This patent application claims priority from Italian patent application no. 102018000008426 filed on Jul. 9, 2018, the entire disclosure of which is incorporated herein by reference.
The present invention relates to a machine for making a protective joint about an annular junction portion of a pipeline for transporting hydrocarbons.
The pipelines for transporting hydrocarbons are composed of sections of pipe that are joined together. Each section of pipe usually comprises a metal cylinder, generally made of steel, on which a protective coating made of polymer material is applied, which has the function of protecting the metal pipe. Optionally, the pipe may have a further external coating made of gunite or concrete, the function of which is to weigh down the pipeline. The lengths at the free and opposite ends of each section of pipe are uncoated so that the steel cylinders can be welded together. Each of these uncoated lengths is referred to as a “cutback” in the language generally used in this technical sector.
The joining operation, which can be carried out both in ground installations and in ships for laying submarine pipelines, involves welding the steel cylinders, generally in several welding passes. Once a welding ring has been made between two steel cylinders, an uncoated annular junction portion straddles the weld. As a result, during the assembly step, the pipeline has, in sequence, a plurality of annular junction portions, each of which is formed from two uncoated lengths placed next to each other and welded together, and, therefore, it is necessary to make a protective joint at each annular junction portion.
The making and application of the protective joint along each annular junction portion is in practice called “Field Joint Coating” and involves preparing the surface of the annular junction portion and coating it with polymer materials. In more detail, a plurality of operations need to be performed on each annular junction portion in accordance with the following sequence:
The adhesive polymer material and the polymer material for making the “Top Coat” are selected from compatible materials for making a union by fusion.
The operations described are particularly critical when performed on a pipeline during assembly onboard a pipeline-laying ship because the space available is limited and the pipeline, during assembly, is partially laid on the bed of a water body and cannot rotate about its longitudinal axis. In addition, the protective joint must meet certain quality requirements such as perfect adhesion to the pipeline and to the ends of the pre-existing coating. It must also guarantee a minimum thickness that varies according to the application and to the customer's requirements. In a pipeline-laying ship, the joining of the sections of pipe and the “Field Joint Coating” operations are performed in the respective workstations distributed along a pipeline advancement path. The average speed of advancement of the pipeline is a function of the maximum time taken in one of the work stations to carry out one or more operations. At present, the restoration of the coating, as a whole, is a time-consuming operation. This is because the operations for heating the annular junction portion and the application of the different layers must necessarily be performed in a single station, so as to benefit from the heating of the annular junction portion and to avoid contamination between the application of the subsequent layers. The advancement speed of the pipeline and, consequently, of the pipeline-laying ship are affected by the slowness of the remaining operations required for the restoration of the protective coating at the annular junction portions.
The purpose of the present invention is to provide a machine for making a protective joint about an annular junction portion of a pipeline that is capable of reducing the dwell time of the pipeline.
In accordance with the present invention, a machine is provided to make a protective joint about an annular junction portion of a pipeline, the machine comprising a selectively clampable guide system about a pipeline extending along a longitudinal axis on opposite sides with respect to an annular junction portion and configured to define an annular path about the annular junction portion; at least one heating unit moveable along the annular path and configured to heat the annular junction portion; at least one spray unit moveable along the annular path and configured to apply at least one polymer material to the annular junction portion; and one extrusion die moveable along the annular path and configured to apply a protective foil about the annular junction portion.
In this way, during the step in which the guide system is coupled to the pipeline, it is possible to perform the heating operations, the application of powdered polymer material on the annular portion, and the application of the protective foil. Regardless of how the different operations are managed, a considerable saving of time results from the fact that only one coupling to the pipeline and one uncoupling from the pipeline are required to allow the execution of three separate operations. In addition, the heating operations and the application of polymer powders and of the protective foil can be performed in quick succession so as to prevent the cooling of the annular junction portion and to promote the forming of chemical bonds between the polymer materials. In other words, it is also possible to heat the annular junction portion to relatively low temperatures because the application of the polymer powders and of the protective foil can be performed in quick succession. This results in significant energy savings.
In particular, the heating unit, the spray unit, and the extrusion die have respective widths commensurate with the width of the annular junction portion so that they can perform their respective operations along the annular junction portion in a reduced number of revolutions about the pipeline.
This configuration allows the number of revolutions of the heating unit, the spray unit, and the extrusion die, about the annular junction portion, to be minimized. The reduction in the number of revolutions is important because the heating unit must be powered by an electrical cable, the spray unit must be fed by a flexible conduit for feeding the powders, and the extrusion die must be fed by means of a conduit with polymer in a paste state.
In particular, the machine comprises a control system configured to control the positions of the heating unit, the spray unit, and the extrusion die along the annular path of the guide system. The control of the position is required to determine the sequence of the heating operations, the application of the powders and of the protective foil.
In accordance with the present invention, the control system is configured to control the operating status of the heating unit, the operating status of the spray unit, and the operating status of the extrusion die along the annular path of the guide system.
In this way, it is possible to define the optimal sequence of the heating operations and the application of the powders and of the protective foil according to the absolute and relative positions of the heating unit, the spraying unit, and the extrusion die, and of their direction of advancement.
In particular, the machine comprises a carriage configured to advance along the annular path of the guide system in a first direction about the annular junction portion and in a second direction opposite to the first direction—the heating unit, the spray unit, and the extrusion die being mounted on said carriage.
In this way, the machine is particularly simple and the relative position between the heating unit, the spray unit, and the extrusion die is predefined.
In particular, the heating unit, the spray unit, and the extrusion die are arranged in sequence along the carriage.
With this configuration, it is possible to carry out, in quick succession, the heating of the annular junction portion, the spraying of the powders on the annular junction portion just heated, and the application of the protective foil on the portion on which the powders have just been applied.
In accordance with a variant of the present invention, the machine comprises a further heating unit and a further spray unit mounted on the carriage.
In this way, it is possible to reduce the heating and powder application times.
In particular, the two heating units are arranged at opposite ends of the carriage and, preferably, at 180° to each other, and each spray unit is arranged between the extrusion die and a respective spray unit.
According to a further alternative, the heating unit and the spray unit are integrated in an assembly comprising a plurality of nozzles, which are distributed along a direction parallel to the longitudinal axis of the pipeline, and a U-shaped inductor, which is arranged about the plurality of nozzles.
In this way, the heating and the powder application can be carried out with alternating revolutions of 180° about the annular junction portion, while the application of the protective foil requires a slightly greater stroke than a complete revolution in order to overlap the corners of the protective foil.
A further purpose of the present invention is to provide a method for making a protective joint about an annular junction portion of a pipeline that mitigates the drawbacks of the prior art.
In accordance with the present invention, a method is provided for making a protective joint about an annular junction portion of a pipeline, the method comprising the following steps:
The application of this method allows the time it takes to make the protective joint to be considerably reduced.
In particular, the heating unit, the spray unit, and the extrusion die have respective widths commensurate with the width of the annular junction portion. This is so that they can quickly perform their respective operations along the annular junction portion and limit the number of revolutions about the annular junction portion.
In particular, the method involves controlling the positions of the heating unit, the spray unit, and the extrusion die along the annular path of the guide system by means of a control system for continuously monitoring the position of the same along the guide system.
In particular, the method involves controlling the operating status of the heating unit, the operating status of the spray unit, and the operating status of the extrusion die along the annular path of the guide system by means of a control system.
Thanks to the control system, it is possible to set the heating unit, the spray unit, and the extrusion die in active and rest mode according to their absolute and relative positions and their direction of advancement along the annular path.
In accordance with the present invention, the method involves advancing a carriage along the annular path of the guide system in a first direction about the annular junction portion and in a second direction opposite to the first direction—the heating unit, the spray unit, and the extrusion die being mounted on said carriage.
This solution simplifies the construction of a machine used to implement the method that is the subject of the present invention and the operating modes.
In accordance with a first embodiment of the present invention, the method involves heating the annular junction portion and applying the polymer material, by spraying, and the protective foil in sequence during one or more revolutions of the carriage about the annular junction portion.
In accordance with another embodiment of the present invention, the method involves advancing a further heating unit and a further spray unit, mounted on said carriage, along the annular path.
In accordance with this embodiment, the method involves heating the annular junction portion and applying the polymer material, by spraying, about the annular junction portion and applying the protective foil, once the application of the sprayed material is complete.
Further characteristics and advantages of the present invention will become clear from the following description of its preferred embodiments, with reference to the accompanying drawings, wherein:
In
Each section of pipe 2 has two opposite free ends 5 (only one of which is shown in
The pipeline 1 is formed by means of joining the sections of pipe 2. With reference to the present description, pipeline 1 is also understood to mean the pipeline under construction consisting, for example, of only two sections of pipe 2 joined together.
The joining of the sections of pipe 2 also involves, in addition to the welding of the metal cylinders 3, the making of a seamless coating of the pre-existing coatings 4. This operation involves applying a protective foil 9 about the annular junction portion 8 and about two end portions 10 of the coating 4. It also involves making the protective foil 9 adhere to the annular junction portion 8 and to the end portions 10 of the coatings 4.
The application of the protective foil 9 generally requires operations to prepare the surface of the annular junction portion 8 and of the end portions 10, in order to facilitate the adhesion of the protective foil 9. These operations consist in cleaning, for example, by means of blasting, and in heating, for example by induction, the annular junction portion 8.
The protective foil 9 has a thickness between 1 and 7 mm and is made of a polymer, preferably polyolefin, preferably PE or PP.
The protective foil 9 is wider than the width of the annular junction portion 8 (measured along the longitudinal axis A1) so that it partially overlaps the coatings 4 at the respective end portions 10. In addition, it is long enough to ensure the coverage of the perimeter of the annular junction portion 8, including the partial overlapping of the end edges of the protective foil 9.
The protective foil 9 is made by extrusion, and is applied about the pipeline 1.
This technique allows you to obtain a protective foil 9, which, in the application step, is very flexible and well suited to the shape of the coating 4 and of the annular junction portion 8. It also adheres closely to the pipeline 1 as shown in
Prior to the application of the protective joint 9, a thin layer of polymer material, in particular epoxy material, is applied to the annular junction portion, which has the function of a primer, as well as a layer of polymer adhesive.
With reference to
In
The machine 12 is configured to perform machining cycles, each of which involves coupling to the pipeline 1 about an annular junction portion 8 (
The construction of the pipeline 1 involves advancing the pipeline 1 step-by-step in a direction D1 (
In the present description, the adjective “axial” refers to the longitudinal axis A of the pipeline 1.
In this case, the machine 12 comprises:
The frame 13 has the function of supporting the manipulator 15, which supports the extrusion line 14, which comprises a laminating device 20, an extrusion device 21, and an extrusion die 22.
In accordance with the preferred embodiment shown in the attached figures, the laminating device 20 is connected to the extrusion device 21 by means of a flexible conduit 23 so that the laminating device 20 and the extrusion device 21 can be arranged elements in relative motion.
Similarly, the extrusion die 22 and the extrusion device 21 are connected to each other by a further flexible conduit 24 so that the extrusion die 22 and the extrusion device 21 can be mounted on elements that are moveable relative to each other. The flexible conduit is collected on a winder 25 for winding and respectively unwinding the flexible conduit 24 in a controlled manner.
The extrusion die 22 basically comprises an extrusion mouth having a through-cross-section to precisely shape the cross-section of the protective foil 9 (
The manipulator 15 comprises a guide system 26 configured to guide the heating unit 18, the spray unit 19, and the extrusion die 22 along an annular path; an articulated mechanism 27 to selectively arrange the guide system 26 between a position about the pipeline 1 (
With reference to
With reference to
With reference to
The previously described embodiment of the machine 12 involves several functional modes, some of which are described below. It should be noted that the machine 12 is extremely versatile and the choice of a functional mode depends on many factors such as, for example, the size of the pipeline, the thickness of the steel cylinder, and the power that the heating unit can deliver. In fact, the surface of the steel cylinder must reach a certain temperature before applying the polymers, in powder form, so as to ensure the adhesion and fusion of the powders in contact with the steel cylinder.
With reference to
The carriage 32 (not shown) advances the heating unit 18, the spray unit 19, the extrusion die 22, the roller 33, and the lateral heaters 34 in direction D2 about the pipeline 1.
The heating unit 18 is immediately activated and heats the annular junction portion (
With reference to
In
With reference to
With reference to
In
This solution allows the joining of the protective foil 9 along the β angle. In practice, with a revolution slightly higher than 360°, a plurality of operations are carried out, in quick succession, on the pipeline 1.
In accordance with the variant in
When in use, the heating and powder spraying operations are performed along a 180° sector by means of a heating unit 18 and the adjacent spray unit 19, while the other heating unit 18 and the other spray unit 19 are not in the operating mode.
During the return stroke, the remaining 180° sector is heated and coated with powders by means of the heating unit 18 and the spray unit 19, which have remained inactive during the forward stroke, while the heating unit 18 and the spray unit 19, which are active during the forward stroke, are deactivated. Subsequently, both the heating units 18 and both the spray units 19 are deactivated, while the extrusion die 22, the roller 33, and the lateral heaters are operational and advanced along a sector slightly greater than 360°.
In the variant in
When in use, the heating and polymer material powder-spraying operations can be carried out simultaneously, so that, by means of a 180° advance in direction D3, it is possible to heat and apply the powder over a 360° sector. In addition, with an advancement of slightly more than 360° in the opposite direction, the protective foil 9 is applied (
As an alternative to the functional modes described above, the heating unit may perform complete or partial revolutions about the annular junction portion when the temperature of the annular junction portion has reached the predetermined temperature. Subsequently, the powders are applied by means of the spray unit.
The heating unit can also be activated during the powder application step so that it heats portions of the annular junction portion, on which the powders have already been applied. This functional mode has the main function of preventing the cooling of the annular junction portion.
The present invention extends to further variants which are not explicitly described and which fall within the scope of protection of the attached claims.
In accordance with a variant not shown, one or more heating units and one or more spray units, and the extrusion die are distributed on two carriages, which are controlled independently of each other.
Number | Date | Country | Kind |
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102018000008426 | Sep 2018 | IT | national |
Filing Document | Filing Date | Country | Kind |
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PCT/IB2019/057490 | 9/5/2019 | WO | 00 |