Patent Application
20220250109
This patent application claims priority from Italian patent application no. 102019000011901 filed on 16 Jul. 2019, the entire disclosure of which is incorporated herein by reference.
The present invention relates to a system and method for field internally coating a pipe joint.
In particular, the present invention relates to a system for internally coating a joint of a metal pipe during the laying operations of said pipe on a bed of a body of water, without limiting thereby the wide range of possible applications of the present invention.
Generally, the laying of pipes on a bed of a body of water is carried out by a vessel, which is configured to transport, connect and lay a plurality of pipe sections.
Before being laid on the bed of the body of water, the ends of the pipe sections are field welded together to form a pipe.
In more detail, one end of a pipe section is welded to one end of the pipe and then the vessel is advanced to allow the introduction of said pipe section into the body of water.
The internal and external surfaces of each pipe section are coated with at least one coating to prevent corrosion, heat loss and to reduce the pressure drop of the transported fluid.
This coating is generally applied to each pipe section during the manufacturing stage, in a pipe section manufacturing plant.
However, the end portion of each pipe section is not coated because the high temperatures of the welding could damage the coating.
Therefore, the inner and outer surfaces of the welded end of each pipe section must be coated in the field after welding.
Generally, the coating is made by the application of a polymer, such as an epoxy resin, which must be applied to the inner surface of the pipe section at a temperature within a predetermined range.
As known from U.S. 8,800,396 and GB 2,258,901, a machine configured to advance inside the pipe is used to field coat the inner surface of the pipe sections, comprising a coating transport system and an applicator to apply the coating to the inner surface of the pipe with FBE resins, which enable relatively thin coatings to be produced.
The purpose of the present invention is to provide a system for field internally coating a pipe joint which overcomes the drawbacks of the prior art.
According to the present invention a system is provided for field internally coating a pipe joint; the system comprising a polymer application unit, which comprises:
Thanks to the present invention, it is possible to store, feed and mix the components of a two-component polymer in the application unit inside the pipe. In particular, the mixing of the polymer components is carried out in a mixer just before the polymer is applied to the inner surface of the pipe in order to achieve optimal mixing of the components and to promote an optimal coating of the joint with elevated thicknesses.
In particular, the polymer application unit comprises a first and a second motor, preferably electric, configured to independently control the first and second pump so as to selectively vary the respective flow rates of the first and the second pump.
In this way, the flow rate of each component fed to the mixer can be adjusted independently to accurately vary the composition of the polymer applied to the inner surface of the pipe.
In particular, the applicator comprises a first rotating body, preferably in the shape of a disc, configured to project the polymer in a centrifugal manner onto the internal surface of the pipe.
Thanks to the rotation of the first rotating body, the polymer is applied homogeneously by centrifugal force diffusion, which determines the atomization of the polymer.
In particular, the applicator comprises a second body having an annular-shaped end facing the first body so as to form an annular cavity to guide the polymer between the first and the second body towards the inner surface of the pipe.
In this way, the polymer is diffused through the annular cavity, increasing the precision of the polymer application.
In particular, the polymer application unit comprises at least one sensor, preferably at least one camera, to monitor the coating operations.
In this way, signals related to the condition of the inner surface of the pipe can be emitted to control the coating operation of the inner surface of the pipe.
In particular, the at least one sensor is configured to rotate at least partially around an axis parallel to the longitudinal axis of the pipe.
In this way, the condition of each annular sector of the inner pipe surface can be monitored.
In particular, the polymer application unit comprises a third motor, preferably electric, configured to control the rotation of the applicator.
In this way, the third motor allows the rotation of the applicator.
In particular, the polymer application unit comprises a first tube to hydraulically connect the first pump to the mixer and a second tube to hydraulically connect the second pump to the mixer; the temperatures of the first and second component in the mixer, in the first and the second tube and in the first and the second pump being maintained within a first and a second predetermined temperature range.
In this way, the temperature of the first and second components in the first and second pipe can be kept substantially constant and the first and second components can be fed to the mixer at a pre-established first and second temperature.
In particular, the polymer application unit comprises a valve coupled to the mixer and configured to interrupt the supply of the first and the second component to the mixer and avoid mixing the first and the second component.
In this way, during interruptions in the polymer application process, the mixing and feeding of the polymer to the applicator is interrupted and prevents unwanted and uncontrolled mixing of the first and second components.
In particular, the polymer application unit comprises a third tube and a fourth tube, which hydraulically connect the valve respectively to the first and the second tank and allow the recirculation of the first and the second component in the first and the second tank; the valve being configured to selectively feed the first and the second component to the mixer or to the third and the fourth tube.
In this way, the first and second pumps continue to operate even when the polymer application is interrupted.
The ratio of surface area to volume of the tubes is greater than the ratio of surface area to volume of the tanks. In other words, the heating power of said tubes is greater than the heating power of said tanks. As a result, the recirculation of the first and second component is carried out to bring the first and second component to a given optimum temperature for the specific application.
In particular, the first, the second, the third and the fourth tube are coated with an insulating material.
In this way, the chemical-physical properties of the first and second component in the polymer application unit can be precisely controlled.
In particular, the polymer application unit comprises a second cart configured to slide on the first cart in a direction parallel to the longitudinal axis of the pipe to move the mixer, the applicator and the conduit with respect to the first cart.
In this way, the second cart allows the applicator and mixer to move independently of the first cart.
In particular, during coating operations, the second cart allows the reciprocating movement of the applicator around the portion of the internal surface of the pipe to be coated so as to apply a plurality of polymer coats on the internal surface of the pipe, avoiding the movement of the first cart and allowing considerable energy savings.
In particular, the second cart is motorized so as to control the position of the second cart with respect to the first cart.
In this way, the sliding of the second cart on the first cart can be controlled in a simple and effective way.
In particular, the first and second pumps and the first and second tanks are fixed on the first cart.
In this way, the second cart allows the applicator and mixer to move independently of the first and second tank and of the first and second pump.
In particular, the polymer application unit comprises a drip tray for the polymer; said free end of the conduit being selectively movable between the applicator and the drip tray.
In this way, and in consideration of the fact that longer interruptions than the normally predefined ones may occur between one application of the polymer and the next due to unforeseen circumstances, the polymer can be fed from the duct to the drip tray, preventing the polymer from polymerising inside the mixer and the duct.
In particular, the polymer application unit comprises a third cart configured to slide in a direction parallel to the longitudinal axis of the pipe to move the mixer and the free end of the conduit with respect to the applicator.
In this way, the third cart allows the mixer and the conduit to be moved independently of the applicator.
In more detail, during the momentary interruption of the polymer application operations, the third cart can be moved to place the free end of the conduit at the drip tray and feed the polymer into the drip tray.
In particular, the third cart is motorized so as to control the position of the third cart simply and effectively.
In particular, the polymer application unit comprises at least one containment device for each tube, which is configured to control the curvature of the respective tube and avoid contact between the respective tube and the inner surface of the pipe.
In this way, each flexible tube is guided by the respective containment element so that, while one of the second or third carts is sliding on another of the first and second carts, each flexible tube does not come into contact with the inner surface of the pipe or obstruct the sliding of the carts.
In particular, the system comprises a finishing unit of the inner surface of the pipe, configured to prepare the inner surface of the pipe for the polymer application, and a locomotion unit configured to move the polymer application unit and the finishing unit inside the pipe.
In this way, the system is able to machine the inner surface of the pipe independently and move around inside the pipe.
In particular, the finishing unit comprises at least one tank configured to contain an abrasive material; a rotating wheel configured to centrifugally emit the abrasive material onto the inner surface of the pipe; a device to recover the abrasive material; and a containment chamber, configured to contain the rotating wheel and the recovery device, and to delimit the portion of pipe where the abrasive material is emitted.
In this way, the surface portion of the pipe to be coated is subjected to a finishing treatment, such as sandblasting, to eliminate irregularities.
Another purpose of the present invention is to devise a method for field internally coating a pipe joint which overcomes at least one of the drawbacks of the prior art.
According to the present invention a method for field internally coating a pipe joint by the application of a polymer is provided, the method comprising:
selectively advancing a polymer application unit inside a pipe in a direction parallel to the longitudinal axis of the pipe;
feeding through a first and a second pump respectively the first and the second component from the first and the second tank to a mixer;
mixing the first and second component to form a polymer with a specific composition;
feeding the polymer from the mixer to a rotating disc applicator via a conduit; and
applying the polymer to the pipe by means of the applicator.
Thanks to this method, it is possible to internally coat a pipe joint in an effective manner and to make coatings of elevated thickness.
In particular, the method comprises independently controlling the first and second pump.
In this way, it is possible to independently vary the flow rate of the first and second components fed to the mixer to vary the chemical-physical characteristics of the polymer.
In particular, the method comprises monitoring the coating operations and inspecting the inner surface of the pipe by means of at least one sensor, preferably by at least one camera.
In this way, it is possible to emit signals related to the chemical-physical characteristics of the inner surface of the pipe and the coating operations to control and monitor the coating operations.
In particular, the method comprises maintaining within a first and a second predetermined temperature range, the temperatures of the first and the second component in the mixer, in the first and the second pump, and in a first and a second tube respectively connecting the first and the second pump to the mixer.
In this way, the first and second components are fed to the mixer at a first fixed temperature and a second fixed temperature respectively.
In particular, the method involves moving the mixer, the applicator and the conduit in relation to the first and second pump and the first and second tanks.
In other words, during the coating application operations, it is possible to move the applicator keeping the first and second tanks and the first and second pumps stationary.
In this way, the coating can be applied precisely to the inner surface of the pipe section to be coated and several coats can be given without moving the entire system, thus saving energy.
In particular, the method involves moving the mixer and one free end of the conduit relative to the applicator.
In particular, the method comprises selectively feeding the polymer into a drip tray.
In particular, the method comprises selectively moving one free end of the conduit between the applicator and the drip tray.
In this way, it is possible to keep the polymer moving inside the mixer and the conduit in the event of particularly prolonged stops, during which the polymer could polymerise in the mixer and in the conduit.
Other characteristics and advantages of the present invention will become clear from the following description of a non-limiting example of an embodiment made with reference to the appended drawings, wherein:
With reference to
The system 1 comprises a finishing unit 4 of the inner surface of the pipe 3, configured to prepare the inner surface of the pipe 3 for the polymer application; a polymer application unit 5, configured to apply the polymer to the inner surface of the pipe 3; and a locomotion unit 6 configured to move the polymer application unit 5 and the finishing unit 4 inside the pipe 3 in a direction D parallel to the longitudinal axis A.
The finishing unit 4, the polymer application unit 5 and the locomotion unit 6 are connected to each other.
In the case shown in
The locomotion unit 6 comprises a cart 7, which is configured to move inside the pipe 3 in the direction D; and a motor unit 8, which is configured to provide the necessary propulsion to the locomotion unit 6 to move the entire system 1 inside the pipe 3 in the direction D.
Although only one locomotion unit 6 is shown in
The finishing unit 4 comprises at least one tank 9 configured to contain an abrasive material; a rotating wheel 10 configured to centrifugally emit the abrasive material onto the inner surface of the pipe 3; a recovery device 11 of the abrasive material; and a containment chamber 12, bounded by two walls 13 and configured to contain the rotating wheel 10 and to delimit the section of pipe 3 onto which the abrasive material is emitted.
According to an embodiment not shown in the appended drawings, the recovery device 11 comprises a suction nozzle of the abrasive material, which slides along a guide in a direction substantially perpendicular to the longitudinal axis A and is actuated by an actuator, preferably a pneumatic cylinder, and by a motor, preferably a linear stepped motor, so as to allow the sliding of the suction nozzle along said guide. In more detail, said actuator is configured to move the suction nozzle from a parking position to a working position and said motor is configured to position the suction nozzle at a precise distance from the pipe surface 3.
The polymer application unit 5 comprises a cart 14 configured to selectively advance inside the pipe 3 in the direction D; a tank 15 and a tank 16, which are configured to contain a first and second polymer component respectively; a mixer 17, preferably a static mixer, configured to mix the first and second component; a pump 18 and a pump 19 to supply the first and second component respectively from the tank 15 and the tank 16 to the mixer 17; an applicator 20 configured to apply the polymer to the pipe 3; and a conduit 21 having a free end configured to be placed near the applicator 20 to supply the polymer from the mixer 17 to the applicator 20.
The first component is a base polymer component, while the second component is the curing component.
The polymer is composed of a two-component liquid epoxy polymer mixture. In a preferred embodiment, the polymer is a thermosetting epoxy resin. The product SP-9888® manufactured by Specialty Polymer Coating Inc. #100, 5350-272nd Street Langley, BC V4W 1S3, is particularly suitable for this purpose.
In the case in
The polymer application unit 5 comprises a valve 22 coupled to the mixer 17 and configured to selectively cut off the supply of the first and second component to the mixer 17 and selectively prevent mixing of the first and second component; two electric motors 23 and 24, which are attached to the cart 14 and control the respective pumps 18 and 19; two flexible tubes 25 and 26, which hydraulically connect the pumps 18 and 19 to the mixer 17 through the valve 22; and two flexible hoses 27 and 28, which hydraulically connect the valve 22 to the tank 15 and tank 16 respectively and allow recirculation of the first and second component in the respective tanks 15 and 16.
According to an embodiment not shown in the appended drawings, the tubes 27 and 28 respectively connect the tubes 25 and 26 to the respective tanks 15 and 16 and are equipped with respective recirculation valves, which are configured to selectively close or open the passage of the first and second component to the respective tanks 15 and 16 so as to allow or prevent recirculation of the first and second component.
In the preferred embodiment, the tubes 25, 26, 27 and are coated with an insulating material to keep the temperature of the first and second component constant inside the tubes 25, 26, 27 and 28.
In addition, the temperature of the first and second components in the tanks 15 and 16 and in the valve 22 is kept constant.
In more detail, the polymer application unit 5 comprises a plurality of temperature sensors to measure the temperature of the first component in the tank 15, pump 18, tube 25, tube 27 and mixer 17 and to measure the temperature of the second component in the tank 16, pump 19, tube 26, tube 28 and mixer 17.
According to a particular embodiment, the polymer application unit 5 comprises at least one heat exchange device, not shown in the appended drawings, configured to regulate the temperature of the first and second components inside the tubes 25, 26, 27 and 28. The applicator 20 comprises a first, rotating, disc-shaped body and a second body with an annular-shaped end facing the first body to form an annular cavity to centrifugally emit the polymer from the annular cavity onto the inner surface of the pipe 3.
According to one embodiment of the present invention, the rotation axis of the first rotating body substantially coincides with the longitudinal axis A of the pipe 3.
The polymer application unit 5 comprises an electric motor 29 configured to control the rotation of the first rotating body.
In a preferred embodiment, the polymer application unit 5 comprises at least one sensor, not shown in the appended drawings, which is configured to rotate at least partially around an axis parallel to the longitudinal axis A and to monitor the coating operations.
In a particular embodiment, the polymer application unit 5 comprises a camera, not shown in the appended drawings, which is configured to rotate around the longitudinal axis A to provide video and/or images of the inner surface of the pipe 3.
In the case shown in
In other words, the cart 30 is configured to control its position relative to the cart 14, and the cart 32 is configured to control its position relative to the cart 14 and the cart 30.
The applicator 20 and drip tray 31 are arranged on the cart 30 so that they slide in the direction D with respect to the cart 14.
One end of the conduit 21 is attached to the mixer 17, which is located on the cart 32 so as to allow the sliding of the conduit 21 and mixer 17 with respect to the cart 14 and cart 30 in the direction D, selectively allowing the polymer to be fed from the conduit 21 to the applicator 20 or from the conduit 21 to the drip tray 31.
With reference to
Each containment device 33 comprises a plurality of meshes 34 coupled together by pins 35 so as to allow a relative rotation between the coupled meshes 34.
In use and with reference to
In more detail, the finishing unit 4 is moved inside the pipe 3 in such a way that the joint 2 is enclosed between the walls 13 of the containment chamber 12.
Subsequently, the abrasive material is fed from the tank 9 to the rotating wheel 10, which, by turning, emits the abrasive material centrifugally on the internal surface of the pipe 3 at the joint 2 in order to eliminate the irregularities of the internal surface of the pipe 3 caused by the welding process to facilitate the subsequent application of the polymer.
The abrasive material is recovered by the recovery device 11 for possible reuse later in a further finishing process.
At the end of the finishing process, the system 1 is again moved by the locomotion unit 6 in the direction D, to position the applicator 20 near the joint 2 and start the polymer application process.
At this stage, the pumps 18 and 19 feed the first component and the second component from the tanks 15 and 16 to the mixer 17 via the valve 22.
The motors 23 and 24 respectively control the pumps 18 and 19 independently, so as to regulate the flow rate of the first and second components fed to the mixer 17.
In particular, the motors 23 and 24 are configured to control the pumps 18 and 19 so as to progressively vary the flow rate of the first and second component at the beginning and at the end of the polymer application operations.
The temperature of the first and second components inside the tubes 25 and 26 is kept constant.
In the mixer 17, the first and second components are mixed to form the polymer to be applied to the inner surface of the pipe 3.
The polymer obtained by mixing the first and second components is fed from the mixer 17 to the conduit 21, which in turn feeds the applicator 20 through the free end of the conduit 21.
The first body of the applicator 20 is rotated by the electric motor 29 and centrifugally projects the polymer onto the inner surface of the pipe 3 at the joint 2.
With reference to
In more detail, the cart 30 slides alternately along the direction D to apply a plurality of coats to the internal surface of the pipe 3 at the joint 2.
With reference to
At this stage, the valve 22 interrupts the supply of the first and second components to the mixer 17 and directs the flow of the first and second components to the tubes 27 and 28 respectively so that the first and second components can be recirculated to the tank 15 and the tank 16.
According to a variant of the present invention, the valve 22 continues to feed the first and second components to the mixer 17 in order to prevent the polymer from hardening in the mixer 17.
The tubes 25, 26, 27 and 28 are flexible and therefore do not obstruct the sliding of the cart 30 on the cart 14 and the sliding of the cart 32 on the cart 30.
A plurality of sensors, not shown in the appended drawings, monitor the progress of the finishing and polymer application operations, and measure the chemical-physical characteristics of the internal surface of the pipe 3.
Although in this description the system 1 is used for the internal coating of joints 2 of a pipe 3 when laying the pipe 3 on a bed of a body of water, the system 1 can be used for internally coating a generic cylindrical body in other fields of application.
It is apparent that variations may be made to the present invention while remaining within the scope of protection of the appended claims.
According to an alternative embodiment, the cart 32 is omitted and the mixer 17 is placed on the cart 30.
According to a further alternative embodiment, the cart 30 is omitted and the drip tray 31 and applicator 20 are placed on the cart 14.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102019000011901 | Jul 2019 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2020/056703 | 7/16/2020 | WO |
