 5502 has been raised (to its raised configuration) by the radial positioning system 5506 so that the weld torch 5502 is positioned at the correct/desired/predetermined distance from the pipes 1022a, 1022b for the welding procedure.
  • the radial positioning system 5506 may include a linear actuator.
  • the radial positioning system 5506 may include the radial weld torch (electric) motor 5512, a lead screw 5514, and a lead nut 5516.
  • the motor 5512 is configured (e.g., mechanically connected) to rotate the lead screw 5514.
  • the motor 5512 is configured to rotate either clockwise or counter clockwise direction so as to cause the raising or lowering of the weld torch 5502 substantially parallel to the radial axis R-R (as shown in FIG. 8) of the pipes 1022a, 1022b.
  • the motor 5512 is configured to be directly connected to rotate the lead screw 5514.
  • the motor 5512 is configured to be indirectly connected, e.g., through a series of gears or a gearbox, to rotate the lead screw 5514.
  • the lead screw 5514 includes threads machined on its outer surface and extending along its length.
  • the lead nut 5516 is constructed and arranged to be threaded onto the lead screw 5514 and includes complimentary threads machined on its inner surface.
  • the radial positioning system 5506 includes two front vertical guide rod members 5 18 and 5520 that are positioned parallel to and on both sides of the lead screw 5514.
  • the front vertical guide rod members 5518 and 5520 are each connected to the base member 5509 of the torch housing assembly 5504 on one end thereof and connected to the first transverse housing member 5522 on the other end thereof.
  • the end portions of the front vertical guide rod members 5518 and 5520 are received in openings formed in the base member 5509 of the torch housing assembly 5504 to connect the front vertical guide rod members 5518 and 5520 to the base member 5509 of the torch housing assembly 5504.
  • the end portions of the front vertical guide rod members 5518 and 5520 are received in openings formed in the first transverse housing member 5522 to connect the front vertical guide rod members 5518 and 5520 to the first transverse housing member 5522.
  • an end portion of the lead screw 5514 (that is opposite to its end portion connected to the motor 5512) is constructed and arranged to pass through an opening 5534 in the first transverse housing member 5522.
  • the radial positioning system 5506 includes two rear vertical guide rod members 5600 and 5602 that are positioned parallel to the lead screw 5514 and the two front vertical guide rod members 5518 and 5520.
  • the rear vertical guide rod members 5600 and 5602 are each connected to the base member 5509 of the torch housing assembly 5504 on one end thereof and connected to the second transverse housing member 5523 on the other end thereof
  • the end portions of the rear vertical guide rod members 5600 and 5602 are received in openings formed in the base member 5509 of the torch housing assembly 5504 to connect the rear vertical guide rod members 5600 and 5602 to the base member 5509 of the torch housing assembly 5504.
  • the end portions of the rear vertical guide rod members 5600 and 5602 are received in openings formed in the second transverse housing member 5523 to connect the rear vertical guide rod members 5600 and 5602 to the second transverse housing member 5523.
  • the radial positioning system 5506 also includes a transverse radial positioning member 5524 and two vertical radial positioning members 5526.
  • the two vertical radial positioning members 5526 are connected to both end portions of the transverse radial positioning member 5524.
  • the transverse radial positioning member 5524 and the two vertical radial positioning members 5526 of the radial positioning system 5506 are configured to be movable during the radial movement of the weld torch 5502.
  • the transverse radial positioning member 5524 may have protruding end portions 5528 that are configured to engage with notches or protruding end portions receiving openings 5530 of the two vertical radial positioning members 5526. In one embodiment, after the protruding end portions 5528 of the transverse radial positioning member 5524 are received in the notches or protruding end portions receiving openings 5530 of the two vertical radial positioning members 5526, the transverse radial positioning member 5524 and the two vertical radial positioning members 5526 may then be securely connected to each other using any suitable fastening mechanism (e.g., fastener members 5532).
  • any suitable fastening mechanism e.g., fastener members 5532
  • the transverse radial positioning member 5524 includes openings to receive the front vertical guide rod members 5518 and 5520 threrethrough. This configuration enables the transverse radial positioning member 5524 to be slidable to adjusted positions on the front vertical guide rod members 5518 and 5520.
  • the lead screw 5514 is configured to pass through a central opening 5536 of the transverse radial positioning member 5524.
  • the radial positioning system 5506 also includes two rear radial positioning members 5604 and 5606. In one embodiment, the two vertical radial positioning members 5526 are connected to the two rear radial positioning members 5604 and 5606. In one embodiment, the two rear radial positioning members 5604 and 5606 and the two vertical radial positioning members 5526 of the radial positioning system 5506 are configured to be movable during the radial movement of the weld torch 5502.
  • each rear radial positioning members 5604 and 5606 have end portions that are configured to engage with end portions of its corresponding vertical radial positioning member 5526. In one embodiment, after the end portions of the rear radial positioning members 5604 and 5606 are engaged with end portions of the two vertical radial positioning members 5526, each rear radial positioning member 5604 and 5606 may then be securely connected to its corresponding vertical radial positioning member 5526 using any suitable fastening mechanism (e.g., fastener members 5608).
  • any suitable fastening mechanism e.g., fastener members 5608
  • the rear radial positioning members 5604 and 5606 include openings to receive the rear vertical guide rod members 5600 and 5602, respectively threrethrough. This configuration enables the rear radial positioning members 5604 and 5606 to be slidable to adjusted positions on the rear vertical guide rod members 5600 and 5602.
  • the lead nut 5516 is configured to interlock with a portion of the transverse radial positioning member 5524 so that the rotation of the lead nut 5516 is prevented along with the lead screw 5514. That is, the lead nut 5516 is restrained from rotating along with the lead screw 5514, therefore the lead nut 5516 is configured to travel up and down the lead screw 5514.
  • the lead nut 5516 is interlocked and positioned in the central opening 5536 of the transverse radial positioning member 5524.
  • the lead screw 5 14 is configured to pass through an opening of the interlocked lead nut 5516.
  • the two vertical radial positioning members 5526 are connected to each other using a front and a rear transverse support members 5610 and 5612.
  • the front transverse support member 5610 is constructed and arranged to be connected to the front, and bottom portions of the two vertical radial positioning members 5526 using any suitable fastening mechanism (e.g., fastener members 5614).
  • the rear transverse support member 5612 is constructed and arranged to be connected to the rear and bottom portions of the two vertical radial positioning members 5526 using any suitable fastening mechanism (e.g., fastener members 5616).
  • the weld assembly 5500 also includes two vertical positioning members 5538 and a top positioning member 5540.
  • the two vertical positioning members 5538 are each connected to end portions of the top positioning member 5540.
  • the end portions of the top positioning member 5540 each may have a L-shaped configuration.
  • corresponding connection portions of the two vertical positioning members 5538 may include complementary shaped configurations that are configured to engage with the L-shaped configurations of the end portions of the top positioning member 5540.
  • the top positioning member 5540 and the two vertical positioning members 5538 may then be securely connected to each other using any suitable fastening mechanism (e.g., fastener members 5542).
  • any suitable fastening mechanism e.g., fastener members 5542.
  • the axial positioning system 5508 is configured to enable the weld torch 5502 to move axially to keep the weld torch 5502 in the weld bevel as the weld torch 5502 travels around the pipe and to allow the weld torch 5502 to oscillate within the weld bevel if needed to completely fill the bevel.
  • FIG. 47 shows the weld torch 5502 positioned in a normal, centered axial position.
  • the axial positioning system 5508 is configured to provide the weld torch 5502 with a +/- 1 inch axial travel.
  • the weld torch 5502 has been moved by the axial positioning system 5508 to +1 inch of axial travel and -1 inch of axial travel, respectively so that the weld torch 5502 is positioned at the correct/desired/predetermined distance from the pipe for welding.
  • FIGS. 50 and 51 show a left side perspective view and an exploded view of the weld head assembly 5500, where some components of the weld head assembly 5500 are not shown for sake of clarity.
  • FIG. 52 shows a bottom perspective view of the top positioning member 5540 of the weld head assembly.
  • FIG. 53 shows a top elevational view of the weld head assembly 5500, where some components of the weld head assembly 5500 are not shown for sake of clarity.
  • the axial positioning system 5508 may be a linear actuator.
  • the axial positioning system 5508 may include the axial weld torch (electric) motor 5550, a lead screw 5552, and a lead nut 5554.
  • the structure, the configuration and the operation of each of the motor 5550, the lead screw 5552 and the lead nut 5554 of the axial positioning system 5508 is similar to the motor 5 12, the lead screw 5514 and the lead nut 5516 of the radial positioning system 5506 and, hence, will not be described in great detail here.
  • the lead screw 5552 is rotated by the motor 5550, the lead nut 5554 is driven along the threads.
  • the axial positioning system 5508 includes two horizontal guide rod members 5556 and 5558 that are positioned parallel to and on both sides of the horizontally positioned lead screw 5552.
  • each of the horizontal guide rod members 5556 and 5558 are connected to the top positioning member 5540 at both of their ends.
  • the end portions of the horizontal guide rod members 5556 and 5558 are received in openings formed in the top positioning member 5540 to connect the horizontal guide rod members 5556 and 5558 with the top positioning member 5540.
  • each of the horizontal guide rod members 5556 and 5558 includes a protruding member 5560 that is configured to be received in a corresponding protruding member receiving portion 5562 formed in the opening of the top positioning member 5540 to secure the horizontal guide rod members 5556 and 5558 with the top positioning member 5540.
  • the weld head assembly 5500 includes a weld torch frame 5564 that is configured to receive the weld torch 5502 therein.
  • the weld torch frame 5564 includes three horizontally extending openings 5566, 5568, and 5570 and a vertically extending opening 5572 formed therein.
  • the horizontal guide rod members 5556 and 5558 are configured to pass through the openings 5566 and 5570 of the weld torch frame 5564, respectively.
  • the horizontally positioned lead screw 5552 is configured to pass through the opening 5568 of the weld torch frame 5564.
  • the weld torch 5502 is configured to pass through the opening 5572 of the weld torch frame 5564.
  • the weld torch frame 5564 may include a support portion 5574 that is configured to support portions of the weld torch 5502, when the weld torch 5502 is received in the opening 5572 of the weld torch frame 5564.
  • a portion 5584 of the weld torch frame 5564 is configured to engage with a portion 5586 of the weld torch 5502 so as to prevent any rotation of the weld torch 5502, when the weld torch 5502 is received in the opening 5572 of the weld torch frame 5564.
  • the motor 5550 is configured (e.g., mechanically connected) to rotate the lead screw 5552.
  • the motor 5512 is configured to rotate either clockwise or counter clockwise direction so as to cause the left or right side movement of weld torch 5502 substantially parallel to the axial axis A-A (as shown in FIG. 8) of the pipes 1022a, 1022b.
  • the motor 5550 is configured to be indirectly connected, e.g., through a series of gears 5576, 5578, and 5580, to rotate the lead screw 5552.
  • the motor 5550 comprises an output shaft 5582 and the motor 5550 is operably connected to the lead screw 5552 through the gears 5576, 5578, and 5580 engaging the output shaft 5582 of the motor 5550.
  • the gear 5576 is connected to the output shaft 5582 of the motor 5550
  • the gear 5580 is connected or attached to the lead screw 5552
  • the gears 5576 and 5580 are coupled to each other via the gear 5578.
  • the motor 5550 is configured to be directly connected (i.e., without the gear arrangement) to rotate the lead screw 5552.
  • the lead nut 5554 is configured to interlock with a portion of the weld torch frame 5564 so that the lead nut 5554 is prevented from rotation along with the lead screw 5552. That is, the lead nut 5554 is restrained from rotating along with the lead screw 5552, therefore the lead nut 5554 is configured to travel/move side to side (i.e., substantially parallel to the axial direction Y-Y as shown in FIG. 53) with the lead screw 5552.
  • the lead nut 5554 is interlocked and positioned in the opening 5568 of the weld torch frame 5564.
  • the lead screw 5552 is configured to pass through an opening of the interlocked lead nut 5554.
  • the tilt positioning system 5510 is configured to enable the weld torch 5502 to change its tilt angle in the plane of travel to account for changes in the direction of welding relative to the direction of gravity.
  • the tilt angle of the weld torch 5502 may be changed to accommodate the force of gravity.
  • the tilt angle of the weld torch 5502 may be adjusted to compensate for different orientation due to gravity.
  • the angular orientation of the weld torch 5502 is controlled based upon the profile of the interface region.
  • the tilt angle of the weld torch 5502 may be adjusted based on the on-the-fly weld profile data.
  • the tilt angle of the weld torch 5502 may be adjusted based on the on- the-fly weld profile data to accommodate and/or compensate for other weld conditions (i.e., not just the force of gravity).
  • the weld torch is able to articulate during the weld operation, it is able to take into account gravitational forces acting on the weld pool, as the weld torch rotates about the fixed pipe.
  • the angle of the weld torch can change by being operated by the at least one weld torch motor (i.e., the tilt weld torch motor 5588), based upon whether the weld is torch it traveling upwardly against the force of gravity, or downwardly with the force of gravity.
  • the one or more motors e.g., tilt weld torch motor 5588
  • the one or more motors can also change the weld angle within to rotational plane based up the specific location within the upwards or downwards travel of the weld torch.
  • weld torch can be articulated for some embodiments, it can be better angled to accommodate the force of gravity, and need not be set in a fixed position under the assumption, for example, that it would only be traveling downwardly, with the force of gravity.
  • welding can be accomplished while the weld torch is moving upwardly (against the force of gravity) or downwardly (with the force of gravity).
  • the weld torch can be articulated based on the different rotational position (e.g., a welding operation conducted at 10 degrees from top dead center may ideally slightly different requirements than a weld conducted at 90 degrees from top dead center, due to (for example) gravitational forces applied to the weld pool, as well as the tendency for the weld pool to adhere to the interior surface of the pipe differently at different positions on the pipe to be welded.
  • a welding operation conducted at 10 degrees from top dead center may ideally slightly different requirements than a weld conducted at 90 degrees from top dead center, due to (for example) gravitational forces applied to the weld pool, as well as the tendency for the weld pool to adhere to the interior surface of the pipe differently at different positions on the pipe to be welded.
  • the motors 5030 and 5074 that direct the inspection detector 5056 also rotates the weld torch 5502 circumferentially about a rotational plane to create the weld along the interface region 5136.
  • the angular orientation of the weld torch 5502 is controlled based upon the position of the torch.
  • the weld torch 5502 is configured to pivot along the weld seam about the rotational plane.
  • the weld torch 5502 may be configured such that the weld torch 5502 may include a different torch tilt angle for each 90° of rotation.
  • the weld torch 5502 may include a tilt angle 1 when performing the weld procedure in a section boundary 1 from 2 o'clock position to 5 o'clock position
  • the weld torch 5502 may include a tilt angle 2 when performing the weld procedure in a section boundary 2 from 5 o'clock position to 8 o'clock position
  • the weld torch 5502 may include a tilt angle 3 when performing the weld procedure in a section boundary 3 from 8 o'clock position to 1 1 o'clock position
  • the weld torch 5502 may include a tilt angle 4 when performing the weld procedure in a section boundary 4 from 1 1 o'clock position to 2 o'clock position.
  • the weld torch 5502 may be configured such that the weld torch 5502 may include a different torch tilt angle for each 30° of rotation. In one embodiment, the weld torch 5502 may be configured such that the weld torch 5502 may include a different torch tilt angle for each 60° of rotation. In one embodiment, the weld torch 5502 may be configured such that the weld torch 5502 may include a different torch tilt angle for each 120° of rotation. In one embodiment, the weld torch 5502 may be configured such that the weld torch 5502 may include a different torch tilt angle for any desired degrees of rotation.
  • the weld torch 5502 may be configured to have a continuously variable torch tilt angle to compensate for or accommodate the continuously changing orientation of the weld torch due to gravity. In one embodiment, the weld torch 5502 may be configured to progressively change the torch tilt angle based upon the position at which the weld torch is (i.e., the position of the weld troch along the circumferential weld).
  • FIG. 54 shows the weld torch 5502 is positioned in a normal, non-tilted position.
  • the tilt positioning system 5510 is configured to provide the weld torch 5502 with a +/- 5° of angular tilt.
  • the weld torch 5502 has been moved by the tilt positioning system 5510 to +5°of angular tilt so that the weld torch 5502 is positioned at the correct/desired/predetermined distance from the pipe for welding.
  • FIGS. 5510 shows the tilt positioning system 5510 to +5°of angular tilt so that the weld torch 5502 is positioned at the correct/desired/predetermined distance from the pipe for welding.
  • the weld torch 5502 has been moved by the tilt positioning system 5510 to - 5° of angular tilt, respectively so that the weld torch 5502 is positioned at the correct/desired/predetermined distance from the pipe for welding.
  • the tilt positioning system 5510 is configured to provide the weld torch 5502 with a +/- 7° of angular tilt.
  • the tilt positioning system 5510 is configured to provide the weld torch 5502 with less than +/- 5° of angular tilt.
  • a circumferential arc between the pivot point P and a point of impingement PI (as shown in FIGS. 56 and 58) of the inspection beam of radiation upon the interface region remains generally constant during a welding procedure.
  • the one or more processors 5140 have knowledge of a constant arcuate distance between the pivot point P (e.g., weld tip) and the point of inspection PI, so that the one or more processors 5140 are configured to control the articulation and pivoting movement of the weld torch 5502 based on the pre-weld profile inspection data.
  • the configuration of the weld torch 5502 that enables the weld torch 5502 to pivot about the pivot point P allows the angle of the weld torch 5502 to be changed while welding without affecting the speed at which the weld torch 5502 is travelling. For example, this is especially useful for weld systems with multiple weld torches. In one embodiment, the weld torches will not have their angles changed at the same time, in which case it would be beneficial for a torch's angle to be changed without any adverse effects on the other weld torches.
  • the tilt positioning system 5510 includes the tilt weld torch motor 5588, guide rail members 5544, and guide rollers 5546.
  • the guide rail members 5544 are configured to be engaged with the guide rollers 5546 to facilitate the tilt positioning of the weld torch 5502.
  • the guide rollers 5546 may include two upper and two lower guide rollers.
  • the tilt positioning system 5510 includes one guide rail member 5544 and its four associated guide rollers 5546 positioned on opposing sides of the weld torch assembly 5500.
  • the guide rollers 5546 are constructed and arranged to be connected to their corresponding vertical positioning members 5538.
  • each vertical radial positioning member 5526 is configured to be connected with a corresponding guide rail member 5544 using any suitable fastening mechanism (e.g., fastener members 5548). This configuration enables each vertical radial positioning member 5526 to be connected to the corresponding vertical positioning members 5538 through the engagement of the corresponding guide rail member 5544 and the guide rollers 5546.
  • the motor 5588 is configured (e.g., mechanically connected) to rotate a gear 5590.
  • the motor 5588 is configured to rotate either clockwise or counter clockwise direction so as to cause the forward or rearward tilt movement of weld torch 5502.
  • the motor 5588 is configured to be connected, e.g., through the gear 5590, to the guide rail member 5544. That is, the motor 5588 comprises an output shaft 5592, and the gear 5590 is connected to the output shaft 5592 of the motor 5588. By connecting the motor 5588 to the guide rail member 5544 through the gear 5590, the guide rail 5544 moves when the motor 5588 operates.
  • the guide rail member 5544 is configured to guide the upper and lower guide rollers 5546.
  • the upper and lower guide rollers 5546 are biased against the guide rail member 5544 such that the upper and lower guide rollers 5546 are configured to cause the corresponding vertical positioning member 5538 (connected thereto) to move and thereby enable the weld torch 5502 to change its tilt angle in the plane of travel.
  • the two opposing vertical positioning members 5538 are connected to each other via the top positioning member 5540 such that the movement in one of the vertical positioning members 5538 (i.e., caused by the motor 5588) causes a similar movement in the other of the vertical positioning members 5538.
  • the configuration of the two horizontal guide rod members 5556 and 5558 being connected to the top positioning member 5540 at both of their ends also facilitates the translation of the movement from one of the vertical positioning members 5538 to the other.
  • the operation of the radial positioning system 5506 is discussed in detail below.
  • the lead screw 5514 is rotated by the motor 5512, the lead nut 5516 is driven along the threads.
  • the direction of motion of the lead nut 5516 depends on the direction of rotation of the lead screw 5514 by the motor 5512.
  • the transverse radial positioning member 5524 is configured to travel/move (up or down) the lead screw 5514 along with the lead nut 5516.
  • the slidable engagement between the transverse radial positioning member 5524 and the front vertical guide rod members 5518 and 5520 also facilitate this (up or down) travel/movement of the transverse radial positioning member 5524.
  • transverse radial positioning member 5524 is connected to the two vertical radial positioning members 5526, the (up or down) movement of the transverse radial positioning member 5524 causes the (up or down) movement of the two vertical radial positioning members 5526.
  • the two vertical radial positioning members 5526 are also connected to the two rear radial positioning members 5604 and 5606.
  • the (up or down) movement of the two vertical radial positioning members 5526 causes the (up or down) movement of the two rear radial positioning members 5604 and 5606 on the rear vertical guide rod members 5600 and 5602.
  • the slidable engagement between the rear radial positioning members 5604 and 5606 and the rear vertical guide rod members 5600 and 5602 also aid the (up or down) travel/movement of the two vertical radial positioning members 5526.
  • each vertical radial positioning member 5526 is connected with the corresponding vertical positioning members 5538 through the engagement of the corresponding guide rail member 5544 and guide rollers 5546.
  • the (up or down) movement of each vertical radial positioning member 5526 also causes the (up or down) movement of its corresponding vertical positioning member 5538.
  • the two vertical positioning members 5538 are securely connected to the top positioning member 5540, the (up or down) movement of the two vertical positioning members 5538 causes the (up or down) movement of the top positioning member 5540.
  • the weld torch 5502 is connected to the top positioning member 5540 via the horizontal lead screw 5552, the two horizontal guide rod members 5556 and 5558 and the weld torch frame 5564, the (up or down) movement of the top positioning member 5540 also causes the (up or down) movement of the weld torch 5502.
  • the weld torch 5502 is mounted for movement, by the radial positioning system 5506, such that the weld tip 5503 is configured to move towards and away from the weld surface of the pipes 1022a, 1022b.
  • the operation of the axial positioning system 5508 is discussed in detail below.
  • the lead screw 5552 is rotated by the motor 5550 via the gears 5576, 5578 and 5580, the lead nut 5554 is driven along the threads.
  • the direction of motion of the lead nut 5554 depends on the direction of rotation of the lead screw 5552 by the motor 5550.
  • the weld torch frame 5564 is configured to travel/move (side to side) along with the lead nut 5554.
  • the slidable engagement between the weld torch frame 5564 and the horizontal guide rod members 5556 and 5558 also facilitate this (side to side) travel/movement of the weld torch frame 5564.
  • the slidable engagement between the two horizontal guide rod members 5556 and 5558 and the weld torch frame 5564 also aid the (side to side) travel/movement of the weld torch frame 5564 (and the weld torch 5502).
  • the amount of the axial movement of the weld torch frame 5564 is restricted by an elongated opening 5594 in the top positioning member 5540.
  • the tilt positioning system 5510 is discussed in detail below.
  • the gear 5590 is rotated by the motor 5588, the guide rail member 5544 is driven along the teeth.
  • the direction of motion of the guide rail member 5544 depends on the direction of rotation of the gear 5590 by the motor 5588.
  • the upper and lower guide rollers 5546 that are biased against the guide rail 5544 are configured to cause the corresponding vertical positioning member 5538 (connected to the guide rollers 5546) to move/tilt.
  • the configuration of the two opposing vertical positioning members 5538 being connected to each other via the top positioning member 5540 is such that the movement in one of the vertical positioning members 5538 (i.e., caused by the motor 5588) causes a similar movement in the other of the vertical positioning members 5538.
  • the configuration of the two horizontal guide rod members 5556 and 5558 being connected to the top positioning member 5540 at both of their ends also facilitates the translation of the movement from one of the vertical positioning members 5538 to the other.
  • the weld torch is mounted for movement in a manner such that when it is driven by the tilt weld torch motor 5588, it is articulated or pivoted about a point that is at, or slightly in front, the weld torch tip.
  • the weld torch tip may articulate about a point that sits in the weld pool that it creates during a welding operation.
  • the position of the weld pool will not change relative to a radius drawn to the weld pool, irrespective of the fact that the weld torch may be articulated by the tilt weld torch motor.
  • arc length between the weld pool and the point at which the radiation beam emitted from the inspection laser impinges upon the inner surface of the pipes to be welded remains constant as the orientation motors rotate the weld torch and the inspection laser, irrespective of the articulation of the weld torch by the tilt weld torch motor.
  • the one or more processors can control weld parameters at a particular region of the interface region, knowing the fixed arc length and based on the processor calculating the detected weld profile at the upcoming region in front of the weld tip.
  • the orientation motors are provided with angular encoders operatively connected to the one or more processors to enable the one or more processors to determine the rotational position of the motors and hence the clamps and pipes as well.
  • signals from the inspection detector e.g., inspection laser
  • the inspection detector e.g., inspection laser
  • the one or more processors knowing the fixed arc length, to control the torch at the appropriate location corresponding to the determined position of the weld torch.
  • the point to articulation of the weld torch need not be at the position in front of, or at, the weld tip, and arc length between the weld pool and point of inspection laser beam impingement upon the interface regions need not remain constant.
  • the one or more processors receiving positional information of the weld torch tip from the one or more weld torch motors and/or the inspection detector is used to calculate the actual position of the weld tip relative to the pipe in real time ("on the fly") in order to control the one or more weld torch motors to position the weld torch tip in the desired location based upon the profile data received from the inspection detector.
  • the weld torch is mounted to be moved or driven by the one or more motors in a generally radial direction, along the longitudinal axis of the weld torch tip, either towards or away from the interior surface of the pipe being welded.
  • the longitudinal axis of the weld torch (e.g., through its weld torch tip) is likely not aligned with the radius of the pipe being welded (taken from the central axis) or the radius of the rotatable central hub, due to the fact that the weld torch is typically angled in a forward weld direction (and articulated by the tilt weld torch motor 5588, when referring to the "radial" movement of the weld torch and its tip towards and away from the interior surface of the pipe (e.g., the interface region), such radial movement is being used in the context described above.
  • such radial movement of the weld torch can be considered to refer to longitudinal movement of the weld torch along the weld torch tip axis. Because the weld torch is mounted for movement by the at least one weld torch motor, and specifically the radial weld torch motor 5512 to enable the torch tip is to move towards and away from the weld surface, the weld tip can be moved further away from the interface region after each weld pass to accommodate for weld material build-up. After the first and second pipe engagement structures are fixed relative to the pipes, the weld torch can be used to complete a full root weld pass, the "root" weld pass being the first weld applied between the pipe ends (e.g., one full 360 degree weld).
  • the weld tip can be moved (retracted) slight away from interior surface of the pipes (and in particular away from the weld material of the applied root pass weld) so that the second weld pass (also referred to as the "hot" pass weld can be conducted with the weld tip at an appropriate distance from the root pass weld material.
  • the one or more processors 5140 operating the motors 5030 and 5074 and the one or more weld torches 5502 to generate a complete circumferential weld along the interface region 5136 by rotating the one or more weld torches 5502 along the interface region 5502 in a single rotational direction until the complete circumferential weld is completed.
  • the one or more weld torches 5502 include a plurality of weld torches. In one embodiment, at least one of the plurality of weld torches weld in an upwards rotational direction while at least another of the plurality of weld torches and weld in an downwards rotational direction.
  • the weld tip is configured to be pointing in the weld direction.
  • the weld torch is always pointing into the direction of travel. That is, basically, the weld tip is pointing generally in the direction of travel.
  • the weld torch tilt angle is slightly higher when the weld torch 5502 is performing an uphill weld procedure (where the weld torch 5502 is welding in an upwards rotational direction) and the weld torch tilt angle is slightly less performing a downhill weld procedure (where the weld torch 5502 is welding in a downwards rotational direction).
  • the internal weld system is configured to perform the downhill weld procedure (i.e., weld in the downwards rotational direction) when using a short-arc weld procedure.
  • the productivity and the quality of the weld may be improved.
  • the uphill weld procedure is configured to provide an option to weld both sides of the pipe at the same time instead of the downhill weld procedure being performed on each side in succession. For example, this may a multi-weld torch operation and having multiple weld overlaps. Alternatively, this may provide an option to weld 360° in one, continuous pass to produce a weld with only one overlap. In one embodiment, the requirements of the customer and the size of the pipe may dictate which approach would be used.
  • the weld may be performed with as many weld torches as they fit inside the pipe.
  • the internal weld system 5004 may include four weld torches, six weld torches, or eight weld torches with half of those weld torches performing the weld in the downwards rotational direction and the other half of the weld torches performing the weld in the upwards rotational direction.
  • the half of those weld torches are configured to perform the clockwise weld procedure and the other half of the weld torches are configured to perform the counterclockwise weld procedure.
  • four weld torches of the internal weld system 5004 may be positioned 90° apart from each other and are configured to rotate 90° each. In one embodiment, six weld torches of the internal weld system 5004 may be positioned 60° apart from each other and are configured to rotate 60° each. In one embodiment, eight weld torches of the internal weld system 5004 may be positioned 45° apart from each other and are configured to rotate 45° each. In one embodiment, the internal weld system 5004 may include two weld torches positioned 180 apart from each other and are configured to rotate 180° each. In one embodiment, the internal weld system 5004 may include one weld torch that is configured to rotate 360°.
  • the ability to weld upwards as well as in the downwards direction may improve weld operation speed (weld throughput time) and also improve weld quality (by taking into account the gravitational forces at different locations). Also, where multiple weld torches are provided, welding can take place both upwardly and downwardly at the same time (e.g., plural, circumferentially spaced weld torches, moving in the same rotational direction and simultaneously applying weld material), with at least one weld torch moving upwards while at least another moves downwards. This is time efficient, for example, in comparison with welding downhill on each side of the pipe in sequence.
  • a single weld torch can be used to conduct a single 360-degree weld to provide a continuous weld, with no overlap of weld portions.
  • Such overlap would occur when more than one weld torch is used and the end of each weld seam portion from a trailing weld torch needs to connect with and slightly overlap with the beginning of the weld seam portion applied by a weld torch in front of the trailing weld torch.
  • the continuous 360-degree internal weld can be useful.
  • the weld torches all point in a forward weld direction. In other words, they are pointed slightly in the weld direction so that the weld torch tip "pushes" the weld, rather than trailing the weld. This is true whether the weld torch is positioned internally, as in some embodiments, or externally as in other embodiments described herein. This is illustrated with respect to internal welder, as shown in FIG. 56A. In one embodiment, the weld torch tips are pointing at an angle ⁇ (e.g., a "lead angle") of between 3 degrees to 7 degrees.
  • ⁇ e.g., a "lead angle
  • the lead angle ⁇ is defined as an angle measured between a line (radius) R from the axial center of the pipes being welded to weld torch tip (or the weld pool) as shown in FIG. 56A (the line R can also be considered the radius taken from the axial center of the rotational hub 5078 to the torch tip or weld pool), and a line passing through the longitudinal axis A of the weld torch tip.
  • the weld torch is being rotationally moved in a counterclockwise direction, as depicted by the arrow D. That lead angle ⁇ can be changed by operation of the tilt weld torch motor 5588 as the weld torch is moved circumferentially around the interior of pipes by the orientation motor.
  • the lead angle ⁇ will be slightly higher (e.g., 6 degrees) when the weld torch is traveling upwardly, and slightly lower (e.g., 4 degrees) when traveling downwardly.
  • the lead angle ⁇ can change continuously throughout the travel of a particular weld torch.
  • the pipe can be divided into sectors, with the weld angle ⁇ being changed based on the sector. For example, in considering the full 360 degrees or movement to correspond to the hour hand on a clock, the pipe can be divided into the various o'clock sectors: 2-5, 5-8, 8-1 1 , 1 1-2.
  • the one or more motors can be operated by the one or more processors to change at the sector boundaries.
  • welding is being conducted in an counterclockwise direction in the depiction shown.
  • the one or more processors 5140 sends a signal to the one or more torch motors so that the gear 5590 is rotated and the weld torch 5502 is pivoted (e.g., about point P), such that the axis through the torch (line A) is moved to the opposite side of the radial line R.
  • the angle ⁇ will be negative for clockwise welding. This will enable the weld torch to point in the forwards direction (“pushing" the weld pool) when welding in the clockwise direction.
  • the internal weld system 5004 may include one weld torch WT, a camera C and two inspection detectors L L and L 2 .
  • the weld torch WT and the camera C are separated by a 180° angle. In one embodiment, the angle between the camera and the weld torch WT may vary.
  • one of the two inspection detectors Li and L 2 may be a leading inspection detector that is configured to lead the weld torch WT during the welding procedure and also to provide pre -weld data.
  • the other of the two inspection detectors Li and L 2 may be a trailing inspection detector that is configured to trail the weld torch WT during the welding procedure and to provide post-weld data.
  • the inspection detector Li and the weld torch WT are separated by a 20° angle. In one embodiment, the inspection detector L 2 and the weld torch WT are separated by a 20° angle. In one embodiment, the angle between the inspection detector L 2 and the weld torch WT and the angle between the inspection detector Li and the weld torch WT may vary.
  • the angle between the inspection detector L 2 and the weld torch WT and the angle between the inspection detector Li and the weld torch WT may be adjustable. For example, in one embodiment, when Li is a leading inspection detector, then the angle between the inspection detector Li and the weld torch WT is 20° or less and the angle between the trailing inspection detector L 2 and the weld torch WT is more than 20°. In one embodiment, when L 2 is a leading inspection detector, then the angle between the inspection detector L 2 and the weld torch WT is 20 or less and the angle between the trailing inspection detector Li and the weld torch WT is more than 20°.
  • the inspection detector Li is positioned at its start position.
  • the weld torch WT starts the welding procedure when the weld torch WT is positioned at StartwT.
  • the weld torch WT is configured to travel in a clockwise direction (as indicated by arrow T during the welding procedure.
  • the weld torch WT ends the welding procedure when the weld torch WT reaches StopwT.
  • the torch WT follows the inspection detector L] during its travel from Startw T to Stopw T in the clockwise direction indicated by the arrow Ti.
  • the weld torch WT is moved in a counter clockwise direction (i.e., opposite to the direction of the arrow Ti) such that the inspection detector L 2 is positioned back at its start position, Startw T - [00662]
  • the weld torch WT starts the welding procedure when the weld torch WT is positioned at Startw T .
  • the weld torch WT is configured to travel in a counterclockwise direction (as indicated by arrow T 2 ) during the welding procedure.
  • the weld torch WT ends the welding procedure when the weld torch WT reaches StopwT.
  • the torch WT follows the inspection detector L 2 during its travel from Startw T to Stopw T in the counterclockwise direction indicated by the arrow T 2 .
  • the internal weld system 5004 may include two weld torches WTi and WT 2 , a camera C and one inspection detector L.
  • the inspection detector L and the weld torch WTi are separated by a 20° angle.
  • the inspection detector L and the weld torch WT 2 are separated by a 20° angle.
  • the inspection detector L and the camera C are separated by a 180° angle.
  • the inspection detector L is positioned at its start position.
  • the weld torch WTi starts the welding procedure when the weld torch WTi is positioned at Startwu.
  • the weld torch WTi is configured to travel in a clockwise direction (as indicated by arrow Ti) during the welding procedure.
  • the weld torch WTi ends the welding procedure when the weld torch WTi reaches Stopwn- In one embodiment, as shown in FIG.
  • a weld bead WB W TI is formed by the weld torch WTi as it travels from Startw T i to Stopwn i the clockwise direction indicated by the arrow T
  • the torch WTi follows the inspection detector L during its travel from Startw T i to Stopwn in the clockwise direction indicated by the arrow ⁇
  • the weld torch WTi is moved in a counter clockwise direction (i.e., opposite to the direction of the arrow Ti) such that the inspection detector L is positioned back at its start position as shown in FIG. 67.
  • the weld torch WT 2 starts the welding procedure when the weld torch WT2 is positioned at StartwT2-
  • the weld torch WT2 is configured to travel in a counterclockwise direction (as indicated by arrow T2) during the welding procedure.
  • the weld torch WT2 ends the welding procedure when the weld torch WT 2 reaches StopwT2.
  • a weld bead WB W T2 is formed by the weld torch WT2 as it travels from Start W T2 to StopwT2 in the counterclockwise direction indicated by the arrow T2 as shown in FIG. 69.
  • the torch WT 2 follows the inspection detector L during its travel from Start W T2 to StopwT2 in the counterclockwise direction indicated by the arrow T 2 .
  • the weld torch WT 2 is moved in a clockwise direction (i.e., opposite to the direction of the arrow T2) such that the inspection detector L is positioned back at its start position as shown in FIGS. 64 and 67.
  • the internal weld system 5004 may include one weld torch and one inspection detector.
  • the angle between the inspection detector and the weld torch may be 20° or less.
  • the inspection detector and the weld torch may be separated by an arc length AL (as shown in FIG. 64) of 3 inches.
  • the inspection detector and the weld torch may be separated by an arc length AL of 4 inches.
  • the angle between the inspection detector and the weld torch is 19°.
  • the angle between the inspection detector and the weld torch is 16°.
  • the angle between the inspection detector and the weld torch is 14°
  • the angle between the inspection detector and the weld torch is 12 .
  • FIG. 70 shows a schematic diagram showing the flow of compressed air through the internal weld system 5004, where some components of the internal weld system 5004 are not shown for sake of clarity and to better illustrate the other components and/or features of the internal weld system 5004.
  • the compressed air tank 5128, the brake cylinder 5133, the drive wheel cylinder 5137, brake valve 5190 and drive wheel valve 5192 are shown in the drive section 5010 of the internal weld system 5004.
  • the rear rotary union 5072, the rear clamp control valve 5062, the rear clamp 5144 and the front clamp 5142 are shown in the center section 5008 of the internal weld system 5004.
  • the front rotary union 5032 and the front clamp control valve 5018 are shown in the forward-most section 5006 of the internal weld system 5004.
  • the compressed air tank 5128 has two separate fluid communication lines connected via a valve 51 13.
  • the compressed air tank 5128 is in fluid communication through fluid communication lines with the brake valve 5190 (and the brake cylinder 5133), the drive wheel valve 5192 (and the drive wheel cylinder 5137), the rear clamp control valve 5062 (and the rear clamp 5144), the rear rotary union 5072, the front rotary union 5032, the front clamp control valve 5018 (and the front clamp 5142), and the compressor 5029.
  • the compressed air stored in the compressed air tank 5128 is sent through the fluid line to a valve 5194.
  • a portion of the compressed air received by the valve 5194 is sent to the brake valve 5190 and the remaining portion of the compressed air received by the valve 5194 is sent to a valve 196.
  • the brake valve 5190 is in fluid communication through lines 5198 and 5199 with the brake cylinder 5133.
  • the brake valve 5190 is configured to supply the compressed air to actuate the brake cylinder 5133, when it receives signals from the drive section electronics module 5118.
  • the compressed air operates the brake cylinder 5133 which through its operation provides a brake force to the drive rollers 5122.
  • the brake cylinder 5133 and the brake valve 5190 may be referred to as a brake system that is configured to secure the frame of the internal weld system 5004 from movement at a desired location within the pipes 1022a, 1022b.
  • the brake system that is configured to secure the frame of the internal weld system 5004 from movement at a desired location within the pipes 1022a, 1022b may include a wheel/roller lock.
  • the wheel/roller lock is configured to prevent the one or more of the rollers 5122 to secure the frame of the internal weld system 5004 from movement.
  • the brake system may also include a motor lock.
  • the motor lock is configured to prevent the rotation of the drive motors 5124 that drive the rollers 5122 for the locomotion of the frame of the internal weld system 5004.
  • a portion of the compressed air received by the valve 5196 is sent to the drive wheel valve 5192 and the remaining portion of the compressed air received by the valve 5196 is sent to a valve 5198.
  • the drive wheel valve 5192 is in fluid communication through lines 5200 and 5201 with the drive wheel cylinder 5137.
  • the drive wheel valve 5192 is configured to supply the compressed air to actuate the drive wheel cylinder 5137, when it receives signals from the drive section electronics module 5118.
  • the compressed air operates the drive wheel cylinder 5137 which through its operation provides a drive force to the drive rollers 5122.
  • the drive wheel cylinder 5137 may be operatively connected to an axle having the drive rollers 5122 thereon.
  • the drive wheel cylinder 5137 may be operatively connected to the axle via one or more gear arrangements.
  • both the drive wheel cylinder 5137 and the brake cylinder 5133 are retracted when loading the internal weld system 5004 into the pipes.
  • the drive wheel cylinder 5137 is retracted only when the internal weld system 5004 is taken out of the pipes.
  • the drive wheel cylinder 5137 is extended to accelerate or decelerate (the travel of) the internal weld system 5004 in the pipes
  • a portion of the compressed air received by the valve 5198 is sent to the rear rotary union 5072 and the remaining portion of the compressed air received by the valve 5198 is sent to the rear clamp control valve 5062.
  • the rear clamp control valve 5062 is in fluid communication through lines 5202 and 5203 with the rear clamp 5144.
  • the fluid communication line 5202 is used for the extension of the clamps 5144 and the fluid communication line 5203 is used for the retraction of the clamps 5144.
  • the rear clamp control valve 5062 is configured to supply the compressed air to actuate and operate the rear clamp 5144, when it receives signals from the center section electronics module 5064.
  • the compressed air output by the rear rotary union 5072 is sent to the front rotary union 5032.
  • the compressed air output by the front rotary union 5032 is sent to a valve 5204.
  • a portion of the compressed air received by the valve 5204 is sent to the front clamp control valve 5018 and the remaining portion of the compressed air received by the valve 5204 is sent to the compressor 5029.
  • the compressor 5029 is configured to recharge the system (e.g., fill the tank with compressed air) using the received compressed air.
  • the front clamp control valve 5018 is in fluid communication through lines 5206 and 5207 with the front clamp 5142.
  • the fluid communication line 5206 is used for the extension of the front clamp 5142 and the fluid communication line 5207 is used for the retraction of the front clamp 5142.
  • the front clamp control valve 5018 is configured to supply the compressed air to actuate and operate the front clamp 5142, when it receives signals from the forward-most electronics module 5014.
  • FIG. 71 shows a schematic diagram showing the flow of power including weld power, communication data, and controls data through the internal weld system 5004, where some components of the internal weld system 5004 are not shown for sake of clarity and to better illustrate the other components and/or features of the internal weld system 5004.
  • the forward-most electronics module 5014, the front rotation motor 5030, the front position sensor 5022, the front clamp control valve 5018, the front slip ring 5016, the wire feed electronics module 5046 of the wire feed assembly 5020, the wire feed systems 5044, and the shield gas control valve 5042 are shown in the forward-most section 5006 of the internal weld system 5004.
  • the rotatable hub 5078, the weld torches 5502, the inspection detectors 5056, the inspection camera 51 12, the front clamp 5142 and the rear clamp 5144, the rear slip ring 5080, the center section electronics module 5064, the rear position sensor 5076, the rear clamp control valve 5062, and the rear rotation motor 5074 are shown in the center section 5008 of the internal weld system 5004.
  • the batteries 51 16, the drive section electronics module 51 18, the brake valve 5190, the drive wheel valve 5192, and the drive motors 5124 are shown in the drive section 5010 of the internal weld system 5004.
  • the weld power is received by the internal weld system 5004 from the umbilical 5034.
  • the weld power, from the umbilical 5034 is supplied to the weld torches 5502 via the front slip ring 5016.
  • the batteries 51 16 of the drive section 5010 are configured to supply the power to all the electronics modules in the internal weld system 5004, including the forward-most electronics module 5014, the wire feed electronics module 5046, the center section electronics module 5064 and the drive section electronics module 51 18.
  • the batteries 5116 of the drive section 5010 are configured to supply the power to all the electric drive motors in the internal weld system 5004, including the front rotation motor 5030, the motors of the wire feed systems 5044, the rear rotation motor 5074, the drive motors 5124, the axial weld torch motor 5550, the radial weld torch motor 5512, and the tilt weld torch motor 5588.
  • the power of the batteries 5116 is directly supplied to the rear slip ring 5080, the center section electronics module 5064 and the drive section electronics module 51 18.
  • the power of the batteries 1 16 is supplied to the front slip ring 5016 via the rear slip ring 5080. That is, the power of the batteries 5116 transfers from the rear slip ring 5080 to the front slip ring 5016.
  • the power from the batteries 5116 is supplied from the front slip ring 5016 to the forward-most electronics module 5014 and the wire feed electronics module 5046.
  • the power of the batteries 51 16 is supplied from the forward- most electronics module 5014 to the front rotation motor 5030 and from the wire feed electronics module 5046 to the motors of the wire feed systems 5044.
  • the power of the batteries 5116 is supplied from the center section electronics module 5064 to the rear rotation motor 5074.
  • the power of the batteries 51 16 is supplied from the drive section electronics module 5118 to the drive motors 5124.
  • the power of the batteries 5116 is supplied from the wire feed electronics module 5046 to the axial weld torch motor 5550, the radial weld torch motor 5512, and the tilt weld torch motor 5588.
  • the batteries 5116 are also configured to supply the power to the inspection camera 51 12 and the inspection detectors 5056.
  • the power of the batteries 51 16 is supplied from the wire feed electronics module 5046 to the inspection camera 51 12 and the inspection detectors 5056.
  • the batteries 5116 are also configured to supply the power to the front position sensor 5022 and the rear position sensor 5076.
  • the power of the batteries 51 16 is supplied from the forward-most electronics module 5014 to the front position sensor 5022 and from the center section electronics module 5064 to the rear position sensor 5076.
  • the batteries 5116 are also configured to supply the power to the front clamp control valve 5018, the shield gas control valve 5042, the rear clamp control valve 5062, the brake valve 5190, and the drive wheel valve 5192.
  • the power of the batteries 51 16 is supplied from the forward-most electronics module 5014 to the front clamp control valve 5018, from the wire feed electronics module 5046 to the shield gas control valve 5042, from the center section electronics module 5064 to the rear clamp control valve 5062, and from the drive section electronics module 5118 to the brake valve 5190, and the drive wheel valve 5192.
  • the internal weld system 5004 is configured to receive and send communication signals via the umbilical 5034 to the external computer system (e.g., have one or more processors).
  • a received communication signal may travel from the umbilical 5034 to the forward-most electronics module 5014, then to the wire feed electronics module 5046 via the front slip ring 5016, then to the center section electronics module 5064 via the rear slip ring 5080, and then to the drive section electronics module 51 1 .
  • a communication signal may travel (in the opposite direction to the received signal) from the drive section electronics module 5118, then to the center section electronics module 5064, then to the wire feed electronics module 5046 via the rear slip ring 5080, then to the forward-most electronics module 5014 via the front slip ring 5016, and to the umbilical (and to the external computer system having one or more processors).
  • the one or more processors 5140 are operatively associated with inspection detector 5056, e.g., inspection laser (or optionally plural inspection detectors 5056 where more than one is provided) through a hardwired communication line or lines 5056a that transmits signals from the inspection laser 5056 to the one or more processors 5140.
  • the hardwired communication line has (i) a movable portion 5056b that moves with inspection detector(s) 5056 while the inspection laser directs the inspection beam along the interface region, and (ii) a stationaiy portion 5056c that remains fixed during movement of the movable portion 5056b.
  • the system further comprises the previously described front slip ring 5016 (which can be, from one perspective, considered part of the hardwired communication line) that provides an interface between a section of the movable portion 5056b and a section of the fixed portion 5056c of the communication line to enable the signals to pass from the movable portion 5056b to the stationary portion 5056c.
  • the previously described front slip ring 5016 (which can be, from one perspective, considered part of the hardwired communication line) that provides an interface between a section of the movable portion 5056b and a section of the fixed portion 5056c of the communication line to enable the signals to pass from the movable portion 5056b to the stationary portion 5056c.
  • the hardwired communication line or lines 5056a are also configured (or alternatively configured if wireless communications are provided for the inspection detectors 5056 to communicate with the one or more processors) to transmit power to the inspection detectors 5056 through the slip ring 5016.
  • the slip ring 5016 comprises an outer stator 5016a and an inner rotor 5016b (see FIG. 26).
  • the inner rotor 5016b and stator 5016a have a bearing 5016k therebetween.
  • the stator 5016a is fixedly mounted with respect to the center frame 5068 (see FIGS. 23 and 24), while the rotor 5016b is connected with the rotatable hub 5078 at its central axis (e.g., see FIG. 24).
  • the rotor 5016b is rotated along with the rotatable hub 5078 when the hub is driven for rotation.
  • the stator 5016a is connected with the stationary portion 5056c of the hardwire communication line, and rotor 5016b connected with the movable portion 5056b of the hardwire communication line, as shown in FIG. 26.
  • the rotor 5016b of the front slip ring 5016 has a hollow cylindrical configuration, with a central passage 5016d therethrough.
  • the passage 5016d allow the passage of other conduits or lines therethrough, and specifically, for example, pneumatic lines from the front rotary union (such as external compressed air lines that will be communicated to compressed air tank 5128).
  • the hardwiring between the inspection detector 5056 and the one or more processors 5140 can, in some embodiments, travel through other components as well.
  • the communication line from the inspection detector 5056 may travel through the wire feed electronics 5046 before being received by the slip ring 5016.
  • the slip ring 5016 permits the movable portion 5056b of the communication line to move with rotatable hub 5078, as the hub 5078 rotates during a scanning operation of the inspection detector 5056, during a pre -weld scan of the interface region between the pipes prior to a welding operation, as well as during the on-the-fly scan of the interface region between the pipes during a welding operation.
  • the slip ring 5016 is further configured to couple the communication connection between the one or more processors 5140 and the inspection camera 5112, as well as provide power to the inspection camera 5112. This can be done through the same hardwired communication line or lines 5056a
  • the one or more processors 5140 are configured to receive camera inspection data from the inspection camera 51 12 prior to, subsequent to, or during a weld operation.
  • the movable portion 5056b moves with the camera (and rotatable hub 5078) while the camera scans the interface region, and stationary portion 5056c remains fixed during movement of the movable portion 5056b that communicates with the camera 5112.
  • slip ring 5016 (and/or slip ring 5080) are configured to communicate power to other components that may rotate with the rotatable hub 5078.
  • power and command lines 5550k for controlling and powering the one or more weld torch motors 5550, 5512, 5588 for controlling the weld torch are all lines that are configured to pass through slip ring 5016.
  • power and command lines 5550k for controlling and powering the one or more weld torch motors 5550, 5512, 5588 for controlling the weld torch are all lines that are configured to pass through slip ring 5016.
  • FIG. 35B weld power lines 5502k for providing weld power to the weld torches 5502
  • the stationary portion of the hardware power line for the weld power line 5502k is labeled as 51 12c and the movable portion of the weld power line is labeled as 51 12b. It can be appreciated that they could alternatively be represented by showing additional lines into the same slip ring 5016, or shown in connection with a separate slip ring.
  • a hardwired communication line 5550k can be provided through slip ring 5016 to provide command (and control), as well as power to the torch motors 5550, 5512, 5588.
  • the movable portion 5550m is of this hardwired line 5550k is shown in Fig. 35B, but not shown in FIG. 26.
  • FIG. 26, as well as FIG. 71, are used to illustrate how slip ring 5016 (or another slip ring) can be used to transmit power and communication to the weld torches 5502 as the weld torches are rotated with the rotatable hub 5078, and as they are powered and controlled to create a weld during a welding operation.
  • the rotatable hub 5078 has a generally hollow cylindrical portion 5078a.
  • the middle of the cylindrical portion at a region that is generally axially aligned with the weld torches, lasers and camera, has a plurality of openings or slots 5078b therethrough.
  • the openings 5078b allow the movable power lines and communication lines from the slip ring 5016 (and optionally from slip ring 5080) to pass radially outwardly from the interior 5078c of the rotatable hub 5078 to the exterior of the hub 5078 for connection with the weld torches, lasers, and camera.
  • the rotatable hub 5078 shown and described herein has a generally cylindrical configuration
  • the hub can be of a different shape.
  • the rotatable hub can be of any tubular shape (e.g., with a hollow square or triangular configuration, just for example).
  • the rotatable hub can also be interchangeably termed a "rotatable frame.”
  • the inspection detector 5056 is mounted on the exterior of the tubular hub, the tubular hub having opposite ends and a radial opening 5078b between the ends.
  • the movable portion 5056b of the power and communication lines extending from the front slip ring 5016 and wire feed electronics module 5046 extends through the interior 5078c of the tubular hub 5078, through the radial opening 5078b, and connected with the one or more inspection detectors 5056.
  • a pneumatic line 5032a carrying shield gas passes through the rear rotary union 5072, through the opening 5080d in the slip ring, and travels through the hollow interior 5078c of the rotatable hub 5078 to one of the shield gas valves 5042 (see FIG. 72), the valves being mounted in the wire feed electronics module 5046 (see FIG. 71) which is mounted on the rotatable hub 5078 for rotation therewith.
  • shield gas an inert gas
  • the pneumatic line 5032a which is a movable line that moves with the rotation of the rotatable hub 5078, after connecting with the shield gas valves 5042, doubles back and again extends through the hollow interior 5078c of the rotatable hub 5078 (thus two lines 5032a are shown in FIG. 24).
  • the pneumatic line 5032a passes through one or more of the openings 5078b so as to be directed into the vicinity of the tip of the weld torch 5502.
  • the pneumatic line 5032a shown in FIG. 35B comprise movable portions of the pneumatic line that will rotate with rotation of the rotatable hub. 5078.
  • FIG. 25 is a partial sectional view of the front rotary union 5032, which is essentially of the same construction of the rear rotary union 5072.
  • the front rotary union 5032 is used to communicate compressed air from an external source 5029 to an on-board compressed air tank 5128.
  • the front rotary union comprises a stator 5032d and a rotor 5032e.
  • the rotor 5032e is mounted on the stator 5032d by ball bearings 5032f.
  • the stator 5032d is fixed relative to the center frame 5068, and the rotor 5032e is coupled to the movable portion 5072d of the pneumatic line, the opposite end of movable portion 5072d connecting with the rotor or the rear rotary union 5072.
  • the movable portion 5072d of the pneumatic line passes through the central passage 5016d of the slip ring 5016 so as to be introduced into the interior 5078c of the rotatable hub 5078 and then to the rotor of the rear rotary union 5072.
  • front slip ring 5016 is illustrated in FIG 26 and the front rotary union 5032 is illustrated in FIG. 25, the same configurations for each will apply to the rear rotary union 5072 and the rear slip ring 5080.
  • FIG. 24 illustrates this attribute in the context of how this applies to the rear slip ring 5080 and rear rotary union 5072.
  • the rear rotary union 5072 has an outer stator 5072a and an inner rotor 5072b.
  • the rotor 5072b receives compressed air from a rotatable pneumatic supply line 5072d (See FIG. 24 and 70; it should be appreciated that FIG. 70 is a schematic drawings and the line 5072d is drawn schematically in FIG. 70, but passes through the interior 5078c of the rotatable hub as shown in FIG. 24).
  • the rotatable supply line 5072d is connected at its opposite end to the rotor of the front rotary union 5032. Specifically, the external supply tank 5029 first passes the compressed gas through the stator of the front rotaiy union 5032 and then exits out through the rotor of the front rotary union 5032.
  • the front rotary union 5032 has its rotor operatively connected with the rotatable hub 5078 so as to be rotatable together.
  • the rotatable supply line 5072d passes from the rotor of the front rotary union 5032 to the rotor 5072b of the rear rotaiy union 5072.
  • the compressed air passed through the stator 5072a of the rear rotary union to a stationary pneumatic supply line 5072f extending therefrom.
  • the fixed pneumatic supply line 5072f is connected through valves to the compressed air tank 5128, which receives compressed air from the external supply tank 5029 periodically, when tank 5128 is depleted.
  • the rotatable supply line 5072d passes from the rotor 5072b through the central opening 5080d in the rear slip ring 5080.
  • the movable pneumatic supply line 5072d then passes through the through passage 5078c within the rotatable hub 5078 for connection with the front rotary union 5032.
  • the rear slip ring 5080 has an inner rotor 5080r, an outer stator 5080s, and a bearing 5080m therebetween.
  • the rear rotary union 5072 also has another stationary line 5072g that receives shield gas from the shield gas tanks 5262 to be described in greater detail later.
  • the shield gas passes from the stator 5072a to the rotor 5072b, and then out from the rotor through the movable pneumatic line 5032a.
  • the movable pneumatic line 5032a passes through the opening 5080d in the slip ring and into passage 5078c.
  • the pneumatic line 5032a moves with the rotation of the rotatable hub 5078.
  • the opposite end of the pneumatic line 5032a connects with the shield gas valves 5042 and then doubles back (hence two lines 5032a shown in FIG. 24) and passes to weld torches 5502. In traveling to the weld torches 5502, the movable pneumatic line 5032a passes through the openings 5078b in the rotatable hub 5078, as can be appreciated from FIG. 72.
  • the front rotary union 5032 is illustrated as having two inlet and outlet ports. As shown, only one of the ports for communicating compressed air through pneumatic line (stationary portion 5032c and movable portion 5072d) is used. The other ports are not functional for the front rotary union, but both ports will be used for the rear rotary union 5072 as will be appreciated from the above description.
  • wireless communication may be provided to/from the inspection detector, camera and/or weld torch, in which case the use of a slip ring for certain functionality can be by passed.
  • the communications signals may not traverse the entire communication path between the umbilical 5034 and the drive section electronics module 51 18 and may travel between specific devices/modules of the communication path.
  • all the electronics modules in the internal weld system 5004 may each include a memory, a secondary storage device, and one or more processors configured to perform system controls.
  • all the electronics modules in the internal weld system 5004 may be configured to receive, process, store, retrieve and transmit signals (sensor or control) and data.
  • these electronics modules may contain other components.
  • various circuitry such as, for example, power supply circuitry, signal conditioning circuitry, solenoid driver circuitry, and/or any other circuitry that is known in the art may be incorporated in the electronics modules.
  • all the electronics modules in the internal weld system 5004 may be configured to transmit control signals that are used to direct the operation of the devices operatively connected thereto and receive data or other signals (sensor) from the devices operatively connected thereto.
  • the forward-most electronics module 5014 is operatively coupled to the front rotation motor 5030, the front position sensor 5022, and the front clamp control valve 5018.
  • the forward-most electronics module 5014 is configured to transmit control signals to control the operation of the front rotation motor 5030 and the front clamp control valve 5018 and receive sensor signals from the front position sensor 5022.
  • the wire feed electronics module 5046 is operatively coupled to the shield gas control valve 5042, the motors of the wire feed systems 5044, the axial weld torch motor 5550, the radial weld torch motor 5512, and the tilt weld torch motor 5588. In one embodiment, the wire feed electronics module 5046 is configured to transmit control signals to control the operation of the shield gas control valve 5042, the motors of the wire feed systems 5044, the axial weld torch motor 5550, the radial weld torch motor 5512, and the tilt weld torch motor 5588.
  • the center section electronics module 5064 is operatively coupled to the rear rotation motor 5074, the rear position sensor 5076, and the rear clamp control valve 5062. In one embodiment, the center section electronics module 5064 is configured to transmit control signals to control the operation of the rear rotation motor 5074 and rear clamp control valve 5062, and receive sensor signals from the rear position sensor 5076.
  • the drive section electronics module 51 18 is operatively coupled to the drive motors 5124, the brake valve 5190, and the drive wheel valve 5192.
  • the drive section electronics module 5118 is configured to transmit control signals to control the operation of the drive motors 5124, the brake valve 5190, and the drive wheel valve 5192.
  • FIG. 72 shows a schematic diagram showing the flow of shield gas through the internal weld system 5004, where some components of the internal weld system 5004are not shown for sake of clarity and to better illustrate the other components and/or features of the internal weld system 5004.
  • an inert/shield gas supply line is configured to direct inert/shield gas from the inert/shield gas source 5262 to a region between the first and second clamps 5142, 5144, and towards a region in a vicinity of the weld tip 5503 of the weld torch 5502, to reduce oxygen in the vicinity of the weld tip 5503 during a welding operation.
  • the shield gas tanks 5262 are shown in the drive section 5010 of the internal weld system 5004.
  • a high pressure regulator 5264 may be positioned in the drive section 5010 of the internal weld system 5004.
  • the high pressure regulator 5264 may be positioned in the center section 5008 of the internal weld system 5004.
  • the rear rotary union 5072, the welding torches 5502, the rotatable hub 5078, the front and rear clamps 5142, 5144, and the front and rear clamps 5142 and 5144 are shown in the center section 5008 of the internal weld system 5004.
  • the front and rear seals 5146 and 5148 may be positioned in the center section 5008 of the internal weld system 5004.
  • the shield gas valves 5042 are shown in the forward- most section 5006 of the internal weld system 5004.
  • the shield gas tanks 5262 are configured to be maintained at a pressure of 500-2400 psi.
  • the shield gas tanks 5262 are in fluid communication through fluid communication lines with the rear rotary union 5072.
  • the shield gas tanks 5262 are in fluid communication with the rear rotary union 5072 via a valve 5266 and the high pressure regulator 5264.
  • the high pressure regulator 5264 is configured to automatically cut off the flow of the purge gas at a pressure of 75 psi. That is, the high pressure regulator 5264 is typically set to reduce the pressure in the shield gas tanks 5262 to about 75 psi in the fluid communication line downstream of the high pressure regulator 5264, and from the rear rotary union 5072 to the shield gas valves 5042.
  • the rear rotary union 5072 is in fluid communication through fluid communication lines with the shield valves 5042.
  • the shield gas stored in the shield gas tanks 5262 is sent through the fluid communication lines to the rear rotary union 5072, and then through the fluid communication lines from the rear rotary union 5072 to the shield gas valves 5042.
  • each shield gas control valve 5042 is configured to control the flow of the shield gas to the corresponding weld torch 5502 through a shield gas line 5268.
  • each weld torch 5502 has a corresponding shield gas control valve 5042 connected to it.
  • the shield gas control valve 5042 is operatively connected to receive control signals from the wire feed electronics module 5046.
  • the shield gas control valve 5042 is configured to supply the shield gas to the corresponding weld torch, when it receives signals from the wire feed electronics module 5046.
  • the drive section 5010 of the internal weld system 5004 may include the purge gas tanks, the shield gas tanks 5262 and the compressed air gas tanks.
  • the shield gas from the shield gas tanks 5262 is only used to supply shield gas to the weld torches 5502.
  • separate purge gas tanks may be configured to fill and maintain the purge gas in the purge gas chamber.
  • the compressed air is used to inflate the seals 5146 and 5148 and to expand the clamps 5142 and 5144.
  • the drive section 5010 of the internal weld system 5004 may include the compressed air gas tanks and the purge/shield gas tanks. That is, the shield and purge gas tanks are one and the same.
  • the compressed air from the compressed air gas tanks is used to inflate the seals 146 and 148 and to expand the clamps 5142 and 5144.
  • the seals 5146 and 5148 are optional in the internal weld system 5004.
  • the shield gas to the weld torches 5502 and the purge gas to the purge gas chamber are supplied by the same gas tank having purge/shield gas. In one embodiment, the supply of the purge gas to the purge gas chamber is optional.
  • the drive section 5010 of the internal weld system 5004 may only include the purge/shield gas tanks (i.e., no compressed air gas tanks). This may be the case for small internal weld systems.
  • the purge/shield gas tanks are configured to supply the purge/shield gas to the weld torches 5502, the purge/shield gas to the purge gas chamber, and the purge/shield gas to inflate the seals 5146 and 5148 and to expand the clamps 5142 and 5144.
  • the seals 5146 and 5148 are optional in the internal weld system 5004.
  • the supply of the purge gas to the purge gas chamber is optional.
  • FIGS. 72A, 72B and 72C show close-up views of the internal weld torch used in a prior art system and the internal weld system 5004, respectively, where the pipes have a gap and radial offset (Hi-Lo) alignment.
  • the pipes 1022a, 1022b have a 1 millimeter gap and radial offset (Hi-Lo).
  • the raised edge of the pipe shields the left side of the weld groove causing reduced weld penetration.
  • the one or more processors 5140 associated with the internal weld system 5004 are configured to receive weld profile data (e.g., prior to, during and subsequent to the welding procedure) and are configured, based on the received weld profile data, to shift its internal weld torch 5502 and/or to tilt its external weld torch 5502 to achieve a full weld penetration.
  • weld profile data from the internal weld system 5004 may be used to make better weld.
  • the one or more processors 5140 are configured to receive profile data related to welding of the interface region 5136 between the first pipe 1022a and the second pipe 1022b from the field system 5000. In one embodiment, the related profile data is based on a scan of the interface region 5136 between the pipes 1022a, 1022b. In one embodiment, the one or more processors 5140 are configured to compare one or more characteristics of the related profile data with one or more predefined profile characteristics to generate a response to the field system 5000. In one embodiment, the one or more processors 5140 are configured to transmit the response to the field system 5000 to cause the field system 5000 to perform one or more operations based on the response.
  • the one or more processors 5140 are configured to transmit a signal to the field system 5000 to stop welding-related procedure, change or develop a welding protocol, save or further analyze profile data of the interface region 5136, save or further analyze pre-weld profile data, save or further analyze post-weld profile data, affirm or modify a version thereof, etc.
  • the one or more processors 5140 are operatively associated with the inspection detector 5056 to determine a profile of the interface region 5136 between the pipes 1022a, 1022b.
  • the weld torch 5502 is configured to create a weld at the interface region 5136 between the pipes 1022a, 1022b based on the profile of the interface region 5136 between the pipes 1022a, 1022b.
  • the weld torch e.g., of the external weld system 7500
  • the one or more processors 5140 are configured to receive inspection data from the inspection detector 5056 prior to, subsequent to, or during a weld operation. In one embodiment, the one or more processors 5140 are configured to receive camera inspection data from the inspection camera 51 12 prior to, subsequent to, or during a weld operation. In one embodiment, the one or more processors 5140 are configured to receive inspection data from the inspection detector 5056 and the camera inspection data from the inspection camera 5112 prior to, subsequent to, or during a weld operation. [00726] In one embodiment, the inspection camera 5112 is configured to scan the welded interface region 5136 after a welding operation.
  • the inspection camera 51 12 is configured to send signals to the one or more processors 5140 based on the scan. In one embodiment, the one or more processors 5140 are configured to determine a characteristic of the welded interface region 5136 based on the signals from the inspection camera 51 12.
  • the one or more processors 5140 are configured to analyze the data to automatically detect undercuts or other shape deviations.
  • a characteristic of the interface region 5136 if a characteristic of the interface region 5136 is greater than a predetermined threshold, it may be referred to as an undesirable characteristic of the interface region 5136. In one embodiment, if a characteristic of the interface region 5136 is greater than a predetermined threshold and a difference between the characteristic and the predetermined threshold is falling within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the interface region 5136 does not need correction. In one embodiment, if a characteristic of the interface region 5136 is greater than a predetermined threshold and a difference between the characteristic and the predetermined threshold is not falling within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the interface region 5136 needs correction.
  • a characteristic of the interface region 5136 is less than a predetermined threshold, it may be referred to as undesirable characteristic of the interface region 5136. In one embodiment, if a characteristic of the interface region 5136 is less than a predetermined threshold and a difference between the characteristic and the predetermined threshold is falling within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the interface region 5136 does not need correction. In one embodiment, if a characteristic of the interface region 5136 is less than a predetermined threshold and a difference between the characteristic and the predetermined threshold is not falling within a predetermined acceptable/allowable range, it is determined that the undesirable characteristic of the interface region 5136 needs correction.
  • a characteristic of the interface region 5136 if a characteristic of the interface region 5136 is not within a predetermined range, it may be referred to as undesirable characteristic of the interface region 5136. In one embodiment, if a characteristic of the interface region 5136 is not within a predetermined range and is falling within an acceptable/allowable range, it is determined that the undesirable characteristic of the interface region 5136 does not need correction. In one embodiment, if a characteristic of the interface region 5136 is not within a predetermined range and is not falling within the acceptable/allowable range, it is determined that the undesirable characteristic of the interface region 5136 does not need correction.
  • the one or more processors 5140 are configured to receive the electronic signals (e.g., generated by the receiver of the inspection detector 5136) to determine whether the undesirable characteristic of the interface region 5136 should be corrected. In one embodiment, in response to detecting one or more undesirable characteristics of the interface region 5136, the one or more processors 5140 are configured to send instructions to the motor 5030, 5074 controlling an axially rotational position of one of the pipes to cause the motor 5030, 5074 to rotate the one of the pipes 1022a, 1022b relative to the other of the pipes 1022a, 1022b to correct the undesirable characteristic. In one embodiment, the motor 5030, 5074 is configured for moving a radially extending clamp 5142, 5144.
  • the weld torch 5502 operatively connected with the one or more processors 5140, is configured to perform a weld operation to weld the pipes 1022a, 1022b together in response to the one or more processors 5140 detecting that no undesirable characteristics exist.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 between the pipes 1022a, 1022b prior to a welding operation and generate pre-weld profile data based thereon. In one embodiment, the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the entire interface region 5136 between the pipes 1022a, 1022b to generate the pre-weld profile data prior to weld material being applied to weld the two pipes 1022a, 1022b together.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 to obtain the pre-weld profile data subsequent to the first clamp 5142 and the second clamp 5144 engaging with the first pipe and second pipe 1022a, 1022b, respectively.
  • the one or more processors 5140 are configured to interact with the inspection camera 51 12, x-ray radiography inspection device, gamma ray inspection device, ultrasonic inspection device, magnetic particle inspection device, eddy current inspection device or other inspection devices to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 prior to the welding operation.
  • the pre-weld scan inspection procedure is the same for the tie-in internal weld system 3001 and the purge and inspection system 7001, and, therefore, will not be described again with reference to the tie-in internal weld system 3001 and the purge and inspection system 7001.
  • the "pre-weld" profile data described herein refers to data obtained from the inspection detector (e.g., such as by an inspection laser) that has scanned the interface region between two pipes to be welded before the weld torch has been activated to commence securing the pipes to one another.
  • This pre-weld profile data is communicated to the one or more processors to determine whether the pipes are sufficiently aligned prior to any weld material being deposited to the interface region.
  • the one or more processors are configured to send signals to the cradles that engage with the exterior surfaces of the pipes.
  • One or both of the cradles can be adjusted based on output signals from the pre-weld profile data to adjust relative positioning between the pipes to bring the alignment of the interface region within an acceptable misalignment value.
  • the pre-weld profile data may include pipe ovality/roundness data.
  • the pipe ovality/roundness data may include location and size of minimum inner diameter, location and size of maximum inner diameter, pipe average inner diameter, pipe average wall thickness, location and size of minimum wall thickness, and/or location and size of maximum wall thickness.
  • the pipe ovality/roundness data may include a comparison between each of location and size of minimum inner diameter, location and size of maximum inner diameter, location and size of minimum wall thickness, and location and size of maximum wall thickness, and their respective predetermined values.
  • the pipe ovality/roundness data may include a comparison between each of pipe average inner diameter and pipe average wall thickness, and their respective predetermined values.
  • the pipe ovality/roundness data may include inner diameter deviations of the pipe at all locations on the circumference of the pipe based on the comparison.
  • the pre-weld profile data may include pipe bevel profile data.
  • the pipe bevel profile data may include pipe bevel geometry.
  • the pipe bevel profile data may include a comparison between each of size and shape of the pipe bevel, root face (land) thickness of the pipe bevel, bevel angle of the pipe bevel, offset of the pipe bevel, and root angle of the pipe bevel, and their respective predetermined values.
  • the pipe bevel profile data may include pipe bevel deviations of the pipe at all locations on the circumference of the pipe based on the comparison.
  • the pre-weld profile data may include weld joint fit-up and alignment data.
  • the weld joint fit-up and alignment data may include data on the gap between internal adjoining ends of the pipes (after pipe alignment).
  • the weld joint fit-up and alignment data may include data on the gap between bevels of the pipes (after pipe alignment).
  • the weld joint fit-up and alignment data may include location and size of minimum gap, location and size of maximum gap, and/or average gap.
  • the weld joint fit-up and alignment data may include a comparison between each of location and size of minimum gap, and location and size of maximum gap, and their respective predetermined values.
  • the weld joint fit-up and alignment data may include a comparison between average gap and its respective predetermined value. In one embodiment, the weld joint fit-up and alignment data may include gap deviations of the pipes at all locations on the circumference of the pipes based on the comparison. In one embodiment, the weld joint fit-up and alignment data may include the minimal differences in height between the pipes (e.g., what is acceptable alignment), etc.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 subsequent to the first clamp 5142 and the second clamp 5144 engaging with the first pipe 1022a and second pipe 1022b, respectively. In one embodiment, the one or more processors 5140 are configured to be operatively connected with the first pipe engagement structure 5052 and the second pipe engagement structure 5054. In one embodiment, the one or more processors 5140 are configured to operate the first pipe engagement structure 5052 and/or the second pipe engagement structure 5054 based on the pre-weld profile data to alter the interface region 136 between the pipes 1022a, 1022b prior to the welding operation.
  • the one or more processors 5140 are configured to alter the interface region 5136 between the pipes 1022a, 1022b prior to the welding operation by driving the first pipe engagement structure 5052 and/or the second pipe engagement structure 5054 to change the roundness (or ovality) of the first pipe 1022a and/or second pipe 1022b based on the pre-weld profile data.
  • the one or more processors 5140 are configured to alter the interface region 5136 between the pipes 1022a, 1022b prior to the welding operation by selectively driving the one or more clamp shoes 5157 of the clamps 5142 and/or 5144 to change the roundness of the first pipe 1022a and/or second pipe 1022b based on the pre-weld profile data.
  • the one or more processors 5140 are configured to alter the interface region 5136 between the pipes 1022a, 1022b prior to the welding operation by driving the first pipe engagement structure 5052 and/or the second pipe engagement structure 5054 to rotate and/or axially move the first pipe 1022a and/or second pipe 1022b based on the pre-weld profile data. In one embodiment, the one or more processors 5140 are configured to alter the interface region 5136 between the pipes 1022a, 1022b prior to the welding operation by rotating one pipe 1022a or 1022b relative to the other 1022a or 1022b.
  • the one or more processors 5140 are configured to develop a welding protocol based on the pre-weld profile data.
  • the welding protocol includes a welding speed and weld torch position protocol.
  • the one or more processors 5140 are configured to operate the cradles 5330 (as shown in FIGS. 10A and 10B) or 6010A and 6010B (as shown in FIG.73) for providing the incoming pipe 1022a at the second end of the pipe 1022b (after the frame assembly of the internal weld system 5004 is positioned at the second end of the pipe 1022b) based on the pre-weld profile data to alter interface region 5136 between the pipes 1022a, 1022b prior to the welding operation.
  • the one or more processors 5140 are configured to control the externally positioned rollers 5332 the cradles 5330 for providing the incoming pipe 1022a at the second end of the pipe 1022b (after the frame assembly of the internal weld system 5004 is positioned at the second end of the first pipe 1022b) based on the pre-weld profile data.
  • the one or more processors 5140 are configured to operate the cradles 5330 (as shown in FIGS. 10A and 10B) or 6010A and 6010B (as shown in FIG.73) to generate relative movement between the first pipe 1022a and second pipe 1022b based on the pre-weld profile data to alter interface region 5136 between the pipes 1022a, 1022b prior to the welding operation.
  • an exterior surface 5346 and/or 5348 (as shown in FIG. 2G) of the first pipe 1022a and/or second pipe 1022b is engaged to adjust the relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determines adjustment is required.
  • the cradles 5330 (as shown in FIGS. 10A and 10B) and 601 OA and 601 OB (as shown in FIG. 73) are operated by the one or more processors 5140 (or otherwise controlled) to engage the exterior surfaces 5346 and/or 5348 (as shown in FIG. 2G) of the first pipe 1022a and/or second pipe 1022b to adjust the relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determines adjustment is required.
  • the first clamp and/or the second clamp 5142, 5144 are released to enable adjustment of relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determined adjustment is required.
  • the first and second clamps are internally positioned clamps and are released to enable adjustment of relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determined adjustment is required.
  • the first and second clamps are externally positioned clamps and are released to enable adjustment of relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determined adjustment is required.
  • the first and second clamps include both internally positioned clamps and the externally positioned clamps. In one embodiment, both the internally positioned clamps and the externally positioned clamps are released to enable adjustment of relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determined adjustment is required.
  • the adjustment of the relative positioning of the pipes 1022a, 1022b may be either automatically performed by the processors 5140 controlling the externally positioned rollers 5332 (as shown in FIGS. 10A and 10B) or performed by an operator using a crane and (internal and/or external) clamps.
  • the adjustment of the relative positioning of the pipes 1022a, 1022b may also be referred to as re-alignment of the pipes 1022a, 1022b.
  • the adjustment of the relative positioning of the pipes 1022a, 1022b may include an adjustment along the longitudinal axis of the pipes 1022a, 1022b, and/or an adjustment along the radial axis of the pipes 1022a, 1022b.
  • the adjustment of the relative positioning of the pipes 1022a, 1022b may include position adjustment and orientation adjustment of the pipes 1022a, 1022b.
  • the adjustment of the relative positioning of the pipes 1022a, 1022b (based on the pre-weld profile data) may include up and down movement and longitudinal movement (along the longitudinal axis of the pipes 1022a, 1022b).
  • the internal and/or external clamp(s) (holding the pipes 1022a, 1022b in place during the pre-weld procedure) are released and a crane, electronically controlled externally positioned rollers 5332 or other such devices may be used to maneuver the pipe based on the pre-weld profile data.
  • the internal and/or external clamp(s) (holding the pipes 1022a, 1022b in place during the pre-weld procedure) are released before the re-alignment procedure.
  • the pipes 1022a, 1022b are clamped back using the external and/or internal clamps.
  • a new pipe to be welded 1022a may be rotated about its longitudinal axis relative to the prior pipe that has been welded 1022b, based on the pre-weld profile data that has been obtained from the inspection detector (e.g., the inspection laser) 5056.
  • the pre-weld profile data can be used to determine that, in some instances, the relative rotational positions of the pipes 1022a and 1022b can be changed to effect a better match for welding.
  • the inspection detector 5056 can generate signals that are processed by the one or more processors 5140 to determine a more beneficial rotational position for the incoming pipe 1022a to be welded. Such rotation can be accomplished by the one or more processors 5140 activating the front rotation motor 5030 to rotate the pipe 1022a prior to a welding operation. In particular, to rotate the incoming pipe 1022a, the center frame 5068 remains rotatably fixed with respect to the previously welded pipe.
  • This rotationally fixed relationship between the center frame 5068 and pipe 1022b is accomplished by having the rear clamp 5144 actuated by the one or more processors 5140 to be securely engaged with the interior surface of pipe 1022b to prevent relative rotation therebetween.
  • the rear rotation motor 5074 is not activated by the processor 5140 and its motor shaft is locked from rotation.
  • the entire rotatable hub 5078 remains rotatably fixed relative to the center frame 5068 and the pipe 1022b.
  • the front rotation motor 5030 is then activated. Its shaft rotates to drive the gear train as shown in Fig.
  • the clamp 5142 rotates around the rotatable hub 5078 on the bearings 5108, 5098 that are between the clamp 5142 and the rotatable hub 5078. Because the clamp 5142 is extended and clamped to the interior surface of the pipe 1022a, the pipe 1022a is rotated as a result to the located determined by the one or more processors 5140 based upon the pre-weld scanned information received from the inspection detector 5056.
  • rollers 5332 on the external cradle (5330, 6010A, 6010B) are instructed by the one or more processors 5140 to optionally be in a freewheeling state where they are passive, or optionally the one or more motors operatively connected with the rollers 5332 are instructed by the one or more processors 5140 to drive to rollers 5332 at a rotational speed commensurate with (similar to or the same as) the speed at which the front rotation motor 5030 drives the rotation from inside the pipe 1022a.
  • This latter approach provides rotational forces to the pipe 1022a from both inside and outside the pipe, although in some embodiments, either driving force alone may be sufficient.
  • the clamps 5142 and 5144 are engaged with the associated pipes 1022a and 1022b to prevent relative rotation between the frame 5026 and pipe 1022a, and to prevent rotation between the center frame 5068 and the pipe 1022b.
  • the clamps 5142 and 5144 need not be responsible for this function.
  • wheels operatively associated with both frames may be configured to engage the associated pipes with sufficient friction and/or outward force to prevent relative rotation between the pipes and frames.
  • the wheels the effect or permit locomotion between the frames and the pipes permit generally longitudinal movement only between the frames and pipes and prevent relative rotational movement therebetween. This can be true for wheels on one or more of the frames.
  • the wheel engagement option can be used on only one of the frames, on both of the frames, and can optionally be used in combination with the clamping methodology for one or both of the frames.
  • the pipe rotation techniques described herein can also be used to return the frames to a desired "start” or “home” rotational position after a welding operation is completed and a new pipe comes in for the next pre-weld scan.
  • the one or more processors 5140 are configured to send the pre -weld profile data to a remote processor for further processing.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 136 between the pipes 1022a, 1022b during a welding operation, at a region of the interface prior to weld material being deposited thereon, and generate on-the-fly profile data.
  • the on-the-fly profile data refers to data obtained from the inspection detector during a welding operation.
  • the on-the-fly profile data is taken from a position immediately before (in front of) the region that is being welded (for example, 1-6 inches in front of the region being welded).
  • the inspection detector scans the interface region in the region about to be welded so as to provide data on the profile of the interface region immediately before the weld material is deposited.
  • the profile of the interface region between the pipes may change slightly as increasing more of the interface region is welded. In other words, the sequential welding itself may slightly alter the alignment/positioning of the pipes at the interface region at the portions of the interface region yet to be welded.
  • the inspection detector measures the profile of the interface region immediately before the weld torch deposit's weld material on the yet- to-be welded regions of the interface region, and signals from the inspection detector are received and used by the one or more processors to output signals/instructions to the weld torch and/or its motors to control various weld torch parameters to tailor the weld to the pipes as they are being welded.
  • the weld torch parameters can include one or more of the following: wire feed speed, wire consumption, oscillation width, oscillation waveform, oscillation amplitude, weld time, gas flow rate, power levels of the weld arc, weld current, weld voltage, weld impedance, weld torch travel speed, position of the weld tip of the weld torch along the pipe axis, angular positioning of the weld tip of the weld torch with respect to its rotational plane and/or the distance of the weld tip of the weld torch to the inner surfaces of the pipes to be welded.
  • the on-the-fly weld profile data may include a high-low (Hi-Lo) data.
  • the high-low (Hi-Lo) may generally refer to a height difference between the bevel edges of the pipes after their alignment.
  • the high-low (Hi-Lo) data may include a comparison between each of location and size of minimum height difference, and location and size of maximum height difference, and their respective predetermined values.
  • the high-low (Hi-Lo) data may include a comparison between average height difference and its respective predetermined value.
  • the high-low (Hi-Lo) data may include height difference deviations of the pipes at all locations on the circumference of the pipes based on the comparison.
  • the on-the-fly weld profile data may include weld joint characteristics.
  • the on-the-fly weld profile data may include width of the weld joint and root gap of the weld joint.
  • the one or more processors 5140 are configured to generate weld signals to control the weld torch 5502 based on the on-the-fly profile data. In one embodiment, the one or more processors 5140 are configured to control a position and speed of the weld torch 5502 based on-the-fly profile data during a weld operation. In one embodiment, the torch motor 5588 is operatively connected to the one or more processors 5140 to control an angle of the weld torch 5502 during the weld operation.
  • the one or processors 5140 are configured to instruct the one or more torch motors 5512 to move the weld tip 5503 further away from the interface region 5136 after each weld pass to accommodate for weld material build-up. In one embodiment, the one or processors 5140 are configured to control the axial weld torch motor 5550 to control the axial motion of the weld torch 5502 (i.e., move the weld tip 5503 further away from the interface region 5136).
  • the one or more processors 5140 are configured to generate an initial plotted weld profile based on the pre-weld profile data and modify/adapt the initial plotted weld profile based the on-the-fly profile data.
  • wire feed speed, oscillation width, power levels of the weld arc, and/or the distance of the weld tip 5503 of the weld torch 5502 to the surfaces of the pipes to be welded may be controlled based the on-the-fly profile data.
  • the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 between the pipes 1022a, 1022b subsequent to a welding operation and generate post-weld profile data based thereon.
  • the post-weld profile data is obtained with the inspection detector 5056 positioned within the first pipe 1022a and/or the second pipe 1022b, without disengaging the first pipe engagement structure 5052 or the second pipe engaging structure 5054 from the interior surface 5130 of the first pipe 1022a or the interior surface 5132 of the second pipe 1022b, respectively.
  • the one or more processors 5140 are configured to interact with the inspection camera 51 12, x-ray radiography inspection device, gamma ray inspection device, ultrasonic inspection device, magnetic particle inspection device, eddy current inspection device or other inspection devices to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 subsequent to a welding operation.
  • the post-weld profile data may include profile(s) of the formed weld beads.
  • the post- weld profile data may include profile(s) of the formed root pass weld layer.
  • the post-weld profile data may include weld shape characteristics such as mismatch, bead concavity, and the re-entrant angle.
  • the one or more processors 5140 are configured to cause, based on the post-weld profile data, another weld operation to be performed on the interface region 5136 between the pipes 1022a, 1022b.
  • weld variables/parameters have well known relationships. That is, a change in one weld variable/parameter has a corresponding change in the other weld variable/parameter.
  • the weld variable/parameters such as, weld current, weld voltage, weld torch travel speed, and heat input are all connected. For example, if the weld current increases and all other weld variable/parameters remain constant, then voltage should decrease. Also, if the weld torch travel speed increases and all other weld variables/parameters remain constant, then heat input should decrease.
  • the one or more processors 5140 are configured to analyze of the data gathered (e.g., prior to, subsequent to, or during a weld operation) to detect problems and make process/parameter changes. In one embodiment, based on the analysis and detection, the one or more processors 5140 are configured to take the internal weld system 5004 off-line for maintenance as needed to prevent a recurrence.
  • every data point collected/received by the one or more processors 5140 prior to, subsequent to, or during a weld operation is compared to its corresponding (Gold Standard) ideal weld value. If any process variables differ by more than a set/predetermined limit, these differences can be flagged. If the differences persist for longer than the maximum allowable defect size, the weld process can be stopped so that the weld can be repaired. Over time, the ideal weld values and the allowable limits may be improved as more weld data is collected.
  • the one or more processors may be configured to see what happened right before the deviation occurred and determine if there is a deficiency in the control loop programming that allowed the deviation to occur. If so, the one or more processors can send an updated control loop program to the internal weld system 5004 and observe if the change improves the performance of the internal weld system 5004.
  • the one or more processors may also be configured to monitor the commands being given to the internal weld system 5004 locally by the operator. If these commands are determined to cause the weld defects, the one or more processors are configured to send a message to the operator to stop providing commands to the internal weld system 5004. If the commands are determined to prevent weld defects, the one or more processors are configured to send a message to all operators instructing them to begin using the commands.
  • the one or more processors are configured to collect and analyze the Non-Destructive Test (NDT) data.
  • NDT Non-Destructive Test
  • the locations where the weld defects are detected can be compared back to the weld parameters that were logged at the same location, even if the defect is small enough to not require repair.
  • the one or more processors will be able to know about the weld defects that would not be included in a traditional inspection report. This gives the one or more processors a very good statistical sample for every welding parameter and the quality of the resulting weld.
  • This statistical model can be used to determine the best settings for each welding parameter as well as the allowable deviation from the setting.
  • These new parameters can be communicated directly to the internal weld system 5004 as each new NDT scan improves the statistical model.
  • the computer system 5138 (comprising the one or more processors 5140) may be a computer system local to the field system 5000.
  • the computer system 5138 may be a computer system positioned remotely from the field system 5000 (e.g., remote computer system 13704 or other remote computer system) and may be communicatively connected to the field system 5000 or a local computer system thereof.
  • the one or more processors 5140 may receive (via a receiver) inspection data associated with an inspection of the interface region 5136 between the pipes 1022a, 1022b from the field system 5000 (e.g., raw data from the inspection devices, 2D or 3D imaging data, or other data from the inspection).
  • One or more inspection devices used for the inspection may comprise one or any combination of an inspection laser, an inspection camera, an x-ray radiography inspection device, a gamma ray inspection device, an ultrasonic inspection device, a magnetic particle inspection device, eddy current inspection device, a temperature monitor, or other inspection device.
  • the inspection data may respectively comprise one or any combination of laser inspection data, camera inspection data, x-ray inspection data, gamma ray inspection data, ultrasound inspection data, magnetic particle inspection data, eddy current inspection data, temperature inspection data, or other inspection data.
  • the one or more processors 5140 may automatically generate a response comprising profile data for the interface region 5136 (e.g., pre-weld profile data, on- the-fly profile data, post-weld profile data, or other data) based on the received inspection data, and transmit (via a transmitter) the profile data to the field system 5000.
  • profile data for the interface region 5136 e.g., pre-weld profile data, on- the-fly profile data, post-weld profile data, or other data
  • the one or more processors 5140 may use the received inspection data to generate a response comprising pre-weld profile data for the interface region 136, and transmit (via a transmitter) the pre-weld profile data to the field system 5000.
  • the one or more processors 5140 may use the received inspection data to generate a response comprising on-the-fly-weld profile data for the interface region 5136, and transmit (via a transmitter) the on-the-fly profile data to the field system 5000. In one embodiment, where the received inspection data is based on a scan of the interface region subsequent a welding operation, the one or more processors 5140 may use the received inspection data to generate a response comprising post-weld profile data for the interface region 5136, and transmit (via a transmitter) the post- weld profile data to the field system 5000.
  • the one or more processors 5140 may automatically generate a response comprising one or more welding protocols or other operation protocols based on the received inspection data, and transmit (via a transmitter) the operation protocols as control operation data to the field system 5000.
  • the field system 5000 may perform one or more operations based on the received operation protocols.
  • the one or more processors 5140 may generate profile data based on the received inspection data to obtain the profile data for the interface region 5136 (e.g., pre-weld profile data, on-the-fly profile data, post-weld profile data, or other profile data).
  • the one or more processors 5140 may use the profile data to obtain the welding protocols or other operation protocols, and transmit (via a transmitter) the operation protocols to the field system 5000.
  • the one or more processors 5140 may generate a welding protocol or other operation protocol based on inspection data associated with one or more other pipes (other than pipes 1022a, 1022b), data related to input parameters (e.g., welding or other parameters) used to perform one or more operations (e.g., welding or other operations) on the other pipes, data related to observations of the operations, or other data.
  • the one or more processors 5140 may obtain the inspection data from one or more field systems, and analyze the inspection data to determine whether and which of the pipes have defects.
  • the processors may then compare one or more sets of observations of an operation performed on one or more objects determined to have a defect (after the performance of the operation) against one or more other sets of observations of the same operation performed on one or more other objects without the defect to determine the circumstances that likely caused the defect (as described in further detail herein elsewhere). Based on the comparison, the one or more processors 5140 may generate the welding protocol or other operation protocol such that the operation protocol avoids or would otherwise addresses the circumstances (likely to have caused the defect) when the operation protocol is used for one or more subsequent operations (e.g., subsequent operations that are the same or similar to the operation performed and observed).
  • the one or more processors 5140 may obtain pre-weld profile data for the interface region 5136 (between the pipes 1022a, 1022b), where the pre-weld profile data is based a scan of the interface region 5136 at the field system 5000 prior to a welding operation.
  • the one or more processors may receive the pre-weld profile data from the field system 5000.
  • the one or more processors 5140 may generate the pre-weld profile data based on inspection data received from the field system 5000.
  • the one or more processors 5136 may analyze the pre-weld profile data to generate a response to the field system 5000.
  • the one or more processors 5140 may compare one or more characteristics of the pre-weld profile data (e.g., pipe ovality/roundness characteristics, pipe bevel profile characteristics, weld joint fit- up and alignment characteristics, or other characteristics) with one or more characteristics of acceptable predefined pre-weld profiles. Based on the comparison, the processors 5140 may transmit (via a transmitter) a response as control operation data to field system 5000 indicating whether the field system 5000 is to begin the welding operation.
  • the processors 5140 may transmit (via a transmitter) a response as control operation data to field system 5000 indicating whether the field system 5000 is to begin the welding operation.
  • the response may specify that the interface region 5136 is within specification for the welding operation, indicating that the field system 5000 is to be begin the welding operation.
  • the response may additionally or alternatively comprise one or more welding protocols for the welding operation.
  • the response may specify that the interface region 5136 is not within specification, indicating that the field system 5000 should not perform the welding operation on the interface region 136 in its current state.
  • the response may indicate a need to alter the interface region 5136 prior to the welding operation (e.g., a need to realign the pipes 1022a, 1022b or other alternations).
  • the response may cause the field system 5000 to operate a pipe engagement structure of the field system 5000 to alter the interface region 5136 prior to the welding operation so that the interface region 5136 is within specification for the welding operation.
  • the one or more processors 5140 may compare one or more characteristics of profile data (obtain based on a scan of the interface region 5136 at the field system 5000) with one or more predefined profile characteristics to determine one or more matching characteristics. Based on the matching characteristics, for example, the one or more processors 5140 may automatically determine one or more welding protocols for welding the interface region 5136 between the pipes 1022a, 1022b, and transmit (via a transmitter) the one or more welding protocols to the field system 5000 to cause the field system 5000 to perform a welding operation on the interface region 5136 based on the one or more welding protocols.
  • a welding protocol may comprise one or more input parameters, such as wire feed speed, wire consumption, oscillation width, oscillation waveform, oscillation amplitude, weld time, gas flow rate, power levels of the weld arc, weld current, weld voltage, weld impedance, weld torch travel speed, position of the weld tip of the weld torch along the pipe axis, angular positioning of the weld tip of the weld torch with respect to its rotational plane, the distance of the weld tip of the weld torch to the inner surfaces of the pipes to be welded, or other parameters.
  • input parameters such as wire feed speed, wire consumption, oscillation width, oscillation waveform, oscillation amplitude, weld time, gas flow rate, power levels of the weld arc, weld current, weld voltage, weld impedance, weld torch travel speed, position of the weld tip of the weld torch along the pipe axis, angular positioning of the weld tip
  • the one or more processors 5140 may obtain on-the-fly profile data for the interface region 5136 (between the pipes 1022a, 1022b), where the on-the-fly profile data is based a scan of the interface region 5136 at the field system 5000 during a welding operation.
  • the one or more processors 5140 may receive (via a receiver) the on-the-fly profile data from the field system 5000.
  • the one or more processors 5140 may generate the on-the-fly profile data based on inspection data received from the field system 5000.
  • the one or more processors 5140 may analyze the on-the-fly profile data to generate a response to the field system 5000.
  • the one or more processors 5140 may compare one or more characteristics of the on-the-fly profile data (e.g., pipe ovality/roundness characteristics, pipe bevel profile characteristics, weld joint fit-up and alignment characteristics, weld shape characteristics, or other characteristics) with one or more characteristics of acceptable predefined profiles (e.g., predefined pre-weld profiles, predefined post-weld profiles, or other profiles). Based on the comparison, the processors 5140 may transmit a response to field system 5000 comprising on-the-fly updates to one or more welding characteristics for the welding operation. As an example, the response may cause the field system 5000 to control a weld torch based on the on-the fly -updates to the welding characteristics during the welding operation.
  • one or more characteristics of the on-the-fly profile data e.g., pipe ovality/roundness characteristics, pipe bevel profile characteristics, weld joint fit-up and alignment characteristics, weld shape characteristics, or other characteristics
  • acceptable predefined profiles e.g., predefined
  • the one or more processors 140 may obtain post-weld profile data for the interface region 5136 (between the pipes 1022a, 1022b), where the post-weld profile data is based a scan of the interface region 5136 at the field system 5000 subsequent to a welding operation.
  • the one or more processors 5140 may receive (via a receiver) the post-weld profile data from the field system 5000.
  • the one or more processors 5140 may generate the post-weld profile data based on inspection data received from the field system 5000.
  • the one or more processors 5140 may analyze the on-the-fly profile to generate a response to the field system 5000.
  • the one or more processors 5140 may compare one or more characteristics of the post- weld profile data (e.g., weld shape characteristics or other characteristics) with one or more characteristics of acceptable predefined post-weld profiles. Based on the comparison, the processors 5140 may transmit (via a transmitter) a response to field system 5000 indicating whether a result of the welding operation is acceptable. Additionally or alternatively, the one or more processors 5140 may automatically determine one or more welding protocols for a subsequent operation (e.g., an operation that repairs or compensates for a defect resulting from the welding operation, an operation that typically follows the welding operation if no defect of significance is detected, etc.), and include the one or more welding protocols in the transmitted response.
  • a subsequent operation e.g., an operation that repairs or compensates for a defect resulting from the welding operation, an operation that typically follows the welding operation if no defect of significance is detected, etc.
  • the response may specify that the root pass layer resulting from the welding operation is within specification, and the response may specify that preparation for a subsequent welding operation for a hot pass is to begin. As such, the response may cause the field system 5000 to initiate performance of the hot pass operation on the interface region 5136. As another example, the response may specify that the resulting root pass layer is not within specification. In one use case, for instance, the response may specify that the field system 5000 should not proceed with the hot pass operation until further notice. In another use case, the response may specify that the field system 5000 is to proceed with a different welding protocol (than otherwise pre-planned for the hot pass operation), where the different welding protocol repairs or compensates for the resulting root pass layer not being within specification.
  • the one or more processors 5140 may transmit, to a remote computer system, inspection data associated with an inspection of a region (e.g., interface region 5136 or other region) between the pipes 1022a, 1022b.
  • the transmitted inspection data may, for example, comprise one or any combination of the types of inspection data described herein.
  • the one or more processors 5140 may receive (via a receiver) a response from the remote computer system responsive to transmitting the inspection data to the remote computer system (e.g., a response comprising pre -weld profile data, on-the-fly profile data, post-weld profile data, an affirmation of transmitted profile data, a welding or other operation protocol, an alert indicating a defect, or other data).
  • the response may be derived from the transmitted inspection data and additional data received by the remote computer system.
  • the additional data may be related to observations of one or more operations performed on other pipes, inspection of the other pipes, one or more input parameters used to perform the observed operations, or other data (as described herein).
  • one or more operations in a field system may be managed based on previously unavailable large data pools with data from the same field system and/or other field systems.
  • the data pools comprising data on the observation of operations on the other pipes, the inspection of the other pipes, the input parameters for performing the observed operations, or other data from the same field system or other field systems
  • the data pools may be used to generate and select one or more welding or other operation protocols for subsequent operations (as described herein) to prevent or reduce weld defects or create better welds for current and future customers.
  • the large pool of data from different field systems may be used to improve inspection and analysis thereof (as described herein) to provide current and future customers with better products (e.g., by reducing weld defects, detecting defects earlier in the process, etc.).
  • the one or more processors 5140 may transmit a profile of the interface region 5136 between the pipes 1022a, 1022b to a remote computer system (e.g., a profile derived based on a scan of the interface region 5136).
  • the one or more processors 5140 may receive (via a receiver) an affirmation of the profile of the interface region or a modified version of the profile of the interface region 5136 from the remote computer system.
  • the one or more processors may cause a weld torch of the weld system 5004 to create a weld at the interface region 136 based on the affirmation or the modified version of the profile of the interface region 3136.
  • the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the interface region 5136 between the pipes 1022a, 1022b to obtain inspection data (e.g., raw data from the inspection devices, 2D or 3D imaging data, or other data from the inspection).
  • the inspection devices used for the inspection may comprise one or any combination of the types of inspection devices described herein.
  • the obtained inspection data may respectively comprise one or any combination of the types of inspection data described herein.
  • the one or more processors 5140 may determine the profile of the interface region 5136 based on the obtained inspection data, but may also transmit the inspection data to the remote computer system to assess the inspection data.
  • the one or more processors 5140 may transmit its determined profile of the interface region 5136 to the remote computer system for an accuracy check. Based on its own assessment of the inspection data, the remote computer system may respond to the one or more processors 5140 with an affirmation of the profile of the interface region 5136, an indication that the profile provided is inaccurate, or other response. Additionally or alternatively, if the profile provided is inaccurate, the remote computer system may respond with its own modified version of the profile of the interface region 5316 derived from the remote computer system's assessment of the inspection data.
  • the one or more processors 5140 may cause a weld torch of the weld system 5004 to begin or continue a welding operation based on its determined profile of the interface region 5136 to create the weld at the interface region 5316. If, however, a modified version of the profile is received, the one or more processors 5140 may cause a weld torch of the weld system 5004 to begin or continue a welding operation based on the modified version of the profile to create the weld at the interface region 5316.
  • the one or more processors 5140 may interact with an inspection laser of the weld system 5004 to scan the interface region 5136 between the pipes 1022a, 1022b to determine a profile of the interface region 136 prior to a welding operation and generate pre-weld profile data based on the scan.
  • the one or more processors 5140 may transmit the pre-weld profile data to a remote computer system.
  • the one or more processors 5140 may receive (via a receiver) an affirmation of the pre-weld profile data or a modified version of the pre- weld profile data from the remote computer system.
  • the one or more processors may operate pipe engagement structure 5052 and/or pipe engagement structure 5054 based on the affirmation or the modified version of the pre-weld profile data to alter the interface region 5136 between the pipes prior to the welding operation.
  • the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the interface region 136 between the pipes 1022a, 1022b to obtain inspection data prior to a welding operation on the interface region 136.
  • the inspection devices used for the inspection may comprise one or any combination of the types of inspection devices described herein.
  • the obtained inspection data may respectively comprise one or any combination of the types of inspection data described herein.
  • the one or more processors 5140 may generate pre-weld profile data based on the obtained inspection data, but may also transmit the inspection data to the remote computer system to assess the inspection data.
  • the one or more processors 5140 may transmit its generated pre-weld profile data to the remote computer system for an accuracy check.
  • the remote computer system may respond to the one or more processors 5140 with an affirmation of the pre-weld profile data, an indication that the pre-weld profile data provided is inaccurate, or other response. Additionally or alternatively, if the pre-weld profile data provided is inaccurate, the remote computer system may respond with its own modified version of the pre-weld profile data derived from the remote computer system's assessment of the inspection data.
  • the one or more processors 5140 may cause pipe engagement structures 5052, 5054 realign the pipes 1022a, 1022b prior to a welding operation to create the weld at the interface region 5136. If, however, a modified version of the pre-weld profile data is received, the one or more processors 5140 may instead utilize the modified version to perform subsequent operations, such as using the modified version to determine whether realignment is needed and how it is to be performed, to select a welding protocol to use to create a weld at the interface region 5136, etc.
  • the one or more processors 5140 may develop a welding protocol based on the affirmation or the modified version of the pre-weld profile data (received from the remote computer system). As an example, if the affirmation of the pre-weld profile data is received, the one or more processors 5140 may use its generated pre-weld profile data to develop a welding protocol to be used to perform a welding operation on the interface region 5136. As another example, if the modified version of the pre-weld profile data is received, the one or more processors 5140 may use the modified version to develop a welding protocol to be used to perform a welding operation on the interface region 5136.
  • the one or more processors 5140 may interact with an inspection laser of the weld system 5004 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 during a welding operation and generate on-the-fly profile data based on the scan.
  • the one or more processors 5140 may transmit (via a transmitter) the on-the-fly profile data to a remote computer system.
  • the one or more processors 5140 may receive (via a receiver) an affirmation of the on-the-fly profile data or a modified version of the on-the-fly profile data from the remote computer system. In one embodiment, the one or more processors 5140 may control a weld torch of the weld system 5004 based on the affirmation or the modified version of the one-the-fly profile data during the welding operation.
  • the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the interface region 5136 between the pipes 1022a, 1022b to obtain inspection data during a welding operation on the interface region 5136.
  • the inspection devices used for the inspection may comprise one or any combination of the types of inspection devices described herein.
  • the obtained inspection data may respectively comprise one or any combination of the types of inspection data described herein.
  • the one or more processors 5140 may generate on-the-fly profile data based on the obtained inspection data, but may also transmit the inspection data to the remote computer system to assess the inspection data.
  • the one or more processors 5140 may transmit its generated on-the-fly profile data to the remote computer system for an accuracy check.
  • the remote computer system may respond to the one or more processors 140 with an affirmation of the on-the-fly profile data, an indication that the on-the-fly profile data provided is inaccurate, or other response. Additionally or alternatively, if the post-weld profile data provided is inaccurate, the remote computer system may respond with its own modified version of the on-the-fly profile data derived from the remote computer system's assessment of the inspection data.
  • the one or more processors 5140 may use its generated on-the-fly profile data to update the welding parameters being used to control the weld torch of the weld system 5004 protocol (to perform the welding operation on the interface region 5136) as the welding operation is being performed.
  • the one or more processors 5140 may use the modified version to update the welding parameters being used to control the weld torch of the weld system 5004 protocol (to perform the welding operation on the interface region 5136) as the welding operation is being performed.
  • the one or more processors 5140 may interact with an inspection laser of the weld system 5004 to scan the interface region 5136 between the pipes 1022a, 1022b to determine the profile of the interface region 5136 subsequent to a welding operation and generate post- weld profile data based on the scan.
  • the one or more processors 5140 may transmit the post-weld profile data to a remote computer system.
  • the one or more processors 5140 may receive (via a receiver) an affirmation of the post- weld profile data or a modified version of the post-weld profile data from the remote computer system.
  • the one or more processors 5140 of the field system 5000 may cause one or more inspection devices to inspect the interface region 5136 between the pipes 1022a, 1022b to obtain inspection data subsequent to a welding operation on the interface region 5136.
  • the inspection devices used for the inspection may comprise one or any combination of the types of inspection devices described herein.
  • the obtained inspection data may respectively comprise one or any combination of the types of inspection data described herein.
  • the one or more processors 5140 may generate post-weld profile data based on the obtained inspection data, but may also transmit the inspection data to the remote computer system to assess the inspection data.
  • the one or more processors 5140 may transmit its generated post-weld profile data to the remote computer system for an accuracy check.
  • the remote computer system may respond to the one or more processors 5140 with an affirmation of the post-weld profile data, an indication that the post-weld profile data provided is inaccurate, or other response. Additionally or alternatively, if the post-weld profile data provided is inaccurate, the remote computer system may respond with its own modified version of the post-weld profile data derived from the remote computer system's assessment of the inspection data.
  • the one or more processors 5140 may cause, based on the affirmation or the modified version of the post-weld profile data (received from the remote computer system), another weld operation to be performed on the interface region 5136 between the pipes.
  • the one or more processors 5140 may use its generated post-weld profile data to determine whether a result of a welding operation has one or more defects, whether the interface region 5136 is ready for the next stage of operations, or other determinations.
  • post-weld profile data of the root pass layer in the interface region 5316 may reveal that the root pass layer is insufficiently thick.
  • the post-weld profile data may be utilized to determine welding parameters for a welding operation to repair the insufficient thickness or welding parameters for a hot pass operation to produce a hot pass layer (on the root pass layer) that compensates for the insufficient thickness of the root pass layer.
  • the one or more processors 5140 may use the modified version to perform the foregoing in lieu of its generated post-weld profile data.
  • the welding parameters that affect the quality of the weld may include voltage, current, weld torch travel speed, wire feed speed, gas flow, etc.
  • the other welding parameters that affect the quality of the weld may include impedance, temperature, etc.
  • the voltage used during the welding procedure may affect the weld bead width and weld bead shape. In one embodiment, the voltage is measured in volts. In one embodiment, the weld system may include a voltage sensor configured to measure the voltage of the power source that is used to create the welding arc.
  • the current used during the welding procedure may affect the penetration of the weld bead.
  • the current is measured in amperes.
  • the weld system may include a current sensor configured to measure the current of the power source that is used to create the welding arc.
  • the weld feed speed is a rate of travel of a weld electrode, during the welding procedure, along a joint being welded.
  • the weld electrode is fed from a welding torch.
  • the weld speed may be controlled by controlling the welding torch that feeds the weld electrode.
  • the weld speed during the welding procedure may affect the size of the weld bead and/or the penetration of the weld bead.
  • the weld speed is measured in millimeters/second or inches/minutes.
  • the wire feed speed/wire usage is a rate at which the weld electrode material/filler material is being consumed (or fed into the weld) during the welding procedure.
  • the wire feed speed is measured in millimeters/second or inches/minutes.
  • the weld system may include a wire feed speed sensor that is configured to sense a flow of the weld electrode material.
  • the rate of change of the weight of the spool allows the weld system to measure the rate at which weld wire 5007 is feeding into the weld.
  • the feed motor runs at a set/predetermined rate, but the wheel that pushes the wire 5007 may slip due to either minor variations in the wire 5007 or due to wear of the feed wheel itself. These slips may be temporary in nature, and their presence may be logged and used in the quality control feedback loop. If the slippage is persistent, the one or more processors 5140 may be configured to increase the speed of the feed motor to compensate. Over time, the speed overdrive ratio may need to be increased. Eventually it will not be possible to compensate, and the weld system 5004 will be taken out of service for maintenance.
  • tracking the rate of overdrive ratio increase across all weld systems allows the one or more processors to determine the best limit for the maximum allowable overdrive ratio. That setting may then be transmitted to all of the weld systems in service.
  • the one or more processors 5140 may be configured to update the value at any time as data becomes available in order to minimize process interruptions and minimize the frequency of machine down time for maintenance.
  • the weld system may include a gas flow sensor that is configured to sense/detect the flow rate of the shield gases used in the welding procedure.
  • the shield gas may be an active gas that is configured to shield the molten weld pool.
  • the gas flow sensor is configured to provide a signal proportional to the gas flow rate in the shield gas line.
  • the one or more processors 5140 of the field system 5000 are configured to stop welding if the gas flow rate of the shield gas is not within a predetermined gas flow rate range.
  • the pipes are preheated before the welding procedure.
  • the temperature of the pipes may be monitored by one or more temperature sensors of the weld system.
  • the one or more temperature sensors are configured to measure the temperature of the pipe at each point along the weld.
  • the one or more processors 5140 of the field system 5000 are configured to stop the welding procedure if the temperatures of the pipes are not within a predetermined temperature range.
  • the weld system may include an impedance sensor that is configured to sense/detect an input electrical impedance of the weld system.
  • the correct wire/weld electrode/filler material is to be used for each welding pass.
  • the only difference between two spools of wire is a 0.1 millimeter difference in the wire diameter. If the manufacturer label for the spool of wire has been smudged or has faded, the wrong spool could be loaded onto the weld system.
  • An RFID tag on the spool has a spool identifier. In one embodiment, the RFID tag on the spool may be read by a sensor on the weld system. If the RFID tag has the wrong spool identifier, the weld system is configured to not feed the wire material and to alert the user to change to the correct wire.
  • the spool weight may be monitored by the one or more processors 5140 of the field system 5000. If the weld wire runs out during a weld procedure, the voltage signal that the processor uses to manage the distance between the weld tip and the work piece goes to zero. The processor moves the tip closer to the work piece in response which causes the tip to touch the molten weld metal and cause a copper inclusion defect. Therefore, knowing the exact weight of the wire remaining on the spool helps the weld system prevent the start of a welding pass that requires more weld wire than what is available. Also, if the spool weight stops changing, then that may be an indication of an empty spool or a failure in a wire feeding mechanism. In either case, the one or more processors 5140 of the field system 5000 are configured to stop the welding procedure.
  • the one or more processors 5140 of the field system 5000 are configured to track the weight of every spool in real time. Each welding pass in a weld joint requires a different amount of wire due to the change in diameter and the change in the width of the weld groove being filled. [00809] If the one or more processors 5140 of the field system 5000 determines that a spool will end up with too little wire to complete the next weld pass, but that it would have enough wire to complete a different weld pass, the one or more processors 5140 of the field system 5000 may be configured to inform an operator to remove the spool and give it to a different operator.
  • a spool starts with 10 pounds of wire, and the weld pass being performed by the weld system requires 1.3 pounds of wire.
  • the weld system will be able to complete its weld passes on 7 weld joints before the spool has too little wire.
  • That spool When that spool is removed after the 7 th weld pass, that spool will have 0.9 pounds of wire on it that will be wasted. If there is another weld pass that requires, for example, 1.1 pounds of wire, then the one or more processors 5140 of the field system 5000 are configured to alert the operator to remove the spool after only 6 weld passes. In this case, the spool will have 2.2 pounds of wire remaining. That spool can then be used for the weld pass that needs only 1.1 pounds of wire to complete 2 such weld passes (and waste no wire).
  • the weld wire 5507 passes through the weld tip 5503.
  • the tip weld tip 5503 also carries a high welding current. Both these factors cause the bore of the weld tip 5503 to wear. As this happens the contact point inside shifts which inherently affects the arc characteristics and hence the weld quality.
  • the weld parameters like voltage, current, wirefeed, power and impedance are monitored in real time. That data is sent to a tablet via the one or more processors to be analyzed for signature comparison of the above mentioned variables due the computationally intensive nature of analysis. When the analysis detects an impending problem, the internal weld system 5004 and the operator are sent a message to change the weld tip 5503 before the next weld. Additionally, this data may be used in the quality control feedback loop. In one embodiment, the results from the quality control feedback loop may be used to update the weld tip deterioration signatures on the fly.
  • the exemplary weld parameters that are used for the uphill and downhill weld procedures are shown in FIG. 72D.
  • the weld parameters shown here are exemplary and are by no means optimized or inclusive of everything that may need to be changed during these welding procedures.
  • the travel speed for the downhill weld procedure is 13.5 inches/minute and for the uphill procedure is 10.0 inches/minute.
  • the amplitude of the cross-groove oscillation is 0.09 inches for the downhill weld procedure and 0.15 inches for the uphill weld procedure.
  • the oscillation speed is 160 beats per minute for the downhill weld procedure and 130 beats per minute for the uphill weld procedure.
  • the wave control 1 i.e., related to the wire feed speed
  • the weld passes were welded at 16.5V with the power supply controlling voltage.
  • the internal weld system 5004 is configured to be operated through a repeating cycle of operation.
  • the one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to control (via control signals) the weld torch motors 5512, 5550, 5588 (via) to retract the weld torches 5502 to their original, retracted positions.
  • the one or more processors 5140 are also configured to send communication signals to the forward- most section electronics module 5014 to control/turn off (via control signals) the front clamp control valve 5018 to retract the first engagement structure 5052 to its original, retracted position and send communication signals to the center section electronics module 5064 to control/turn off (via control signals) the rear clamp control valve 5062 to retract the second engagement structure 5054 to its original, retracted position.
  • the internal weld system 5004 (including the weld torches 5502 and the clamps 5144, 5142) has to be moved to the next weld joint.
  • the one or more processors 5140 are configured to send communication signals to the drive section electronics module 5118 to control (via control signals) the drive motors 5124 to accelerate the internal weld system 5004 to travel a predetermined speed and then decelerate and stop at the next weld joint.
  • the predetermined speed at which the internal weld system 5004 accelerates may be 6 feet/second.
  • the drive section electronics module 5118 sends communication signals to the wire feed electronics module 5046 to check alignment with the end of the pipe.
  • the wire feed electronics module 5046 is configured to operate (turn on) the one or more inspection detectors 5056 to measure where the second engagement structure 5054 are in relation to the end of the pipe.
  • the rotatable hub 5072 may not be operated when the one or more inspection detectors 5056 are measuring where the second engagement structure 5054 are in relation to the end of the pipe.
  • the wire feed electronics module 5046 is configured send the measured distance data to the drive section electronics module 51 18.
  • the drive section electronics module 51 18 is configured to control (via control signals) the drive motors 5124 to move the first and second engagement structures 5052, 5054 by the measured distance data.
  • the drive section electronics module 5118 is configured to send communication signals to the center section electronics module 5064 that the internal weld system 5004 is in position at the next weld joint.
  • the center section electronics module 5064 controls (opens via control signals) the rear clamp control valve 5062 to raise the second engagement structure 5054 and grip the old/existing pipe.
  • next/new pipe segment 1002a is then brought in, and slid over the forward- most section 5006 of the internal weld system 5004 into position by the working crew.
  • the one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to operate the one or more inspection detectors 5056 to check the alignment of the pipes.
  • the one or more processors 5140 may rotate the rotatable hub 5078 to take measurements at multiple locations.
  • the wire feed electronics module 5046 sends communication signals to the forward-most electronics module 5014 to actuate the front clamp 5142.
  • the forward-most electronics module 5014 controls/opens (via control signals) the front clamp control valve 5018 to raise the first engagement structure 5052 and grip the new pipe segment 1002a.
  • the wire feed electronics module 5046 sends communication signals (a message) to the one or more processors 5140 identifying the misalignment between the pipes 1022a, 1022b.
  • this information may be relayed to a crane operator by traditional crane operator hand signals or by an electronic signal to a computer display terminal in the crane cab.
  • the one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to operate the one or more 1 inspection detectors 5056 to measure the gap and radial offset (Hi-Lo) at a plurality of points along the circumference of the weld joint. In one embodiment, this data is communicated out to the one or more processors 5140 and compared against the allowable tolerances.
  • either the one or more processors 5140 or the wire feed electronics module 5046 sends communication signals to the operator indicating that welding may begin or sends communication signals to the wire feed electronics module 5046 to automatically begin the welding procedure.
  • the internal weld system 5004 is configured to weld up to a 4 millimeters of the gap and radial offset (Hi-Lo).
  • the wire feed electronics module 5046 is configured to automatically begin the welding procedure.
  • the one or more processors 5140 are configured to send communication signals through the umbilical 5034 to a weld power supply to turn on the weld power supply to the weld torch(es) 5502.
  • the wire feed electronics module 5046 is configured to control/move one or more weld torches 5502 radially, axially and/or angularly to a proper welding position.
  • the wire feed electronics module 5046 moves one or more weld torches 5502 radially, axially and/or angularly to the correct working distance from the pipe and to the center of the weld joint as measured by the one or more inspection detector(s) 5056.
  • the wire feed electronics module 5046 is also configured to operate (turn on) the shield gas valve(s) 5042 to supply shield gas to the weld torch(es) 5502 and operate the motors of the weld feed system 5044 to begin feeding weld wire or electrode to the weld torch(es) 5502.
  • the wire feed electronics module 5046 sends communication signals to both the forward -most section electronics module 5014 and the center section electronics module 5064 to begin rotation of the rotatable hub 5078. In one embodiment, the wire feed electronics module 5046 sends communication signals to both the forward-most section electronics module 5014 and the center section electronics module 5064 to synchronize the front rotation motor 5030 and the rear rotation motor 5074. In one embodiment, the forward-most section electronics module 5014 sends control signals to operate the front rotation motor 5030 and the center section electronics module 5064 sends control signals to operate the rear rotation motor 5074.
  • the front rotation motor 5030 and the rear rotation motor 5074 are configured to rotate the rotatable hub 5078 while keeping the front and rear clamps 5142, 5144 stationary.
  • the rotatable hub 5078 continues to rotate for the full length of the weld.
  • the wire feed electronics module 5046 is configured to operate the one or more inspection detector(s) 5056 to locate the center of the weld joint and move the weld torch 5502 axially to follow the weld joint.
  • the wire feed electronics module 5046 is configured to measure the voltage of the weld power. The measured voltage data may be used by the wire feed electronics module 5046 to determine the distance of the weld torch 5502 from the pipe. In one embodiment, the wire feed electronics module 5046 is configured to adjust the weld torch 5502 radially to maintain a constant distance of the weld torch 5502 from the pipe. In one embodiment, the wire feed electronics module 5046 may oscillate the weld torch 5502 axially to improve weld quality.
  • the wire feed electronics module 5046 is configured to change the tilt angle of the weld torch 5502 based on which portion of the weld joint is being welded. For example, the tilt angle of the weld torch 5502 in the plane of travel is adjusted to compensate for gravity.
  • the wire feed electronics module 5046 may be configured to vary the wire feed speed or send communication signals to the weld power supply (via the umbilical 5034) to vary the welding current based on the measurement data from the one or more inspection detectors 5056.
  • the welding procedure may be performed by one weld torch in one weld pass by rotating 360°.
  • the start and stop position of the weld may be anywhere along the weld joint.
  • the welding procedure may be performed with N equally spaced weld torches 5502 where the rotatable hub 5078 rotates through (360/N) degrees to deposit one weld pass.
  • the welding procedure may be performed with N equally spaced weld torches 5502 where the rotatable hub 5078 rotates through (2 times (360/N)) degrees to deposit two weld passes.
  • the internal weld system 5004 has three equally spaced weld torches 5502
  • the rotatable hub 5078 rotates through 120° to deposit one weld pass and rotates through 240° to deposit two weld passes.
  • the one or more inspection detectors 5056 detect the existing weld bead and the wire feed electronics module 5046 is configured to move the weld torches 5502 in radially to compensate.
  • the two welding passes may be deposited as above with a pause between the weld passes for a full laser and visual post weld inspection.
  • the welding may be done 360° with N unequally spaced torches 5502 with each weld torch 5502 depositing a successive weld pass for a total of N weld passes in 360° plus the distance from the first torch to the Nth torch.
  • the one or more processors 5140 are configured to send communication signals to the wire feed electronics module 5046 to control (via control signals) the weld torch motors 5512, 5550, 5588 (via) to retract the weld torches 5502 to their original, retracted positions.
  • the weld torches 5502 may be retracted back to their original, home positions for each axis (radial, axial, tilt).
  • the rotatable hub 5078 continues to rotate while the wire feed electronics module 5046 operates the one or more inspection detectors 5056 and one 2D camera 51 12 to inspect the quality of the weld.
  • the one or more processors 140 are configured to send communication signals to the wire feed electronics module 5046 to move a weld torch 5502 to that location and apply additional weld material to repair the defect.
  • the operator may sends communication signals to the forward-most electronics module 5014 to control/turn off (via control signals) the front clamp control valve 5018 to retract the first engagement structure 5052 to its original, retracted position and send communication signals to the center section electronics module 5064 to control/turn off (via control signals) the rear clamp control valve 5062 to retract the second engagement structure 5054 to its original, retracted position.
  • both angular and positional pipe alignment errors may be corrected by sending the control signals from the one or more processors 5140 to the cradles 5330 or the cradles 6010A and 6010B (to control the associated rollers 5332).
  • the purge and inspection system 7001 or the internal weld system 5004 may include one clamp that is constructed and arranged to grip the inner surface of the first pipe 1022b.
  • the cradles 5330 or the cradles 6010A and 6010B are configured to move the second/incoming pipe 1022a into position.
  • the one or more processors 7062 or 5140 are configured to interact with the inspection detector 5056 or 7042 to check the alignment between the pipes and send control signals to the cradles 5330 or the cradles 601 OA and 601 OB to fix any pipe alignment errors (angular or positional).
  • control signals from the one or more processors 5140 are configured to adjust the relative positioning between the pipes (to correct their alignment errors).
  • this procedure may be used on small or thick walled pipes that have a very low ( ⁇ 20) diameter to wall thickness ratio because no amount of clamping power can noticeably change the shape of low D/t pipe.
  • the purge and inspection system 7001 or the internal weld system 5004 may include two clamps.
  • one clamp is constructed and arranged to grip the inner surface of the first pipe 1022b.
  • the cradles 5330 or the cradles 601 OA and 6010B are configured to move the second/incoming pipe 1022a into position.
  • the second clamp is constructed and arranged to grip the inner surface of the second/incoming pipe 1022a.
  • the one or more processors 7062 or 5140 are configured to interact with the inspection detector 5056 or 7042 to check the alignment between the pipes. For example, if the alignment is not good, the second clamp releases the second pipe 1022a.
  • the one or more processors 7062 or 5140 are configured to send control signals to the cradles 5330 or the cradles 6010A and 6010B to fix any pipe alignment errors (angular or positional).
  • the control signals from the one or more processors 5140 are configured to adjust the relative positioning between the pipes (to correct their alignment errors), for example, by altering the positioning of the pipe 1022a.
  • the procedure may continue until the acceptable pipe alignment is achieved by the inspection detector or a predefined number of attempts (e.g., 10) at which time the second pipe 1022a is rejected and a new second pipe is moved into place.
  • the crane and the clamp alignment is used in the onshore pipeline alignment and welding procedure.
  • the angular pipe alignment error may be corrected by providing the instructions to the crane operator and the positional alignment error may be corrected by providing the instructions to the workers to place a shim between the clamp and the pipe.
  • the purge and inspection system 7001 or the internal weld system 5004 may include one clamp that is constructed and arranged to grip the inner surface of the first pipe 1022b.
  • the crane operator moves the second/incoming pipe 1022a into position and the workers place the external clamp around the joint.
  • the one or more processors 7062 or 5140 are configured to interact with the inspection detector 5056 or 7042 to check the alignment between the pipes. If the inspection detector 5056 or 7042 detects angular misalignment/pipe alignment error, instructions are sent to the crane operator to correct angular misalignment/pipe alignment error and the workers release the clamp while the pipe is being moved.
  • inspection detector 5056 or 7042 detects positional misalignment/pipe alignment error, instructions are sent to the workers for the placement and thickness of the shims needed to correct positional misalignment/pipe alignment error.
  • the workers remove the clamp, place the shims, and replace the clamp. The process repeats until the pipe alignment is accepted by the inspection detector.
  • the purge and inspection system 7001 or the internal weld system 5004 may include two clamps.
  • one clamp is constructed and arranged to grip the inner surface of the first pipe 1022b.
  • the crane operator moves the second/incoming pipe 1022a into position.
  • the second clamp is constructed and arranged to grip the inner surface of the second/incoming pipe 1022a.
  • the one or more processors 7062 or 140 are configured to interact with the inspection detector 5056 or 7042 to check the alignment between the pipes. If the inspection detector 5056 or 7042 detects an angular misalignment/pipe alignment error, the second clamp releases the second pipe and instructions are sent to the crane operator to correct the misalignment.
  • the second clamp releases the second pipe and instructions are sent to the workers for the placement and thickness of the shims needed to correct positional misalignment/pipe alignment error.
  • the crane operator moves the second pipe away from the first pipe, the workers place the shims.
  • the crane operator moves the second pipe back into position.
  • the second clamp grips the second pipe. The process repeats until the pipe alignment is accepted by the inspection detector.
  • FIG. 103B shows the pipe alignment, welding and inspection procedures of the internal weld system 5004.
  • the inspection detector 5056 scans 360° of the interface region 5136 between the pipes 1022a, 1022b before any welding takes place. In one embodiment, during the procedure of generating the pre-weld profile data, the inspection detector 5056 is positioned between the clamps and/or seals of the internal weld system 5004 and is turned on. In one embodiment, the weld torch(es) 5502 are turned off during the procedure of generating the pre-weld profile data. In one embodiment, the one or more processors 5140 are configured to interact with the inspection detector 5056 to scan the interface region 136 to obtain the pre-weld profile data subsequent to the first clamp 5142 and the second clamp 5144 engaging with the first pipe 1022a and second pipe 1022b, respectively.
  • the cradles 5330 (as shown in FIGS. 10A and 10B) and 6010A and 6010B (as shown in FIG. 73) are operated by the one or more processors 5140 (or otherwise controlled) to engage the exterior surfaces 5346 and/or 5348 (as shown in FIG. 2G) of the first pipe 1022a and/or second pipe 1022b to adjust the relative positioning of the pipes 1022a, 1022b in the event the pre-weld profile data determines adjustment is required.
  • an interior surface 5130, 5132 of the first pipe 1022a and/or the second pipe 1022b is engaged and manipulated by the first clamp 5142 and the second clamp 5144, respectively to adjust the relative positioning of the pipes 1022a, 1022b in the event the pre- weld profile data determines adjustment is required.
  • the inspection detector 5056 is positioned between the clamps and/or seals of the internal weld system 5004 and is turned on.
  • the one or more processors 5140 are configured to control a position and speed of the weld torch 5502 (or 7502) based on the on-the-fly weld profile data.
  • the on-the-fly scan/inspection procedure is performed during the root pass weld procedure, the hot pass weld procedure, the fill pass weld procedure, and the cap pass weld procedure.
  • an optional radiography inspection procedure (e.g., 1044 as shown in and described with respect to FIG. IB) may be performed between the on-the-fly scan/inspection & hot pass weld procedure and the on-the-fly scan/inspection & fill and cap pass weld procedure.
  • the inspection detector 5056 scans 360° of the interface region 5136 between the pipes 1022a, 1022b subsequent to a welding operation. In one embodiment, during the procedure of generating the post-weld profile data, the inspection detector 5056 is positioned between the clamps and/or seals of the internal weld system 5004 and is turned on. In one embodiment, the weld torch(es) 5502 are turned off during the procedure of generating the post-weld profile data.
  • a weld inspection procedure (e.g., 1008 as shown in and described with respect to FIG. IB) may be performed after the post-weld scan/inspection procedure.
  • FIG. 103B The procedures of FIG. 103B are described with respect to the internal weld system 5004. However, as shown in FIG. 103B, it is contemplated that the same procedures apply the tie-in internal weld system 3001 and the purge and inspection system 7001, and, therefore, will not be described again with reference to the tie-in internal weld system 3001 and the purge and inspection system 7001. [00852] Because, in one or more embodiments, the pipe has been welded from the interior, (i.e. the root pass weld has been applied from inside the pipe) the resulting root weld can be superior in that it better takes into account any mismatch and/or high-low regions within the pipe.
  • the pipe can also be provided with positive root enforcement on top of the root weld pass.
  • the hot weld pass, and even a further weld pass applied internally, can provide a small curved bump that extends slightly internally in the pipe to further reinforce the pipe.
  • the internal diameter of the pipe could be structured to be slightly smaller at the region of the weld than the internal diameter of the welded pipe at regions that contain just the pipe material without the weld.
  • the hot pass layer of the weld material has at least a portion thereof disposed closer to the longitudinal axis of the pipe than the interior surfaces of the welded pipes in regions of the welded pipes immediately adjacent to the weld material on opposite sides of the weld material.
  • the internal weld system 5004 disclosed herein is configured to weld pipes that are at least 30' long. In other embodiments, the internal weld system 5004, 3001 disclosed herein is configured to weld pipes that are 26" in diameter or less. In yet other embodiments, the internal weld system 5004 can weld pipes that are less than 24" in diameter. In yet other embodiments, the internal weld system 5004 disclosed herein is configured to weld pipes that are both, at least 30' long and less than 24" in diameter.
  • FIGS. 73-85 show and disclose another embodiment of the internal weld system in accordance with another embodiment of the present patent application.
  • the present patent application provides a system for aligning and welding together the faces of two pipe segments.
  • the system includes an external alignment mechanism and a welding mechanism.
  • the external alignment mechanisms may be as sophisticated as the line up modules shown in the drawings or as simple as a tipton clamp as illustrated in U.S. Patent No. 1,693,064.
  • the mechanisms used may also be suitable for on or off shore pipeline construction.
  • U.S. Patent No. 1 ,693,064 is incorporated herein by reference in its entirety. Whatever mechanism is employed, the external alignment mechanism supports and adjustably positions each segment so that the segments are substantially collinear or axially aligned along their longitudinal axes.
  • the external alignment mechanism may support a pipe segment and may include powered features that allow the position and orientation of the pipe to be adjusted.
  • the external alignment mechanism may include rollers that allow the pipe to move longitudinally.
  • the pipe may also be supported by rollers that allow the pipe to be rolled about the longitudinal axis and moved up and down.
  • the position and orientation adjustments may be automatic as by motor power or hydraulic power controlled at an operator station or fed into a central controller that automatically controls an aligns the segments based on predetermined alignment parameters or feedback from an internal laser reading an interface or joint profile.
  • the welding mechanism is an internal welding machine that applies a weld (e.g., a gas metal arc weld "GMAW" ) from inside the pipe segments to a face or edge joint of the segment and into a v-shaped opening formed by chamfered edges of the two pipe segments (other cross-sectional shapes other than a V may be used also).
  • a weld e.g., a gas metal arc weld "GMAW”
  • GMAW gas metal arc weld
  • the welding mechanism includes a carriage capable of engaging the inner walls of the pipe to secure or lock itself within the pipe in a fixed position and a welding portion rotatably supported from the carriage within the pipe.
  • the internal welder is located within the aligned pipe and then positioned longitudinally so that a weld head or torch is in longitudinal proximity to the edge joint.
  • the welding mechanism also includes a rotary mechanism for rotating the welding portion relative to the carriage.
  • the weld head or torch is rotatably supported on the welding portion about the pipe longitudinal axis so that the torch may closely follow the entire interior joint interface in an orbital rotation.
  • the torch of the articulating head follows the edge joint around the entire interior circumference of the pipe applying weld material.
  • various control elements may move the weld head axially along the pipe relative to the carriage, radially toward and away from the joint, and pivotally about a point or axis (e.g., an axis parallel or perpendicular to pipe longitudinal axis A-A).
  • a controller may direct the torches pivoting.
  • the welding mechanism also includes a laser tracking mechanism that works in conjunction with the torch of the welding portion to sense interface joint profile or/and weld material profile to apply weld material to the edge joint in the appropriate location and amount.
  • the laser mechanism surveys the weld and sends a signal to the controller of the articulating weld head to control movement of the head around the entire edge joint.
  • the torch follows the laser as the weld head control system continuously receives weld profile information from the edge joint. The information is then used to continuously adjust the torch to achieve the desired weld structure.
  • the system may include a 2D camera for visual inspection of the weld.
  • the 2D camera is mounted on the welding portion and follows the torch so that an operator can inspect the weld as soon as it is created by the torch.
  • a visual signal is delivered to an external operator display.
  • the 2D camera may be a color camera and a change in coloration may indicate a weld defect to the operator.
  • a perceived change in profile may also indicate a defect.
  • FIG. 73 shows an external alignment mechanism 601 OA and 6010B which is capable of supporting, positioning, and repositioning multiple lengths of pipeline.
  • Each mechanism 6010A and 6010B may include supports (e.g., rollers) upon which a length of pipeline may be supported.
  • a longitudinal roller 6012 moveably supports pipeline segment 6105 such that segment 6105 may be repositioned along its longitudinal direction defined by arrow A.
  • rotational rollers 6014 are rotatable about an axis parallel to axis A-A of support segment 6105 on either side of segment 6105 enabling them to rotate or adjust the angular orientation of segment 6105 about axis A-A.
  • External alignment mechanism 6010 is able to automatically manipulate multiple segments into various positions and orientations via motors, hydraulics, etc. For example the segments may be raised, lowered, rotated, tilted, pivoted, etc.
  • the external alignment mechanisms 6010A and 6010B support multiple segments 6105, 61 10 and adjust their position and orientation until segments 6105, 61 10 are both aligned such that their longitudinal axes A-A are collinear and one end of each of the segments 6105, 61 10 abuts at interface edges.
  • FIG. 74 illustrates an enlarged view of detail 6100 of FIG. 73 in which the edges form a pipe interface 6120 (known as a "fit up" joint).
  • the pipeline aligning and weld system of the present patent application applies a weld to the interior of the interface 6120 from inside the fitted up segments 6105, 61 10.
  • an internal welding mechanism 6300 is rolled into an end of one of the segments 6105 as shown in FIG. 75.
  • a second segment 6110 is then placed on the external alignment mechanism 6010B and manipulated until both the segments 6105, 61 10 are satisfactorily aligned.
  • An external force may then be applied to a reach rod 6345 of the internal welding mechanism 6300 or the mechanism may include automatic self propulsion means for adjusting its axial position within the aligned segments 6105, 61 10.
  • the welding mechanism 6300 includes a carriage 6301 and a welding portion 6302.
  • the carriage 6301 includes at least one alignment mechanism 6340A, 6340B which may expand radially to engage the interior surface of segments 6105 or 6110. This expansion and engagement both secures the axial/longitudinal position of the welding mechanism 6300 relative to segment 6105, 6110 and aligns or radially centers the welding mechanism 6300 within the segments 6105, 61 10.
  • the carriage 6301 also includes a body 63 11 on which rotating mechanism 6335 is supported.
  • the body 6311 is comprised of multiple elongated structural support members that extend between alignment mechanism 6340A and 6340B.
  • the welding portion 6302 includes a similar corresponding structure 6313.
  • the welding portion 6302 is rotatably connected to the carriage 6301 and extends from an end of the carriage 6301. The relative rotation between the carriage 6301 and the welding portion 6302 is facilitated by a rotary mechanism 6335.
  • the rotary mechanism 6335 is secured to the carriage 6301 and automatically (via a motor and gears) rotates welding portion 6302 relative to the carriage 6301 about longitudinal axis A-A.
  • the welding portion 6302 may be cantilevered from the carriage 6301 or may be supported by an additional alignment mechanism 6340C located so that torch 6305 is positioned between alignment mechanisms 6340B and 6340C.
  • the welding portion 6302 is rotatable relative to and between both the alignment mechanisms 6340B and 6340C when the alignment mechanisms 6340B and 6340C expand to secure themselves to the interior of a segment.
  • the carriage 6301 may include a reach rod 6345 which can be structured as an elongated extension from the carriage 6301 which an operator may grasp to insert/push or retract/pull the welding mechanism 6300 to axially position it within a segment 6105, 61 10.
  • FIG. 76 shows an enlarged view of section 6200 of FIG. 75 in which only segment 6105 is present and segment 61 10 is absent.
  • the welding portion 6302 includes a welding group 6303 which comprises a torch 6305, a laser sensor 63 10, and a color camera 6320.
  • the welding portion 6302 further has a body 6313 on which torch 6305, the laser sensor 6310, and the color camera 6320 are supported.
  • the laser 6310 tracks an interior joint of segments 6105, 61 10, and detects an interface profile to be used to position the torch 6305 in applying a weld to the joint interface.
  • the body 6313 extends between the alignment mechanism 6340B and 6340C.
  • Section 6200 shows the welding mechanism 6300 located inside the segment 6105 with the torch 6305 generally pointed in a radially outward direction and positioned to apply a weld to face joint 6120.
  • FIG. 77 shows an embodiment of a general schematic cross-sectional view of the welding mechanism 6300 through section B- B which shows welding group 6303 looking in the direction of insertion of the welding mechanism 6300.
  • FIG. 77 also shows a direction D of rotation of the welding group 6303 when it is rotated by the rotary mechanism 6335. Therefore, a welding action on a particular point along weld joint 6120 will first be acted on by the laser sensor 6310 followed by the torch 6305 and finally by the 2D inspection camera 6320.
  • FIGS. 82-84 illustrate multiple perspectives of the welding portion 6302.
  • FIG. 82 shows a wire delivery system 6322.
  • the wire delivery system 6322 includes a wire spool storage 6323, an optional wire straightener 6325, and a wire feed mechanism 6330 which is automatically controlled to deliver the appropriate amount of wire to the torch 6305.
  • wire delivery mechanism 322 As the rotary mechanism 6335 rotates the welding portion 6302, wire is fed to the torch 6305 by wire delivery mechanism 322.
  • the torch 6305 may be positioned and oriented in multiple ways by multiple mechanisms.
  • the torch 6305 is supported on a manipulator.
  • the manipulator includes a radial positioner, an axial positioner and a pivoter.
  • a radial positioner 6307 e.g., a rack and pinion
  • an axial positioner 6309 e.g., a rack and pinion
  • the manipulator also includes a pivoter 6308 that allows the torch to pivot (e.g., about an axis parallel to segment longitudinal axis A-A).
  • the pivotal movement by the pivoter 6308 may be powered by a motor and gears 6306.
  • the motor may be a stepper motor.
  • the torch manipulator may compound the manipulative movements of the above mentioned elements by dependently supporting the elements.
  • the body 6313 may support the axial positioner which in turn supports the radial positioner which in turn supports the pivoter which in turn supports the torch.
  • the axial positioner may be supported by the radial positioner.
  • any order of support may be employed.
  • the elements of the manipulator are controlled by a controller which receives as input, a series of signals including a signal from the laser 6310 and then processes the information before transmitting a signal to at least the radial positioner 6307, the axial positioner 6309, the pivoter 6308, and the wire delivery system 6322.
  • the torch 6305 is then repositioned and reoriented continuously according to predetermined parameters of the controller based on signals from profile reading laser 6310.
  • FIGS. 73, 80 and 81 illustrate the process of positioning and welding the segments 6105 and 61 10 together.
  • one or more of the following lettered steps may be executed so that: a) a pipe segment 6105 is placed on the alignment device/pipe stand 6010A; b) the internal welding machine 6300 is then inserted into the pipe segment 6105; c) a second pipe segment 6110 is then aligned with the pipe segment 6105 and the welding mechanism 6300 is pulled forward by the reach rod 6345 or automatically driven so that the torch 6305 generally lines up with faces joint 6120 of the pipe segments 6105, 61 10; d) the alignment mechanisms 6340A, 6340B (and if necessary 6340C) are then engaged to secure the welding mechanism 6300 within the pipe segments 6105, 6110; e) in one embodiment (optional), the rotary mechanism 6335 rotates the weld head 6305 to perform an initial scan of interface joint 6120 of the pipe segments 6105
  • the pipe segments 6105, 6110 are realigned/rotated and rescanned by the laser 6310, to improve "fit up”; g) optionally, the internal alignment mechanism 6340C on the rear of the welding mechanism 6300 is engaged to hold the axial position of the welding mechanism 3600 with respect to both the pipe sections 6105, 61 10; h) with the welding mechanism 6300 secure in the pipe segments 6105 and 61 10, the root weld (first weld) cycle begins so that the laser 6310 scans the pipe interface 6120, the torch 6305 follows the laser 6310, and the output from the laser 6310 is used to control the position of the articulated torch 6305, where the position and orientation of the torch 6305 with respect to the interface 6120 is controlled so as to produce the best quality weld; i) in addition to a signal from the laser 6310, thru the arc current monitoring can also be used in directing the torch position; j) after the completion of a 360° weld, the weld head 6305 is rotated back to an original position;
  • a signal from the laser sensor 6310 is sent to an electronic controller of the external alignment mechanism 6010 to automatically reposition one or both of the segments 6105, 61 10 for a more desirable face joint 6120 arrangement.
  • the foregoing steps may be executed in the stated order. However, variations in the order are also contemplated.
  • the laser 6310 could be used to inspect & track simultaneously while the trailing 2D color camera continues inspection after the second weld.
  • the weld is performed in two 180° halves with the same start position. This implementation would require either multiple laser sensors for tracking or a mechanism to physically oscillate the laser and/or the torch in order to maintain the tracking sensor's lead position in both directions of rotation (i.e., rotate the torch and laser so that they switch positions).
  • the present patent application discloses a tie-in internal weld system 3001.
  • the tie-in internal weld system 3001 incorporates all of the features of the internal weld system 5004.
  • the additional features of the tie-in internal weld system 3001 may include a large capacity battery so that the tie-in internal weld system 3001 can travel long distances, and has on-board weld power.
  • the tie-in internal weld system 3001 is configured to operate autonomously so that there is no external cables to the tie-in internal weld system 3001.
  • the tie-in internal weld system 3001 can be used to traverse very long spans of pipe, and perform a welding operation at such locations. This is achievable as the system need not be tethered for power from an external power source.
  • the tie-in internal weld system 3001 may also include a device for pulling the pipes together to close any gaps.
  • the device for pulling the pipes together to close any gaps may be referred to as an ungapping device.
  • the upgapping device is constructed and arranged such that one of the clamps is configured to be moveable relative to the other clamp.
  • the upgapping device is constructed and arranged to be external to the main weld section.
  • the upgapping device is constructed and arranged to be within the pipes.
  • the tie-in internal weld system 3001 includes the forward-most section 3002, the center section 3004, and the drive section 3006 that are similar to that in the internal weld system, 5004.
  • the structure, configuration, components, and operation of the forward-most section 3002, the center section 3004 and the drive section 3006 of the tie-in internal weld system 3001 are similar to the forward-most section, the center section and the drive section of the internal weld system 5004 described in detail above, and, therefore, the structure, configuration, components, and operation of the forward- most section 3002, the center section 3004 and the drive section 3006 of the tie-in internal weld system 3001 will not be described in detail here.
  • the electronics module of the forward-most section 3002, the electronics module of the center section 3004, and the electronics module of the drive section 3006 each include one or more processors.
  • the tie-in internal weld system 3001 includes a frame that is configured to be placed within the pipes 1022a, 1022b, a plurality of rollers 3125 that are configured to rotatably support the frame of the tie-in internal weld system 3001 , a drive motor 3124 that drives the rollers 3125 to move the frame of the tie-in internal weld system 3001 within the pipes 1022a, 1022b, a brake system that secures the frame of the tie-in internal weld system 3001 from movement at a desired location within the pipes 1022a, 1022b, an inspection detector that is carried by the frame of the tie-in internal weld system 3001 and configured to detect a characteristic of an interface region between the pipes 1022a, 1022b, and a weld torch carried by the frame of the tie-in internal weld system 3001.
  • the brake system of the tie-in internal weld system 3001 may include the clamps of the tie-in internal weld system 3001 that are configured to clamp to the pipes 1022a, 1022b, respectively.
  • the brake system of the tie-in internal weld system 3001 may include the brake cylinder and the brake valve of the tie-in internal weld system 3001.
  • the structure, configuration, and/or operation of the rollers 3125, the drive motor 3124, the inspection detector, and the weld torch the tie-in internal weld system 3001 are similar that of the internal weld system 5004 and, therefore will not be described in detail here.
  • the tie-in internal weld system 3001 also includes one or more processors that are operatively connected with the drive motor 3124, the inspection detector and the weld torch.
  • the configuration and operation of the one or more processors of the tie- in internal weld system 3001 are similar to that of the internal weld system 3004 and, therefore will not be described in detail here.
  • the tie-in internal weld system 3001 is entirely untethered. Specifically, the tie-in internal weld system 3001 need not include the reach rod or the umbilical and all the communications to and from the tie-in internal weld system 3001 are entirely wireless. In one embodiment, the tie-in internal weld system 3001 may include a transmitter that is configured to transmit all the communication signals entirely wirelessly from the tie-in internal weld system 3001 to the remote uLog processing system and a receiver that is configured to receive all the communication signals entirely wirelessly from the remote uLog processing system.
  • the one or more processors and/or all the electronic modules of the tie-in internal weld system 3001 are configured to communicate entirely wirelessly with the remote uLog processing system.
  • the inspection detector, the inspection camera, all the sensors, all the motors, all the valves and/or other components/elements of the tie-in internal weld system 3001 are configured to communicate entirely wirelessly with the remote uLog processing system.
  • any information from the tie-in internal weld system can be communicated wirelessly with systems outside the pipe by WiFi, Bluetooth, NFC, by radio frequency, or through cell tower transmissions, just for example.
  • the information is communicated by use of repeaters or extenders, where the transmission signal is to travel long distances or through curved areas.
  • the one or more processors and one or more sensors of the tie- in internal weld system 3001 are configured to monitor the charge levels of the on-board weld power supply, on-board locomotion power supply, and other on-board power supplies. For example, the voltage output by these power supplies may be (continuously or at regular intervals) monitored.
  • the transmitter of the tie-in internal weld system 3001 transmits the monitored battery life/charge level information entirely wirelessly to the remote uLog processing system for further processing.
  • the monitored charge level information of the on-board power supplies may be used to determine an estimated remaining operating time of the tie-in internal weld system 3001.
  • the one or processors of the tie-in internal weld system 3001 may be configured to determine the estimated remaining operating time of the tie-in internal weld system 3001 locally on the tie- in internal weld system 3001.
  • the remote uLog processing system may be configured to determine the estimated remaining operating time of the tie-in internal weld system 3001 based on the wirelessly transmitted battery life/charge level information.
  • the remote uLog processing system may be configured to transmit the estimated remaining operating time of the tie-in internal weld system 3001 to the one or more processors of the tie-in internal weld system 3001.
  • the remote uLog processing system may also be configured to transmit (entirely wirelessly to the tie-in internal weld system 3001) further instructions about the operation of the tie-in internal weld system 3001 based on the estimated remaining operating time of the tie-in internal weld system 3001.
  • the one or more processors and one or more sensors of the tie- in internal weld system 3001 are configured to monitor the gas levels of the on-board inert (shield/purge) gas supply, the on-board air supply, and other on-board gas supplies (e.g., volume or pressure of the compressed air in the on-board compressed air tanks, volume of pressure of the shield or purge gas in the on-board shield/purge gas tanks, etc.). For example, the gas consumption of these gas supplies may be monitored (continuously or at regular intervals).
  • the transmitter of the tie-in internal weld system 3001 transmits the monitored gas level information entirely wirelessly to the remote uLog processing system for further processing.
  • the monitored gas level information of the on-board gas supplies may be used to determine an estimated remaining operating time of the tie-in weld system 3001.
  • the one or more processors of the tie-in internal weld system 3001 may be configured to determine the estimated remaining operating time of the tie-in internal weld system 3001 locally on the tie-in internal weld system 3001.
  • the remote uLog processing system may be configured to determine the estimated remaining operating time of the tie-in internal weld system 3001 based on the wirelessly transmitted gas level information.
  • the remote uLog processing system may be configured to transmit the estimated remaining operating time of the tie-in internal weld system 3001 to the one or more processors of the tie-in internal weld system 3001.
  • the remote uLog processing system may also be configured to transmit (entirely wirelessly to the tie-in internal weld system 3001) further instructions about the operation of the tie-in internal weld system 3001 based on the estimated remaining operating time of the tie-in internal weld system 3001.
  • the one or more processors and one or more sensors of the tie- in internal weld system 3001 are configured to monitor the weld wire material levels of the tie-in internal weld system 3001. For example, the rotations of the wire feed motor (that dispenses the weld wire) and the weight of the remaining weld wire material in the tie-in internal weld system 3001 may be monitored (continuously or at regular intervals) to determine weld wire material levels of the tie-in internal weld system 3001. In one embodiment, the transmitter of the tie-in internal weld system 3001 transmits the monitored weld wire material level information entirely wirelessly to the remote uLog processing system for further processing.
  • the monitored weld wire material level information may be used to determine an estimated remaining operating time of the tie-in internal weld system 3001 (e.g., before the weld wire material runs out or is below a minimum threshold level for operating the tie-in internal weld system 3001).
  • the one or more processors of the tie-in internal weld system 3001 may be configured to determine the estimated remaining operating time of the tie-in internal weld system 3001 locally on the tie-in internal weld system 3001.
  • the remote uLog processing system may be configured to determine the estimated remaining operating time of the tie-in internal weld system based on the wirelessly transmitted weld wire material level information.
  • the remote uLog processing system may be configured to transmit the estimated remaining operating time of the tie-in internal weld system 3001 to the one or more processors of the tie-in internal weld system 3001. In one embodiment, the remote uLog processing system may also be configured to transmit (entirely wirelessly to the tie-in internal weld system 3001 ) further instructions about the operation of the tie-in internal weld system 3001 based on the estimated remaining operating time of the tie-in internal weld system 3001.
  • the remote uLog processing system receives battery charge data from numerous tie-in internal weld systems at different locations (for example, different locations across a country or across the globe) and establishes a data base thereon. That data base is used by the uLog processing system to determine, based on a large data set, expected battery life times based on different operating parameters of the internal weld system. This can be used by the uLog processing system and/or by one or more processors of the tie-in internal weld system 3001 to anticipate batteiy life times for various components based upon present operating conditions of those components. This information can be used by the one or more processors to reduce or regulate power consumption of one or more components by modifying one or more operating parameters.
  • weld speed, weld wire speed, voltage, and current can all be regulated (e.g., lowered) to conserve battery life if the one or more processors determine that such operating conditions can be modified without adversely affecting the associated operation being performed.
  • the battery life, voltage output, and any of the operating parameters are sent wirelessly to a user interface, such as a computer monitor having computer display, so that they can be monitored by a user.
  • a user interface such as a computer monitor having computer display
  • the tie-in internal weld system 3001 also includes the power section 3008 positioned next to the drive section 3006 (i.e., at the back of the tie-in internal weld system 3001).
  • the forward-most section 3002 includes forward-most section frame 3522
  • the center section 3004 includes a center section frame 3524
  • the drive section 3006 includes a drive section frame 3526
  • the power section 3008 includes a power section frame 3528.
  • the frame or frame assembly of tie- in internal weld system 3001 includes the forward-most section frame 3522, the center section frame 3524, the drive section frame 3526 and the power section frame 3528.
  • the frame or frame assembly of the tie-in internal weld system 3001 is configured to be placed within the pipes 1022a, 1022b.
  • the power section 3008 includes an universal joint 3010, a motor power source 3012, a weld torch power source 3014, weld power supplies 3016, and adjustable wheels 3018.
  • the drive section 3006 may be connected to the power section 3008 via the universal joint 3010.
  • the universal joint 3010 is constructed and arranged to allow the tie-in internal weld system 3001 to articulate around bends in the pipeline.

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PCT/US2015/062558 2013-05-23 2015-11-24 Systems and methods for use in welding pipe segments of a pipeline WO2016153562A1 (en)

Priority Applications (17)

Application Number Priority Date Filing Date Title
CN201580080511.1A CN107614193A (zh) 2015-03-26 2015-11-24 用于焊接管线的管段的系统和方法
US15/560,954 US10695876B2 (en) 2013-05-23 2015-11-24 Self-powered welding systems and methods
AU2015387441A AU2015387441B2 (en) 2015-03-26 2015-11-24 Rotating welding system and methods
MYPI2017703554A MY191994A (en) 2015-03-26 2015-11-24 Rotating welding system and methods
CA2980559A CA2980559A1 (en) 2015-03-26 2015-11-24 Rotating welding system and methods
EP15886707.7A EP3274125A4 (en) 2015-03-26 2015-11-24 Systems and methods for use in welding pipe segments of a pipeline
RU2017134991A RU2708721C2 (ru) 2015-03-26 2015-11-24 Системы и способы, используемые при сварке сегментов трубы в трубопроводе
MX2017012366A MX2017012366A (es) 2015-03-26 2015-11-24 Sistemas y metodos para uso en soldadura de segmentos de tubería de un conducto.
BR112017020431-2A BR112017020431B1 (pt) 2015-03-26 2015-11-24 Sistemas e métodos para uso na soldagem de segmentos de tubos de uma tubulação
US15/056,293 US9969031B2 (en) 2015-03-02 2016-02-29 Near-weld purge gas delivery system
PCT/US2016/020227 WO2016140951A1 (en) 2015-03-02 2016-03-01 Near-weld purge gas delivery system
US15/441,804 US10480862B2 (en) 2013-05-23 2017-02-24 Systems and methods for use in welding pipe segments of a pipeline
ZA2017/06249A ZA201706249B (en) 2015-03-26 2017-09-14 Rotating welding system and methods
US15/714,117 US10589371B2 (en) 2013-05-23 2017-09-25 Rotating welding system and methods
US15/714,054 US11767934B2 (en) 2013-05-23 2017-09-25 Internally welded pipes
US16/589,637 US11175099B2 (en) 2013-05-23 2019-10-01 Systems and methods for use in welding pipe segments of a pipeline
AU2021229209A AU2021229209A1 (en) 2015-03-26 2021-09-09 Rotating welding system and methods

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PCT/US2015/022665 WO2015148765A1 (en) 2014-03-28 2015-03-26 Internal pipeline cooler
USPCT/US2015/022665 2015-03-26
US201562175201P 2015-06-12 2015-06-12
US62/175,201 2015-06-12
US201562189716P 2015-07-07 2015-07-07
US62/189,716 2015-07-07
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PCT/US2015/022665 Continuation-In-Part WO2015148765A1 (en) 2013-05-23 2015-03-26 Internal pipeline cooler
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US15/056,293 Continuation-In-Part US9969031B2 (en) 2015-03-02 2016-02-29 Near-weld purge gas delivery system
US15/714,054 Continuation US11767934B2 (en) 2013-05-23 2017-09-25 Internally welded pipes
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CN114274158A (zh) * 2021-12-31 2022-04-05 北京博清科技有限公司 爬行焊接机器人的控制方法、控制器以及焊接系统
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CN113001070A (zh) 2021-06-22
RU2017134991A (ru) 2019-04-05
CA2980559A1 (en) 2016-09-29
MY191994A (en) 2022-07-22
BR112017020431B1 (pt) 2021-09-14
EP3274125A1 (en) 2018-01-31
MX2017012366A (es) 2018-02-19
RU2017134991A3 (ru) 2019-05-29
RU2708721C2 (ru) 2019-12-11
AU2021229209A1 (en) 2021-10-07
RU2019138447A (ru) 2019-12-05
EP3274125A4 (en) 2018-12-12
BR112017020431A2 (pt) 2018-07-03
AU2015387441A1 (en) 2017-11-09
CN107614193A (zh) 2018-01-19
AU2015387441B2 (en) 2021-06-10

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