Patent Application
20080036198
This invention relates to the joining of multi-layered pipes.
The use of coaxial multi-layered pipes is well known. Such pipes are commonly used to simultaneously employ desirable properties of two or more materials in a given application. For example, in order to convey a corrosive chemical, a pipe construction material to be in contact with the chemical would need to be resistant to that chemical, however, the chemical-resistant material may not have sufficient mechanical strength to contain the fluid pressure needed to convey the chemical along the pipe. This problem is addressed by introducing a second layer of pipe construction material separated from the chemical by the first, chemical-resistant layer. The second layer need not be resistant to the chemical but is selected to have the mechanical properties needed to contain the chemical as it is conveyed through the pipe line. In the foregoing example, the first (or inner, chemical-resistant) layer may be a polymer and the second (or outer, mechanically reinforcing) layer, a metal, although other combinations of materials are also possible. A pipe may be referred to as a “metal dominant” pipe because the metal layer influences the mechanical properties of the pipe. However, such a pipe is a “metal dominant” plastic pipe.
Often, due to the very different chemical nature of adjacent layers in a multi-layer pipe, the layers of the pipe cannot be bonded together. In such a situation, a third or tie layer is introduced between the first and second layer, the tie layer having chemical properties which enable it to be bonded directly with each of the adjacent layers.
It will be understood that multiple additional layers optionally interspersed with additional tie layers may be included in a multi-layer pipe as previously described.
It will be appreciated that, particularly in hostile environments, there is a high potential for delamination of the multi-layered pipes.
Conventionally, multi-layer pipes of the type previously described are connected by means of mechanical fittings. These mechanical fittings are typically configured to retain the layers of the pipe in compression with each other and so prevent delamination of the pipe. Such fittings may comprise a “push-fit” annulus for receiving the pipe or a crimping mechanism for crimping the pipe ends.
It is known to connect single layer plastic pipes using thermal fusion couplings. The latter include a coiled length of metal which is bedded into the coupling during manufacture. The coupling is then fitted around a pipe and an electrical current is passed through the metal coil. The heat produced by the electrical current causes local melting and fusion of the coupling to the outer surface of the pipe. Electrical current may be passed directly through the coil (this is known as electro-fusion) or may be induced into the coil by means of a second coil positioned around the first, the second coil carrying an alternating electrical current (this is known as fusion by induction heating). It will be appreciated that different coil configurations may be more suited to one of electro-fusion or induction heating than the other.
The use of conventional thermal fusion coupling techniques in multi-layer pipes has been considered but is disadvantageous as these techniques serve only to join couplings to the outer layer of the multi-layered pipes providing no means for preventing delamination of the pipes. Furthermore, these couplings require a relatively complex, multi-stage construction rendering them slow and expensive to manufacture.
Electro-fusion coupling has been used in relation to “plastic dominant” multi-layered pipes. The properties of such a plastic dominant pipe are determined by the plastic layers of the pipe. The plastic dominant multi-layered pipe typically comprises a thick inner layer of plastics material covered by a thin foil of metal which is in turn coated with a thin, outer layer of plastic material. The thinness of the outer layer and inclusion of the metal layer renders it difficult to achieve good fusion between the pipe and the coupling. The problem is addressed by removing the outer plastic and metal foil layer and attaching the coupling directly to the inner, thicker plastic pipe. Although such an arrangement does partially protect the pipe end from delamination by preventing exposure to pipe contents, it is only suitable for plastic dominant composite pipes where the metal layer is close to the outer surface of the pipe. Furthermore, the arrangement does not protect against exposure to the external environment which may be as damaging to the unprotected pipe end as the pipe contents.
The present invention aims to provide more cost effective, alternative methods for joining multi-layered pipes and to reduce the incidence of delamination in pipes after coupling.
In accordance with the present invention there is provided a method for joining a multi-layered plastic pipe to a coupling, the multi-layered pipe including at least an outer and an inner layer of thermoplastic material and a core layer of metal or other conductive material which is less than 2 mm thick and the pipe having an outside diameter of from 20 mm to 110 mm, the coupling comprising a unitary piece of thermoplastic material, the method comprising; providing a coupling including a recess for receiving an end of the multi-layered pipe, the recess being configured, in use, to permit the coupling to contact the inner and outermost layers of the multi-layered pipe received in the recess; fitting an end of the multi-layered pipe into the recess of the coupling; introducing heat to both the coupling and either the inner layer alone or both the inner and outer layers of the multi-layered pipe sufficient to cause local melting at the interface between the coupling and either the inner layer alone or both the inner and outermost layers.
It will be appreciated that, by using a coupling which interfaces with both the inner and outermost layers of the pipe, the ends of all layers of the pipe can be sealed within the pipe-coupling join. It is recognised though that for certain sizes and sections of pipe it may only be possible to weld/fuse to the inner pipe layer. This is considered acceptable as the coupling still provides protection of the pipe end from exposure to both the pipes contents and external environment, and the single weld is of sufficient mechanical strength to contain the pipe contents.
Although the pipe comprises a core layer of metal or other conductive material it will be understood that the present invention relates to a plastic composite pipe.
Optionally the inner and/or outermost layers of the pipe comprise ethylene/octane copolymers known as polyethylene of raised temperature performance (“PE-RT”). Such polymers are chosen to operate over a wide range of temperatures from sub-zero to elevated temperatures thus enabling a single system to be adaptable to a number of applications. These polymers do not require any subsequent curing process thus overcoming any cross linking/curing issues associated with cross linked polyethylene and readily lend themselves to thermal jointing techniques. Alternative materials for the innermost and outermost layers include but are not strictly limited to; MDPE, HDPE and PP. The innermost and outermost layers may comprise the same or different materials.
Desirably, the outermost layer has a thickness in the range from 0.5 mm to 1.5 mm for pipes with outside diameters of 20 mm to 110 mm. The inner layer desirably has a thickness of from 0.75 mm to 5.0 mm for pipes with outside diameters of 20 mm to 110 mm.
It is to be understood that the lower thicknesses in these ranges relate to layers used with pipes of smaller outer diameter and the upper thicknesses in these ranges relate to layers used with pipes of greater outer diameter.
For optimum joining conditions the thickness of the outermost layer is kept to a minimum.
Preferably, the conductive layer of the multi-layered pipe is positioned nearer to the outermost layer than to the inner layer.
The optimum-coupling ratio occurs when the outermost layer is thinner than the inner layer whereby the efficiency of the joining method is improved due to secondary currents induced in the conductive layer from a work coil. The direction of heat flow is directed to the inner pipe layer by a thinner outermost layer because air is a better insulator than the thermoplastic outermost layer. Directing heat towards the inner layer, which is the primary joining layer, reduces power requirements and joining cycle times.
The recess of the coupling is desirably an annular recess defined by an outer and an inner wall (or spigot). The inner wall desirably has a thickness of from 1.5 mm to 10.0 mm for use with pipes of outside diameters of 20 mm to 110 mm. Such sections are sufficient to prevent deformation, buckling or collapse during the welding/fusion process as well as providing the required level of pressure resistance should the pipe end not be fully inserted into the annular recess. By providing an innermost wall of the coupling that is of minimum thickness, heat flow from the conductive layer to the primary joining surface of the multi-layered pipe (the outer thermoplastic layer) is increased.
Preferably, the thickness of an outermost wall of the coupling is from 2.0 mm to 5.0 mm for use with pipes of outside diameters of 20 mm to 110 mm. By providing an outermost wall of the coupling that is of minimum thickness, the coupling allows the work coil to be closer to the conductive layer of the multi-layered pipe such that the coupling ratio is improved.
It is to be understood that the lower thickness in these ranges relates to pipes of smaller outer diameter and the upper thickness in these ranges relates to pipes of greater outer diameter.
The coupling optionally comprises the same material as is used for one or both of the innermost and outermost layers of the pipe, though this is not essential. Whether or not the same material, the material of the coupling is selected to be compatible with the materials of the innermost and outermost layers in the sense that it will fuse with them under appropriate conditions of temperature and pressure.
Various methods may be used to introduce heat to both the coupling and the inner and outer layers of the multi-layered pipe. In one alternative, heat is introduced by electromagnetic induction. The coupling with the pipe end received in the recess is surrounded by an electrically conducting coil. An alternating electrical current is passed through the coil. The passage of the current through the coil induces a current in the conducting layer of the pipe. This current causes local heating sufficient to melt the surrounding thermoplastic layers of the pipe and the thermoplastic of the coupling, thus the pipe and coupling become thermally bonded.
Preferably the thickness of the conductive layer is from 0.2 mm to 1.2 mm, wherein a thinner conductive layer is used with a pipe of smaller outer diameter and a thicker conductive layer is used with a pipe of greater outer diameter.
It is advantageous for the inner thermoplastic layer to reach a higher temperature than the outer thermoplastic layer as quickly as possible. When the conductive layer is a poor conductor of heat a conductive layer of reduced thickness increases the heating efficiency of the method. Also, a thin conductive layer is easier to form from a sheet into a pipe.
Preferably, the combined thickness of the outer and inner thermoplastic layers is greater than the thickness of the core conductive layer.
Optionally, where this method is to be used, the core layer of the pipe comprises aluminum.
Preferably, the core layer comprises a ferromagnetic material such as magnetic stainless steel. The magnetic stainless steel layer is not limited to any specific type or grade of stainless steel but can comprise martenistic stainless steel, ferritic stainless steel, Duplex or Super Duplex stainless steel.
Magnetic stainless steel is advantageous in that the induction heating of such materials is more efficient than for most non-ferromagnetic materials, thus less power is required to cause local melting of the pipe and coupling. Typically, the electrical load in a work coil required to cause local melting of a pipe and coupling when the core layer of the pipe comprises aluminum is 500A. Typically, when the core layer comprises stainless steel the electrical load is reduced to 100A. The improved efficiency reduces energy requirements because higher conductive layer temperatures are reached more quickly with an associated reduction in power requirements and weld cycles.
The reduced power requirements for a pipe comprising a stainless steel core layer allow for the use of a smaller, lighter and less expensive induction power supply. Alternatively, a similar rated power supply unit is capable of performing multiple, simultaneous joinings or joining pipes of greater outside diameter. The current required in the work coil is consequently reduced and design options for the work coil are increased. For example, permitting more portable and lower cost induction welding units to be used. Fewer electrical contacts would be required within a specifically designed work coil to cope with a reduced work coil current, which is advantageous when locating contacts in the limited work space of a coil and housing.
Preferably, where the conductive layer comprises stainless steel the thickness of the conductive layer is from 0.2 mm to 0.8 mm.
Using known solid state induction techniques, the heating parameters for the method such as, cycle time, current frequency and power input can be accurately controlled allowing a high degree of repeatability contributing to consistency of joint integrity and a reduction in rejects.
Where the core layer comprises aluminum or magnetic stainless steel, using a pre-programmable variable power input, the aluminum or magnetic stainless steel interface temperature is desirably maintained at between about 200° C. and 260° C. The amount of energy needed to achieve the temperatures can be determined from the power applied to the electrically conducting coil, the surface area of aluminum or magnetic stainless steel, in the core layer to be heated, and the weld cycle time.
The weld cycle time is desirably in the region 10s to 300s depending upon pipe diameter, around 10s for the smallest diameters and 300s for largest.
Where the core layer comprises aluminum or magnetic stainless steel, the operating frequency of the electrically conducting (work) coil is desirably between about 40 kHz and 60 kHz again depending on pipe diameter. It will be appreciated that the optimal operating frequency used will differ for different metallic materials. The frequency chosen reflects the inherent characteristics of the materials structure and is influenced by the materials inherent conductivity and resistivity and whether or not the material is magnetic. Determination of an appropriate frequency for a pipe and coupling of given structure is assumed to be well within the capabilities of the skilled reader.
The work coil is supplied with an alternating current and corresponding voltage by induction welding equipment. The induction welding equipment typically comprises of an induction power supply unit, connected to a remote output circuit by an inter-connecting power lead. The work coil connects directly to the remote output circuit. The alternating current in the work coil induces a magnetic field that surrounds the work coil and any object, in this case the metal layer within the pipe, that is located within the work coil. The magnetic field sets up secondary eddy currents in the metal layer of the pipe which, through resistive effects, cause the metal to heat.
The induction welding equipment is desirably of a design which is portable and lightweight. In one embodiment, this is achieved by designing the internal electronic circuitry to operate from a 110V AC power input such that the need for any internal voltage transformer as used in conventional induction welding equipment is removed. (It will be appreciated that the transformer is the heaviest item within a conventional induction welding power supply unit.) The supply voltage is transformed using industry standard portable transformers, for example of the type commonly used in the construction industry. The resistive characteristics of the internal electronic components of the induction power supply unit are selected to minimize the heat generated by the components and the consequent amount of cooling required. Whilst, in conventional systems, water cooling of the induction power supply unit is necessary to remove the excess heat, in the present embodiment, cooling is achieved through strategic, direct assembly of the internal electronic circuitry onto a lightweight aluminum finned heat sink which also forms an integral part of the superstructure of the induction welding power supply unit. As a result of the novel design described, the weight of the induction welding power supply unit is typically no greater than 15 kg compared to from 35 to 50 kg for conventional equipment having the same maximum power rating. The inter-connecting power leads of the novel equipment enable an operator to perform a number of welds at a distance from the induction welding power supply unit. This significantly reduces the effort required by the operator in carrying equipment throughout an installation and increases mobility. The length of the inter-connecting power lead is typically 3-5 m. It is necessary to compensate for the power losses along the inter-connecting power lead with the use of a specially designed remote output circuit box. This is air-cooled and typically weighs 1-3 kg and is considerably smaller than the induction welding power supply unit.
Conveniently, the electrically conducting coil can be provided in the form of a flexible wire which can be coiled around the pipe in an appropriate configuration to provide the desired heating effect. The efficiency of the heating process may be enhanced through the use of a special construction of wire, commonly referred to as litz wire. The wire is constructed from a number of individually insulated copper wires that are twisted or braided together. The construction of the wire reduces eddy current losses and skin effect problems to the extent that efficiencies are increased. A more efficient work coil allows for shorter joining cycle times and reduces power requirements. The litz wire is also advantageous because heat build up is minimised. This enables the work coil to operate without water cooling which is a normal requirement for standard copper work coils. The fact that the coil is capable of maintaining a safe working temperature, without the use of an artificial cooling media, is advantageous because an installer does not require the use of a water supply which can be difficult to source on a new build installation. It will be appreciated that the optimum configuration for the coil can be determined from the coupling ratio of the coil to the pipe (i.e. the inner diameter of the coil and the outer diameter of the metal layer of the work piece) from the parameters of the electrical supply to be provided to the coil and the heating characteristics of the core metal layer.
Preferably, the work coil has between 3 and 6 full turns.
The number of turns of the work coil is selected according to the frequency of the power output and the outer diameter of the pipe or fitting that is to be joined.
Preferably, an inter-changeable Remote Output Circuit (ROC) is used to connect the work coil to the power supply units.
An ROC allows for correction of the work coil to optimise its efficiency.
Accurate positioning of the flexible coil may be achieved by providing a two part cylinder which is sized to clamp around the pipe and fitting. The two parts of the cylinder may be hingedly connected or may be fastenable together by any conventional, mechanical means. One or more guides may be provided in or on the outer surface of the cylinder to receive the wire and hold it in an appropriate configuration. For example, a guide may be provided in the form of a helical groove machined into the outer surface of the cylinder at an appropriate depth and with an appropriate pitch for receiving the flexible wire. Whilst a helical configuration is convenient, it will be appreciated it is not essential. Once the wire is held in place in the guide or guides, it is desirably clamped in place by a restraining device, optionally in the form of a second cylindrical clamp.
Other suitable restraining devices include but are not strictly limited to a strap or a clip.
Preferably, the coil contains electrical contacts to connect the work coil which in combination are able to carry the electrical current load of the work coil.
The cylinder comprises a material which has a relatively low heat conductivity, which is not inductive and which is not compatible (i.e. it will not fuse) with the materials of the coupling and pipe under the conditions applied for fusing the coupling to the pipe. For example, the material of the cylinder may have a melting point which is significantly higher than that of the coupling/pipe. Optionally, the cylinder may be coated with a material which is incompatible with those of the coupling/pipe, its body comprising a different material. The incompatible material of the cylinder or its coating may, optionally, comprise a crystalline engineering thermoplastic material for example nylon or acetal.
It will be appreciated that the flexible wire when combined with a variety of differently sized, helically grooved cylindrical clamps, is adaptable for use with pipes in a wide range of diameters (e.g. from 20-110 mm).
As an alternative to the flexible coil, a cylinder clamp similar to that already described may be provided with an integral coil. This does not necessarily need to be a helical coil—other configurations may be used. The coil is moulded or bonded into position in the cylinder which is designed in such a manner that it may be placed around the pipe/fitting joint, for example it may consist of two half shells which may be connected via a hinge or other similar device, which allows continuation of the coil wire from one half shell to another. When the cylinder is reformed (i.e the two parts are closed or fastened together), the corresponding pieces of coil are matched up thereby reforming the coil. Optionally, in this arrangement, the ends of the coil may be terminated in a specific manner so as to ensure intimate contact of the ends of the coil when it is reformed.
Heat generation by mutual induction is time and energy efficient, thus joining costs and process times can be minimised. The process is clean and non polluting producing no harmful emissions, noise or waste heat which may significantly affect the surrounding environment and as such is safe and not unpleasant for installers to use.
It will be appreciated that other means could be used to create heat in a metallic or other conductive layer which could, in turn, conduct heat to surrounding thermoplastic layers and a coupling. For example, current may be applied directly to the metal or conductive layer. The metal layer may also be employed to conduct heat from another heat source and to the thermoplastic layers and coupling. Other heating means and methods will no doubt occur to the skilled addressee without departing from the scope of the invention as defined by the appended claims.
In another alternative suitable for use in pipes with or without a metallic/conductive middle layer, the coupling and inner and outermost layers of the pipe may be heated using socket fusion. Using heating tools shaped to complement the cross section of the coupling and the pipe end, the tools are placed into the recess of the coupling and over the ends of the pipe extending some way along the exposed surfaces of the inner and outermost pipe layers.
Heat is applied to the tools which in turn heat by conduction, the section of the coupling defining the recess, and the exposed surfaces of the pipe. Heat may be applied to the heating tools when in situ or prior to application to the coupling and pipe end. Once local melting of the coupling and pipe begins to occur, the heating tools are removed and the pipe end is inserted into the recess of the coupling. In this alternative, the recess of the coupling is desirably sized to close tolerances to ensure an interference fit of the pipe end in the recess. This ensures a joint pressure sufficient to bond the pipe end with the coupling when inserted.
Any known method can be used to heat the heating tools, for example (but not strictly limited to); resistance heating, heating by conduction and heating by induction.
Heating parameters for heating the tools such as heat soak time and temperature can be accurately controlled allowing a high degree of repeatability of the method contributing to consistency of joint integrity and a reduction in joint rejection.
In common with the first embodiment, this process is a clean and non polluting producing no harmful emissions, noise or waste heat which may significantly affect the surrounding environment and as such is safe and not unpleasant for installers to use.
In further embodiments of the invention, pipes of multi-layer construction can be joined using fittings of the design as previously described and any method which creates sufficient heat to melt exposed thermoplastic surfaces of the pipes and fittings which, when placed in contact with each other fuse to form a joint which encloses and protects the pipe end. Such methods already known in field of pipe joining include (but are not strictly limited to) ultrasonic and spin welding.
The method of the invention provides a homogenous weld about the pipe end enclosing the ends of each of the layers of the pipe and which is less susceptive to thermal effects such as shrinkage or expansion often encountered in the use of mechanical fittings and which can ultimately result in leakage of materials carried in the pipe. As the bore of the pipe is included in the seal and the pipe end face isolated from internal fluid pressures of fluids conveyed through the pipe, the incidence of pipe end delamination is, consequently, eliminated. Enclosing of the pipe ends and in particular, the end of the metal layer also serves to prevent contamination of the contents of the pipe which might occur were the metal layer exposed to contents and to corrode and breakaway or dissolve in solution in the pipe contents.
Optionally, the cross-section of the coupling defining the recess may be U-shaped, J-shaped or L-shaped.
The flow of heat when using a J-shaped or L-shaped coupling is improved because the material from which the coupling is made has greater thermal conductivity than air. The shape of the coupling allows more heat to flow to the multi-layered pipe within the coupling.
The coupling configurations ensure that the bore of the pipe is always included in the seal and assists in the elimination of pipe end delamination. It is to be understood that the term coupling as stated herein is intended to include pipe end fittings for closing the ends of pipes as well as fittings for joining pipes together. The method has application in joining of pipes to couplings of all types including but not strictly limited to; T-junctions, elbows, 45° elbows, cross pieces and Y-pieces. The couplings are conveniently provided with annular recesses in their open ends configured to receive the ends of pipes to be joined.
The resulting joint is considerably more leak proof than joints provided by mechanical methods such as mechanical crimping.
To assist the reader in understanding the invention, there follows a description of some embodiments of pipes and couplings to which the invention may be applied and of apparatus which may be used to perform the invention.
The following Figures are referred to in the discussion which follows:
As can be seen from
In the left hand side of
d illustrates an arrangement similar to that of
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The two parts are joined so as to enclose two pipe ends 64, 65 which in turn are connected by a thermoplastic coupling (not shown). With the two parts 61, 62 joined together, a flexible wire 69 is coiled around the outer surface of the closed clamp and is received in a helical groove 60 provided in the outer surface of the clamp.
The ends of the wire 69 are provided with terminals 66 which, in turn, can be plugged into sockets of a remote output circuit 67.
In
A cable 803 capable of delivering 110V is provided between the transformer 801 and a portable power induction power supply unit 804. The 110V AC power supply is received as an input to the induction power supply unit 804 via cable 803. The induction power supply unit 804 is embodied in a lightweight box and has an approximate total weight of 15 kg. On a top surface of the box is an operator interface panel 805 by means of which an operator can select the appropriate welding conditions, that have been predetermined to affect the optimum power output and cycle time from the induction power supply unit to the work coil that surrounds the pipe and fitting to be welded. One or more sides of the supply unit 804 comprise a number of conductive fins 806 (for example, aluminum) which act as a heat sink dispersing heat generated internally of the induction power supply unit. The induction power supply unit 804 is also provided with one or more carrying handles 802.
Once the desired characteristics of the output supply voltage have been selected by the operator, the output supply voltage directed to the work coil via an interconnecting lead 807 from the induction power supply unit 804 to a remote output circuit box 808 (approximate weight 1-3 kg). The interconnecting lead 807 is designedly long (for example about 3-5 meters). The remote output circuit box 808 includes circuitry to compensate for losses or distortions on the characteristics of the selected output supply voltage incurred in transmission through the interconnecting lead 807. The approximate weight of the remote output circuit is 1-3 kg.
As can be seen from
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/GB2005/000682 | Feb 2005 | US |
| Child | 11844528 | Aug 2007 | US |
