The present embodiments generally relate to machines for forming armour structures around the outer diameter of tubular members, such as pipes, to enhance strength, burst pressure, and other characteristics.
In some industries, such as the oil and gas industry, pipes are often used to transport and/or store fluid. Flexible pipes may be desired due to their versatility for use in a variety of locations and ease of installation. For example, flexible pipe is typically used for deep water extraction of oil and gas to the surface. Another use is for providing passages for hydraulics, power cables, control wires, fiber optic cables, and the like. While flexible pipes have theft advantages, the flexible material typically used to form flexible pipes often lacks appropriate burst pressure, or maximum pressure that can be contained prior to failure, for certain applications. To overcome this shortcoming, one or more layers of armour can be placed around the outer surface of the pipe. For example, the pipe may be armoured with a layer of elongated strips wound about the outer surface of the pipe in a helical pattern. The strips are typically formed as rectangular or circular ships made of steel or another material with a high tensile strength.
To form the armour, the pipe is typically fed longitudinally through an armouring machine. Armouring machines typically include equipment that rotates about the longitudinal axis of the pipe while simultaneously feeding and winding the strips around the pipe's outer surface. Often, each layer of armour includes many strips placed next to each other on the outer surface of pipe. The pipe may be ted through multiple winding assemblies such that multiple layers of armour are provided.
A problem typically encountered when using armouring machines of the type described above is what is referred to as a “shingle.” A shingle occurs when one or more strips does not lay flat on the outer surface of the pipe (or on an outer surface of the underlying layer), and/or when one or more strips overlap, forming a discontinuity. Shingles are problematic because when they occur, the strips may fail to cover the entirety of the outer surface of the pipe or underlying layer, thus reducing the effectiveness of the armour. Further, in a multi-layer armour structure, when an underlying layer has a shingle, the problem may compromise layers above due to a discontinuous base surface.
At minimum, shingles typically require stoppage of the armouring process such that the armouring machine can be adjusted and the problem corrected. Machine adjustment often requires re-feeding (also re-stringing) the strips from reels of the armouring machine through a support disk and to a guide plate, which can be a lengthy and tedious process. More seriously, if left undetected, shingles may compromise the integrity of the pipe, which may increase the risk of issues such as leaks, explosions, implosions, and/or other problems when the pipe is in use.
In one aspect, the present embodiments generally relate to an assembly for an armouring machine. The assembly may include a support disk, the support disk defining a central opening for receiving a pipe and a plurality of perimeter openings for receiving a plurality of strips, and the support disk being rotatable about a longitudinal axis passing through the central opening. The assembly may further include a guide plate surrounding the longitudinal axis and including a plurality of guide structures, the guide structures being positioned for receiving the strips as they move downstream from the support disk. The assembly may further include an actuation device that is mechanically coupled to the guide plate, where actuation of the actuation device causes rotation of the guide plate with respect to the support disk.
In another aspect, the present embodiments generally relate to another assembly for an armouring machine with a support disk, the support disk defining a central opening for receiving a pipe and a plurality of perimeter openings for receiving a plurality of strips, and the support disk being rotatable about a longitudinal axis passing through the central opening. The assembly may further include a guide plate surrounding the longitudinal axis and including a plurality of guide structures, the guide structures being positioned for receiving the strips as they move downstream from the support disk. The assembly may further include a support arm with a first end coupled to the support disk and a second end coupled to the guide plate, the support arm having an adjustable portion with a variable length. Varying the length of the adjustable portion may move the guide plate axially along the longitudinal axis with respect to the support disk.
In another aspect, the present embodiments generally relate to a method for forming an amour layer around an outer surface of a pipe. The method may include feeding a strip through a support disk, the support disk defining a central opening for receiving a pipe and a perimeter opening for receiving the strip, the support disk being rotatable about a longitudinal axis passing through the central opening. The method may further include feeding the strip to a guide plate, the guide plate having a main body surrounding the longitudinal axis and a plurality of guide structures for receiving the strip as the strip moves downstream from the support disk. The method may further include rotating the guide plate with respect to the support disk.
The invention can be better understood with reference to the following drawings/figures and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
The present embodiments are described with reference to the drawings in which like elements are referred to by like numerals. The relationship and functioning of the various elements of this invention are better understood from the following detailed description. However, the embodiments of the invention are not limited to the embodiments illustrated in the drawings. It should be understood that in certain instances, details have been omitted which are not necessary for an understanding of the present invention, such as conventional fabrication and assembly.
The armour around the outer surface 104 of the pipe 102 may be formed with a set of strips 106. The strips 106 may be elongated strips formed of steel or another material with suitable tensile strength. While only one strip 106 is shown in
The strips 106 may have any suitable cross-sectional shape. For example, the strips 106 may have a cross-section that is rectangular and/or round (e.g., circular). One particular embodiment uses strips 106 with a rectangular cross-section measuring 22 mm in width and 10 mm in thickness. Other embodiments call for strips having different dimensions. When strips 106 with a rectangular cross-section are used, the strips 106 may be wound around the outer surface 104 of the pipe 102 in a helical manner with an application angle of about 25 degrees to about 55 degrees, and application angles out of this range are also contemplated. Herein, the “application angle” refers to the angle between the longitudinal axis of the strip 106 and the longitudinal axis 126 of the pipe 102. When other types of strips are used, such as circular strips, the application angle may be between about 13 degrees (or less) and may approach about 90 degrees. While winding, the assembly 100 may apply a tension to the strips 106 as the strips 106 are deployed, such as a tension of between about 150 daN (or less) and about 2000 daN (or more).
The assembly 100 may also include a support disk 110 with a set of perimeter openings 112 for receiving the reels 108. The perimeter openings 112 of the support disk 110 may be placed at or near the outer perimeter of the support disk 110 to properly space the strips 106 with respect to one another, thereby ensuring proper spacing as the strips 106 are fed downstream to a guide plate 114. As described in more detail below (with reference to
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As the pipe 102 is fed through the assembly 100 (e.g., through a set of rollers that pull the pipe 102 through the assembly 100, which are not shown), it may be prevented from rotating about the longitudinal axis 126. The assembly 100, on the other hand (including the reels 108, the support disk 110, the support arm 116, and the guide plate 114), may rotate around the longitudinal axis 126 (and therefore around the pipe 102) as the pipe 102 is fed. While any rotational speed may be used, in one embodiment, the assembly 100 may rotate at a rate of about 10 revolutions per minute. At the same time, the strips 106, which rotate with the assembly 100 until they reach a closing die 130 (shown in
In some applications, it may be desirable to feed each of the strips 106 through a preformer 132. Each perimeter opening 112 of the support disk 110 may be associated with a preformer 132, and the preformers 132 may be attached to (e.g., fixed to) the support disk 110. Herein, “fixed to” means “rigidly attached to” in a permanent or non-permanent manner. The preformers 132 may include a series of rollers (e.g., four rollers each) that bend or otherwise manipulate the shape of the strips 106 such that the strips 106 are cast with a tendency to form a helix. For example, the preformers 132 may flex the strips 106 past theft elastic limit to cast an appropriate helical path length (or helix straight length distance) within the strips 106, which may be determined by the striplayup angle and the diameter of the pipe 102. Advantageously, the helical cast of the strips 106 may enhance the performance of the armour layer, and reduce instances of shingles, since the strips 106 will have a tendency to assume their cast helical shape and lay more naturally (i.e., flat) on the outer surface 104 of the pipe 102. The rollers of the preformers 132 may be replaced with other preformers having rollers of a different size/orientation, and/or the preformers 132 may be adjusted, to adapt the assembly 100 to different application angles, different strip sizes, etc. In some embodiments, the preformers 132 may be adjusted automatically (and controlled by a control system).
After leaving the preformers 132, the strips 106 may extend to the guide plate 114. The guide plate 114 is shown in detail in
In the depicted embodiment, the pins 136, which may be formed of a hardened metal or other material, may be positioned such that the guide openings 138 guide the strips 106 to the closing die 130 in an appropriate orientation and with appropriate spacing. In particular, the pins 136 may be positioned such that they contact the strips 106 as the strips 106 are fed to the closing die 130 if/when the strips 106 would otherwise be offset from their appropriate positions for forming high-quality armour, without shingles. As described in more detail below, the guide plate 114 can be adjusted (e.g., rotated, or moved axially) with respect to upstream components to adjust the orientation and/or angle of the strips 106 as they enter the closing die 130 (and it is noted that the closing die 130 may rotate with the support disk 110).
The support arm 116 may be rotatable with respect to the hub 122, and therefore also rotatable with respect to the support disk 110. The first end 118 of the support arm 116 may be rotatably-connected to the hub 122, and the first end 118 of the support arm 116 may be fixed to a first gear 140. Thus, the first gear 140 may be rotatable with respect to the hub 122, and rotation of the first gear 140 will cause rotation of the support arm 116. A connection flange 144 may connect the support arm 116 to the first gear 140, but the connection flange 144 is optional. The connection flange 144 may be advantageous, as it may act as a connection point for different tooling sizes. For example, the connection flange 144 may be capable of quickly and easily coupling to different support arms 116 having different dimensions (e.g., different diameters and/or lengths).
The first gear 140 may be engaged with a second gear 142. The second gear 142 may be coupled to the hub 122 and/or the support disk 110. In particular, a base portion 146 of the second gear 142, which may include an axle for the second gear 142, may be fixed with respect to the hub 122 and/or the support disk 110. Accordingly, actuation (i.e., rotation) of the second gear 142 may cause the first gear 140 to rotate, thereby causing rotating of the support arm 116. When the support arm 116 is attached to the guide plate 114 in a non-rotatable manner, this action will also cause rotation of the guide plate 114.
The second gear 142 may be actuated (i.e., rotated) through the use of a motor (e.g., within the base portion 146), through manual actuation by an operator, or by any other suitable device or method. Optionally, more than one second gear 142 may be included, such as two second gears 142 as shown in
The gears 140 and 142 and actuation device (e.g., motor) may be included in a so-called actuation assembly 148, where the actuation assembly 148 effects rotation of the support arm 116 and the guide plate 114 about the longitudinal axis 126 (see
Advantageously, the rotatable guide plate 114 may provide the ability to make fine adjustments of the armouring machine to provide a high-quality armour layer. To illustrate, if a shingle (or potential shingle) is detected or anticipated, the problem may be quickly resolved through a slight rotation of the guide plate 114 relative to the support disk 110. Unlike prior armouring machines, this may occur without completely removing the strips 106 from the guide plate 114 first and then re-stringing the machine afterwards, and therefore the timeline for making such an adjustment is substantially shorter with the present embodiments. Further, while not shown, the assembly may include a sensor (e.g., a laser or camera) for sensing a shingle or another issue within the armour. When a control system is included and coupled to the actuation device, the control system may use feedback from the sensor to make an automatic adjustment by rotating the guide plate 114, thereby allowing the assembly 100 may self-correct without manual intervention.
Another common problem associated with machine setup is the ease of stringing the strips 106 into the guide openings 138 of the guide plate 114 during machine setup. For example, particularly when a lot of strips 106 are used (e.g., 96 or more), it is relatively easy for an operator to be one, two, or even three places/units off when selecting a guide opening 138 for a strip 106, particularly the first strip strung, during machine setup. Instead of starting over when this error occurs (which is required with prior armouring machines), the present embodiments allow the guide plate 114 to be rotated into its appropriate position with respect to the support disk 110 to quickly correct this issue, thereby saving the time of removing the strips 106 from the guide plate 114 and then re-feeding them.
Additionally or alternatively, the guide plate 114 can be rotated as needed to account for different types of armour, such as armour formed with a different number of strips 106 and/or strips 106 of a different size, armour formed using a different application angle, a pipe 102 with a different outer diameter, etc. In some embodiments, initial conditions for each type of armour may be programmed into a control system such that when a certain application is selected, the guide plate 114 is rotated into its appropriate position automatically.
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The automatic movement may be programmed in a controller, but it also (or alternatively) may be actuated by a user (e.g. through pressing a button). Automatic adjustment may be particularly advantageous since mechanical access to the adjustable portion 150 may be limited when the strips 106 are present. In some embodiments, a single control system may control adjustment of the preformers 132, the axial position of the guide plate 114 due to varying the length of the adjustable portion 150 of the support arm 116, and/or the rotational position of the guide plate 114 due to varying the rotational position of the support arm 116. Advantageously, a control system of this type may be capable of adapting the assembly 100 to account for a variety of armour types and correct a variety of issues (e.g., shingles) without significant downtime and without significant human intervention.
While various embodiments of the invention have been described, the invention is not to be restricted except in light of the attached claims and theft equivalents. Moreover, the advantages described herein are not necessarily the only advantages of the invention and it is not necessarily expected that every embodiment of the invention will achieve all of the advantages described.
This application claims the benefit of U.S. Provisional Application No. 62/633,989, filed Feb. 22, 2018, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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62633989 | Feb 2018 | US |