APPARATUS FOR COATING PIPES

Abstract

Provided is an apparatus for coating a girth weld and a cutback region surrounding said girth weld, said apparatus having lateral travel at least equal to the length of the cutback region and circumferential rotational travel around the pipe. The apparatus can provide a multiple component coating accurately and safely, without the need for solvent flushing of the apparatus.

Claims

1. An apparatus for coating a girth weld and a cutback region surrounding said girth weld on a coated steel pipe, comprising: a frame having: a roller carriage configured for mounting to a track affixed proximal to said cutback region and circumferentially around said coated steel pipe, said roller carriage having powered circumferential travel means providing circumferential rotational travel of said frame at least 350 degrees around said track, said powered circumferential travel means comprising a powered drive gear on said frame, operatively connected to a motor for powering the powered drive gear along the track, said powered circumferential travel means providing variable, user selectable rotation speed, said powered circumferential travel means providing unidirectional or bidirectional travel; and an arm cantilevered laterally from said frame; said arm having a spray head region at an end of said arm distal to said frame, said spray head region laterally or transversely adjustable relative to the arm and frame; said arm having powered lateral travel means providing lateral travel of the spray head region relative to said frame, the distance of said lateral travel at least equal to the length of half of the cutback region; a controllable means for spraying a mixed, multi-component liquid coating from the spray head region onto the cutback region to be coated; wherein the controllable means further comprises: a cartridge carriage configured to receive at least one cartridge wherein, when in use, the cartridge carriage contains at least one cartridge and at least two components of the multi-component liquid coating housed within said at least one cartridge; displacement means for displacing the at least two components of the multi-component liquid coating out of the at least one cartridge and into a mixer which mixes the at least two components to form the multi-component liquid coating, and therefrom through a spray nozzle attached to said mixer; said spray nozzle affixed to the spray head region and configured to spray the multi-component liquid coating onto the cutback region when the apparatus is mounted to a track affixed proximal to said cutback region; optionally a power source for the powered lateral travel means, the powered circumferential travel means, and/or the means for spraying the mixed, multi-component liquid coating; optionally a plurality of wheels affixed to the roller carriage to facilitate circumferential travel of said frame around said pipe; a controller operatively linked to and controlling the powered lateral travel means, the powered circumferential travel means, and the means for spraying the mixed, multi-component liquid coating, said controller optionally controlling the displacement means for displacing the at least two components; and optionally a control box wired to the controller, said control box having a user interface for operating and/or programming the apparatus.

2. The apparatus of claim 1 further comprising a spray nozzle and a pressurized air input, optionally including a pressurized air preparation means selected from an air filter, an air dryer, and/or a heater, upstream of the pressurized air input and connected thereto by a pressurized air line.

3. The apparatus of claim 1 wherein the displacement means for displacing the at least two components comprises a piston for displacement of each of the components out of the cartridge or cartridges, and a cartridge gun for displacing the pistons, said cartridge gun selected from a pneumatic cartridge gun, an electric cartridge gun, and a hydraulic cartridge gun.

4. The apparatus of claim 1 wherein the powered lateral travel means is a non-captive stepper motor on said frame, turning a lead screw on said arm, which in turn moves the arm relative to the frame.

5. The apparatus of claim 1 wherein the two components of the multi-component liquid coating comprise (a) an epoxy base and (b) an epoxy curing agent, and wherein the cartridges or reservoirs are of an appropriate size to contain sufficient epoxy curing agent and/or epoxy base, respectively, for coating one cutback region.

6. The apparatus of claim 1 further comprising: at least two continuous component inlets each adapted to receive a line through which the component flows; a valve for controlling the flow of the component from the component inlets into the mixer which mixes the components to form the multi-component liquid coating, and therefrom through the spray nozzle attached, optionally by multi-component liquid coating hose, to said mixer.

7. The apparatus of claim 6 further comprising the multi-component liquid coating hose.

8. The apparatus of claim 6 wherein the multi-component liquid coating hose, and/or the spray nozzle, are disposable consumables or reusable.

9. The apparatus of claim 1 wherein the apparatus is less than 50 lbs in weight.

10. A method of coating a cutback region of a pipe, comprising: (a) affixing or clamping a track having a rack, circumferentially around an outer surface coating of said pipe, proximal to said cutback region; (b) mounting an apparatus of claim 60 to said track so that the circumferential travel means engages with the rack; (c) positioning the spray head region laterally within the cutback region of the pipe; (c1) optionally pre-heating the at least one cartridge; (d) installing the at least one cartridge into the cartridge carriage, said at least once cartridge loaded with at least two of the components of the multi-component liquid coating; (e) priming the mixer and spray nozzle with multi-component liquid coating by displacing the components from the cartridge into the mixer and spray nozzle; (f) spraying the multi-component liquid coating out of the spray nozzle onto the cutback region of the pipe while rotating the apparatus around the pipe, optionally comprising providing pressurized air to the nozzle; (g) optionally displacing the spray head region laterally relative to the frame of the apparatus, while rotating the apparatus around the pipe or between rotation cycles, to spray the multi-component liquid coating onto the entirety of the cutback region, resulting in a relatively even coating of the multi-component liquid coating onto cutback region; wherein step (d) is done in any order relative to the other steps, and steps (a), (b), (c), (e) and (f) are done in the order herein provided;

11. The method of claim 10 wherein steps (e) and optionally (f) are computer controlled and automated.

12. A method of coating a cutback region of a pipe, comprising: (a) affixing or clamping a track having a rack, circumferentially around an outer surface coating of said pipe, proximal to said cutback region; (b) mounting an apparatus of claim 42 to said track so that the circumferential travel means engages with the rack; (c) positioning the spray head region laterally within the cutback region of the pipe; (d) installing the high pressure component lines to the continuous component inlets; (e) priming the mixer and spray nozzle with multi-component liquid coating by displacing the components from the high pressure component lines into the mixer and spray nozzle; (f) spraying the multi-component liquid coating out of the spray nozzle onto the cutback region of the pipe while rotating the apparatus around the pipe; (g) optionally displacing the spray head region laterally relative to the frame of the apparatus, while rotating the apparatus around the pipe or between rotation cycles, to spray the multi-component liquid coating onto the entirety of the cutback region, resulting in a relatively even coating of the multi-component liquid coating onto cutback region; wherein step (d) is done in any order relative to the other steps, and steps (a), (b), (c), (e) and (f) are done in the order herein provided.

13. An apparatus for coating a girth weld and a cutback region surrounding said girth weld on a coated steel pipe, comprising: a frame having: a roller carriage configured for mounting to a track affixed proximal to said cutback region and circumferentially around said coated steel pipe, said roller carriage having powered circumferential travel means providing circumferential rotational travel of said frame at least 350 degrees around said track, said powered circumferential travel means comprising a powered drive gear on said frame, operatively connected to a motor for powering the powered drive gear along the track, said powered circumferential travel means providing variable, user selectable rotation speed, said powered circumferential travel means providing unidirectional or bidirectional travel; and an arm cantilevered laterally from said frame; said arm having a spray head region at an end of said arm distal to said frame, said spray head region laterally or transversely adjustable relative to the arm and frame; said arm having powered lateral travel means providing lateral travel of the spray head region relative to said frame, the distance of said lateral travel at least equal to the length of half of the cutback region; a controllable means for spraying a mixed, multi-component liquid coating from the spray head region onto the cutback region to be coated; wherein the controllable means further comprises: a cartridge carriage configured to receive at least one cartridge wherein, when in use, the cartridge carriage contains at least one cartridge and at least two components of the multi-component liquid coating housed within said at least one cartridge; displacement means for displacing the at least two components of the multi-component liquid coating out of the at least one cartridge and into a mixer which mixes the at least two components to form the multi-component liquid coating, and therefrom through a spray nozzle attached to said mixer; said spray nozzle affixed to the spray head region and configured to spray the multi-component liquid coating onto the cutback region when the apparatus is mounted to a track affixed proximal to said cutback region; optionally a power source for the powered lateral travel means, the powered circumferential travel means, and/or the means for spraying the mixed, multi-component liquid coating; optionally a plurality of wheels affixed to the roller carriage to facilitate circumferential travel of said frame around said pipe; a controller operatively linked to and controlling the powered lateral travel means, the powered circumferential travel means, and the means for spraying the mixed, multi-component liquid coating, said controller optionally controlling the displacement means for displacing the at least two components; and optionally a control box wired to the controller, said control box having a user interface for operating and/or programming the apparatus; and wherein the frame comprises a spring biased clamp to releasably mount the roller carriage onto the track.

14. The apparatus of claim 13 wherein the arm comprises at least two shafts linking the spray head region with the frame and slidable relative to the frame.

15. The apparatus of claim 13 wherein the powered drive gear is pneumatically powered.

16. The apparatus of claim 13 wherein the powered drive gear is hydraulically powered.

17. The apparatus of claim 13 wherein the powered drive gear is electrically powered.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0053] FIG. 1 is a front perspective view of an apparatus according to the present invention, affixed to a pipe at a girth weld.

[0054] FIG. 2 is a rear perspective view of the apparatus of FIG. 1.

[0055] FIG. 3 is an enlarged view of the region of FIG. 2 depicted with a “B”.

[0056] FIG. 4 is an isolated, exploded, perspective view of the frame of the apparatus according to the present invention.

[0057] FIG. 5 is a front perspective view of one embodiment of an apparatus according to the present invention.

[0058] FIG. 6 is the rear perspective view of the apparatus of FIG. 1.

[0059] FIG. 7 is an enlarged view of the region of FIG. 6 depicted with an “A”.

[0060] FIG. 8 is a schematic of certain functional elements of an apparatus according to the present invention, connected to a control box.

[0061] FIG. 9 is a front perspective view of a further embodiment of an apparatus according to the present invention.

[0062] FIG. 10 is the rear perspective view of the apparatus of FIG. 9.

[0063] FIG. 11 is a photo of a disposable mixer and cartridge, shown in isolation, for use in the apparatus of FIG. 5.

[0064] FIG. 12 is a photo close-up of the spray head of an apparatus generally similar to that of FIG. 6.

[0065] FIG. 13 is a photo of the apparatus of FIG. 5, connected to a control box.

[0066] FIG. 14 is a schematic of a method of utilizing the apparatus of FIG. 5 to coat a pipe cutback region.

[0067] FIG. 15 is a photo close up of the wireless control pendant of the present invention.

[0068] FIGS. 16A-16F show various views of a control panel for the apparatus according to the present invention.

DETAILED DESCRIPTION

[0069] Described is a relatively small, simple, optionally solvent-free, automated spray apparatus system useful for uniformly coating a cut-back area around a girth weld with a plural component coating, such as a two-part polyurethane or epoxy. The apparatus is in the form of a “bug” which is configured to, and can be mounted on a standard, or optionally on a custom manufactured, track which is clamped to the outer coating of a pipe. The apparatus may be mounted on a single track.

[0070] As shown in FIGS. 1-3, the apparatus 10 is configured to mount onto, and rotate around, track 12 which can be clamped to pipe 14 proximal to cutback region 15. Track 12 comprises a rack 16 which is operably connected to a drive gear 18 on the frame 20 of the apparatus 10. This configuration provides the ability for the apparatus 10 to travel in a motorized, controllable manner, around track 12 and thus around the circumference of the pipe 14 in a ‘rack and pinion’ arrangement. Apparatus also comprises spray nozzle 32 which is cantilevered over the cutback region 3 of the pipe 14.

[0071] FIG. 4 is an isolated, exploded, perspective view of the roller carriage 44 situated on the frame 20 of the apparatus 10 of the present invention. Frame 20 comprises clamping wall 22 which is spring biased with springs 24 to an ‘open’ position, and clamped into a ‘closed’ position utilizing clamping cam handle 26. In the ‘open’ position, the frame 20 may be mounted onto the track 12 and affixed thereto by moving lever 26 such that clamping wall 22 moves to a closed position. Track rollers (28, 30 shown) allow for displacement of the frame 20 around the track 12.

[0072] FIGS. 5-7 show one embodiment of the apparatus of the present invention, a cartridge-based apparatus. Shown is drive gear 18 connected to servo motor 34 and gear head (not shown), through drive engagement cam 36. The servo motor 34 is utilized to turn the drive gear 18, to provide displacement of the apparatus 10 around the circumference of the pipe. Servo motor 34 is controlled by a programmable controller 40 which can be programmed to provide automated displacement of the apparatus 10 around the circumference of the pipe in a desired direction and speed. Also shown, though optional, is drive gear guard 38, which protects the user from injury due to the turning drive gear 18, and protects the rack and pinion mechanism of the drive gear 18 and rack from foreign objects or from spray back of the plural component coating (for example, epoxy). Electronics protective guard 42 can be a plastic or metal plate which protects the key electronic components of the apparatus 10, such as the controller 40, from damage from foreign objects or plural component coating spray back. It would be readily understood to a person of skill in the art that it would be desirable to prevent plural component coating from adhering to the drive gear 18, the rack, or the electronic components of the apparatus 10.

[0073] The apparatus 10 also has cartridge carriage 46 configured to receive cartridges 48, 50. Cartridges 48, 50 may be two separate cartridges, each containing one of the plural components of the coating spray, or, as shown, may be a single cartridge having two segregated bodies each containing one of the plural components of the coating spray. As shown, and its most common embodiment, the apparatus 10 is configured to apply a coating spray having two components, however, it would be understood to a person of skill in the art that if a plural component coating spray having more than two components was desired, the cartridge carriage 46 could easily be configured to receive more than two cartridges, or alternatively, a single cartridge having more than two segregated bodies each containing one of the plural components of the coating spray. Cartridge pistons 52, 54 are configured to enter cartridges 48, 50, and are connected to cartridge gun 56, which is pneumatically or electrically actuated and displaces cartridge pistons 52, 54, thereby displacing the components contained in the cartridge 48, 50 through cartridge nozzles 58, 60. In use, cartridge nozzles 58, 60 are attached to a static mixer having mixing area 130, which is in turn, optionally through a hose 134, attached to spray nozzle 32, at hose adapter 62.

[0074] The actuation of cartridge gun 56 is electronically controlled through controller 40, programmable, and is coordinated with the movement of the apparatus 10 around the pipe 14 and the movement of the spray head 64 relative to the frame 20.

[0075] The ratio of components displaced out of the cartridge nozzles 58, 60 can be controlled through the difference of diameter of the bodies of the cartridges 48, 50, or through a difference in the displacement speed of cartridge pistons 52, 54.

[0076] In certain embodiments, the rate at which the components are delivered to the nozzle is measured by a linear position sensor 61, attached to cartridge gun 56. This sensor may be in the form of a rotary potentiometer, linear potentiometer or non-contact type sensor such as a magnetic potentiometer or optical distance transducer.

[0077] In certain embodiments, the static mixer 130 and hose 134 which connects the static mixer 130 to the spray nozzle 32 are disposable components, reducing the requirement for flushing hoses and solvents. In certain embodiments, the cartridges 48, 50 are pre-loaded with components and disposable. For example, the cartridges 48, 50 can be pre-loaded with the desired amount of components to coat one cut back region, and can be replaced for each cut-back region being coated. In certain embodiments, the cartridges 48, 50 are a Sulzer DP 1L cartridge (Sulzer, Switzerland) and the static mixer 130 is a Sulzer DP static mixer/flex hose assembly.

[0078] In other embodiments, the cartridges are refillable from a low pressure bulk supply of component. Such re-filling can be done between jobs, or it can be done in a continuous manner while the apparatus is in use. In these embodiments, the cartridges may be re-utilized. In such embodiments, the cartridges are configured to receive low pressure component lines (not shown) from a plural component coating spray delivery system (not shown) which may, for example, be a continuous delivery system, with each cartridge receiving, through its own component inlet, a different component of the plural component coating. A valve can be used to control the flow of components through the continuous component inlets. In some embodiments, the low pressure flow of component is continuous, in other embodiments, the low pressure flow of component is automatically controlled, while in use, based on the amount of component left in the cartridge. In such embodiments, the component delivery system is attached to the apparatus through low pressure conduits while the apparatus is in use. In other embodiments, the low pressure flow of component is controlled by the user, for example, by re-filling the cartridges between coating jobs. For example, in some embodiments, the cartridge is re-filled between coating jobs, with a low pressure flow of component, while the user replaces the disposable mixer and nozzle. In such embodiments, in some exemplifications, the apparatus is attached to the component delivery system (through low pressure conduits) while the apparatus is not in use, for example, between coating jobs.

[0079] Apparatus 10 also has sliding arm 66 comprising three slidable shafts 68, 70, 72 each covered by protective bellows 74, 76, 78, respectively. Spray head 64 is connected to the distal end of sliding arm 66 and thus cantilevered over the cutback region 3. It would be appreciated that although three slidable shafts 68, 70, and 72 are shown, any configuration of slidable elements could comprise sliding arm 66. Sliding arm 66 can slide relative to the frame 20 and is displaced by a non-captive stepper motor 80 and lead screw 82 controlled by controller 40 through a multi-channel pneumatic valve body and regulation/velocity control.

[0080] The apparatus 10 has a carrying handle 84 which is adaptable for a hoist ring. However, due to its size and weight, the apparatus 10 can easily be carried by one user utilizing the carrying handle 84.

[0081] The height and position of spray head 64 is adjustable by affixing it at one of spray head attachment points 86. The spray angle can also be adjusted by rotating the spray head 64 relative to the arm 66. Spray head 64 comprises spray nozzle 32 operatively connected to hose adapter 62, and housed in nozzle cradle and quick change adapter 88 for rapidly changing the spray nozzle 32 when required. Spray head 64 optionally, and as shown, also comprises laser alignment module 90 which provides visual identification to the operator of the central target of the spray pattern and facilitates quick alignment of the apparatus during set up to a location on the pipe, typically by aligning the laser “dot” emitted from the laser alignment module 90 to the weld bead at the center of the field joint, and air atomization input adapter 92 which provides pressurized air to the spray nozzle 32. Providing pressurized air through air hose 63 to the spray nozzle 32 allows the pressure of the components to remain low as they are displaced from cartridges 48, 50 to the spray nozzle 32, while still having sufficient pressure to provide a fine spray as the components are released from spray nozzle 32 onto the pipe to be coated.

[0082] Also shown in FIGS. 5 and 6 is spray shield 94, which protects the body of apparatus 10, as well as the track 12, from spray back of the coating spray when in use.

[0083] Apparatus 10 comprises proximity sensors 96, 97, which are inductive type proximity sensors with both safety and accuracy function. The proximity sensors 96, 97 are able to detect when the sliding arm 66 has reached the end of its lateral travel in both directions. The proximity sensors 96, 97 are utilized to stop movement, and prevent unwanted forces from developing in the powertrain and/or drivetrain of the linear stepper motor. For accuracy, the front proximity sensor 96 is used in a homing procedure to detect the “home” position of the lateral slide of the arm—when the arm is fully unextended, the front proximity sensor 96 sets the absolute position of the axis as zero in the controller, then indexes all future positions to this “home” position. As would be understood by a person of skill in the art, this function could equally be provided by rear proximity sensor 97.

[0084] Apparatus 10 also comprises umbilical electrical connector 100 which provides an electrical and electronic connection from the apparatus 10 controller 40 to an external power source (not shown), and/or an external user interface (not shown) or external processor (not shown). Umbilical electrical connector 100 also provides power to drive the servo motor 34, and for the displacement of the sliding arm 66 and/or the cartridge gun body 56/cartridge piston 54 in embodiments where those components are electrically driven. In embodiments where the displacement of the sliding arm 66 and/or the cartridge gun body 56/cartridge piston 54 is pneumatic, apparatus 10 also comprises air quick connect 98 which allows for easy connection of a pressurized air hose (not shown).

[0085] In certain embodiments, and as shown in FIGS. 5-7, the apparatus 10 weighs less than 50 lbs, preferably less than 34 lbs, and is thus easily transportable by one person. Track 12 as shown in FIGS. 1 and 2 weighs about 35 lbs and is therefore also easily transportable by one person.

[0086] In certain embodiments, and as shown in part in FIGS. 5-7 and shown schematically in FIG. 8, the umbilical electrical connector 100 is connected to a control box 102 which provides 5 amp, 240 V power from a power source 104, and compressed air at 90 psi<15 SCFM from compressed air source 106 to controller 40. The controller controls servo motor 34, cartridge gun body 56 and stepper motor 80, providing both power and, where appropriate, compressed air, and controls and receives information from proximity sensor 96 and linear position sensor 61. The control box 102 can be controlled, and programmed, by a user using wireless control pendant 108 which is wirelessly connected to the control box 102. Typically, the control box 102 weighs about 50 lbs, though this weight may be brought down in further iterations of the control box; the umbilical cable (not shown) which connects the control box 102 to the apparatus 10 through air quick connect 98 and umbilical electrical connector 100 typically weighs about 15 lbs.

[0087] In certain embodiments, and as shown in FIGS. 16A-16F, the control box 102 is preconfigured into a field robust rack 103 that includes all components for managing electrical safety, communications, digital controls, programming and air preparation. Programming and operation is managed through an operator Human Machine Interface (HMI) 154. Critical operator interface buttons and signals are available on the front face 156 of the control panel. The enclosure is environmentally protected and controlled with an integral air conditioning unit 158. The supply compressed air is conditioned to remove water mist and particulates with filters 160 and dehumidified with a membrane air drier 162. The air pressure is regulated with a regulator 164 and preheated to a specific supply temperature by a compressed air heater 166. The final temperature of the air is measured with a temperature sensor 167. The umbilical cable air quick connect 98 and electrical connector 100 connect to standard interfaces 168 and 152 respectively.

[0088] A further embodiment of the apparatus is shown in FIGS. 9 and 10, with like parts labelled similarly to the apparatus of FIGS. 5-7. This apparatus 10 differs from that of FIGS. 5-7 in that it is configured for continuous delivery, rather than cartridge-based delivery of the plural components of the coating spray. Continuous delivery plural component systems are generally fully contained, commercially available, systems (available for example, from GRACO, AIRTECH, BINKS or WIWA) that include fluid component preheating and storage, component pressurization, component mixing and final delivery, and optionally management of unused components return to storage. These systems may also include, often as a separate system, a tertiary component (solvent) management that is used to clean out the passageways of the system. In all notable commercially available systems, the principal operating power driving the component delivery is derived from compressed air. The compressed air drives proportioned hydraulic rams to pressurize the components to high pressures and in the correct ratio.

[0089] Similarly to the apparatus of FIGS. 5-7, apparatus 10 is configured to mount onto, and rotate around, track 12 which can be clamped to pipe 14 proximal to cutback region 15. The apparatus 10 is able to travel in a motorized, controllable manner, around track 12 and thus around the circumference of the pipe 14 in a ‘rack and pinion’ arrangement. Drive gear 18 connected to servo motor 34 and gear head (not shown), through drive engagement cam 36. The servo motor 34 is utilized to turn the drive gear 18, to provide displacement of the apparatus 10 around the circumference of the pipe. Servo motor 34 is controlled by a programmable controller 40 which can be programmed to provide automated displacement of the apparatus 10 around the circumference of the pipe in a desired direction and speed. Also shown, though optional, is drive gear guard 38, which protects the user from injury due to the turning drive gear 18, and protects the rack and pinion mechanism of the drive gear 18 and rack from foreign objects or from spray back of the plural component coating (for example, epoxy). Electronics protective guard 42 can be a plastic or metal plate which protects the key electronic components of the apparatus 10, such as the controller 40, from damage from foreign objects or plural component coating spray back. It would be readily understood to a person of skill in the art that it would be desirable to prevent plural component coating from adhering to the drive gear 18, the rack, or the electronic components of the apparatus 10.

[0090] Unlike the apparatus of FIGS. 5-7, the apparatus of FIGS. 9 and 10 does not have a cartridge carriage configured to receive cartridges. Instead, it is configured to be connected to off-the-shelf continuous delivery plural component coating spray systems. Continuous delivery plural component coating systems are available from various venders, such as GRACO, AIRTECH, BINKS and WIWA, and typically provide high pressure two component epoxies.

[0091] Thus, the apparatus of FIGS. 9 and 10 comprises continuous delivery component inlets 110, 112, which are configured to receive high pressure component lines from the plural component coating spray continuous delivery systems (not shown), with each continuous component inlet 110, 112, receiving a different component of the plural component coating. Quick release handle 114 allows for rapid connection and separation of the high pressure component lines to the apparatus 10. A valve 116, which may be hydraulic, electric, or, as shown, pneumatic, controls the flow of the components from component inlets 110, 112 to optionally disposable mixer 118, through mixer outlet 120 and into a high pressure, optionally disposable, tube (not shown) which is connected to spray inlet 122 which is, in turn, operatively connected to spray nozzle 124. One advantage of the apparatus 10 over other plural component coating spray continuous delivery systems may be the size and wieldability of the present apparatus 10, which is much lighter, easily carried and attached to a pipe by one user, and thus safer to use. A second advantage, however, is that in certain optional embodiments, all parts of the apparatus through which flow mixed components are disposable. Thus, all parts of the apparatus that, in a traditional continuous delivery system, would require significant cleaning, flushing, and solvent use, can be disposable and easily user replaced. Even if non-disposable components are used, they are easily removed from the apparatus 10, for cleaning and flushing. This is much more convenient, and can be more environmentally friendly, than flushing plural component coating out of apparatus parts using (often toxic) solvents in the field.

[0092] As would be understood by a person of skill in the art, the apparatus of FIGS. 9-10 could still be cleaned and flushed in a traditional manner, by releasing the high pressure component lines (not shown) connected to the plural component coating spray continuous delivery systems (not shown) utilizing quick release handle 114, and replacing them with high pressure cleaning lines (not shown) configured to release solvent into the apparatus 10.

[0093] The actuation of actuator 116 is electronically controlled through controller 40, programmable, and is coordinated with the movement of the apparatus 10 around the pipe 14 and the movement of the spray nozzle 124 relative to the frame 20.

[0094] The ratio of components displaced can be controlled through use of different pressure lines to the apparatus 10, or through having a separate actuator 116 for each high pressure component line.

[0095] Although not shown in FIGS. 9 and 10, it would be appreciated that the apparatus may also have an adjustable spray head, and multiple spray head attachment points, similar to that of the apparatus of FIGS. 5-7.

[0096] The apparatus 10 has a carrying handle 84 which is adaptable for a hoist ring. However, due to its size and weight, the apparatus 10 can easily be carried by one user utilizing the carrying handle 84.

[0097] FIG. 11 shows a photograph of cartridge 48, 50 in isolation, for use in the apparatus of FIGS. 5-7. Cartridge 48, 50 is mounted into cartridge carriage 46 as shown in FIGS. 5-7. As shown, cartridge 48 and cartridge 50 are actually housed in a single, plastic, bicylinder; metal or other materials may also be used, two separate cartridges may also be used. As shown, cartridge 48 has a larger diameter than cartridge 50, and contains (as the component) an epoxy, whereas cartridge 50 contains (as the component) an associated curing agent.

[0098] FIG. 11 also shows static mixer 126 in isolation, for use in the apparatus of FIGS. 5-7. Static mixer 126 has compound inlet 128 for connection to cartridge nozzle 58, 60, a mixing area 130 which mixes the two components together, and hose 134 for transporting the mixed components to the spray nozzle 32. The mixer 126 shown in FIG. 11 is slightly different than that which would be used with the apparatus of FIGS. 5-7, in that the mixer 126 comprises a built-in spray nozzle 132 and air atomization input adapter 92. Accordingly, the end of the mixer 126 can simply be clipped into the arm of the apparatus, utilizing quick change adapter 88. The advantage of utilizing an “all in one” mixer 126, comprising a built in spray nozzle 132, like the one shown in FIG. 11, is that the entire assembly is disposable, which eliminates the need for cleaning spray nozzle 32. In alternative embodiments, such as that shown in FIG. 5-7, spray nozzle 32 is a separate element, which may be removed for cleaning by utilizing quick change adapter 88. As would be appreciated, the apparatus of FIG. 5-7 is configured so that a separate component spray nozzle 32 such as that depicted in FIGS. 5-7 can be interchanged with a built in component spray nozzle 132 such as that depicted in FIG. 11.

[0099] FIG. 12 is a photograph close-up of the spray head 64 of a further embodiment of the apparatus 10. FIG. 12 clearly shows sliding arm 66 comprising three slidable shafts 68, 70, 72 each covered by protective bellows 74, 76, 78, respectively. Spray head 64 is connected to the distal end of sliding arm 66. Height and position of spray head 64 is adjustable by affixing it at one of spray head attachment points 86. The spray angle can also be adjusted by rotating the spray head 64 relative to the arm 66. Spray head 64 comprises spray nozzle 32 operatively connected to hose adapter 62, which is in turn connected to component hose 134. Spray head 64 comprises air atomization input adapter 92 which provides pressurized air to the spray nozzle 32. Also shown is spray shield 94, which protects the body of apparatus 10, as well as the track 12, from spray back of the coating spray when in use.

[0100] FIG. 13 is a photo showing the apparatus 10 connected to control box 102 by umbilical cable 136, which provides electrical power, compressed air, and a communications conduit. Wireless control pendant 108 and track 12 are also shown.

[0101] FIG. 14 is a schematic briefly describing the use of the apparatus 10 to coat a cutback region. First, the track ring is positioned and mounted onto the outer coating layer of a pipe, proximal to the cutback region. The track ring is clamped in place. The apparatus 10 is mounted to the track ring so that the drive gear 18 is engaged onto rack 16, and locked in place with clamping cam handle 26. The servo motor 34 is engaged to “jog” the apparatus 10 to an accessible location on the side of the pipe. The stepper motor 80 is engaged to center the end of arm 66 on the weld bead situated in the middle of the cutback region. The user confirms the position is set by pressing the “zero” position button 138 on the wireless control pendant 108, shown also at FIG. 15. A pre-heated component cartridge 48, 50 is installed in cartridge carriage 46. The component inlet 128 of static mixer assembly 126 is affixed to the end of the cartridge 48, 50 at cartridge nozzles 58, 60. The other end of static mixer assembly 126, containing built-in spray nozzle 132, is fixed into quick change adapter 88 and a compressed air source is affixed to air atomization input adapter 92. The static mixer assembly and nozzle is primed by pressing the “prime” button 140 on the wireless control pendant 108, which activates the cartridge gun body 56 to displace pistons 52, 54 to displace the two components out of the cartridge and into the mixer 126. The mixed plural component mixture is displaced through nozzle 124 and collected in a receptacle. The apparatus is now primed and ready to coat the pipe. The user pushes the “run” button 142 on the wireless control pendant 108, which initiates the spray cycle. The apparatus 10 progresses through a programmed spray cycle, rotating around the pipe on track 12 and moving arm 66 (and, as a result, spray nozzle 124) laterally to coat the entirety of the cutback region 15. The movement of the apparatus can be programmed in a wide variety of ways; in a preferred embodiment, the apparatus is repeatedly rotated circumferentially around the pipe, with lateral steps of the arm at each rotation. In a preferred embodiment, the spraying occurs continually, though pulse spraying or pauses in the spraying can also occur. As can be appreciated, servo motor 34, cartridge gun body 56, and/or stepper motor 80 may be electronically controlled in a programmable or pre-programmed manner through an on-board computer or through a computer at the control box 102. A user selects the parameters (pipe diameter, desired thickness of coating, and type of coating, for example) on a user interface (for example, control pendant 108) then initiate the start of the coating process; apparatus 10 would then automatically rotate and arm 66 would laterally displace appropriately, while at the same time the main controller would activate the cartridge gun body 56 for the desired application of coating. As shown in FIG. 15, Control pendant 108 also has controls for manual lateral displacement of the arm (out, 148, in, 150) and rotational displacement around the pipe (clockwise 140, counterclockwise 152). By pressing the “shift” button (156), the second function of the buttons can be accessed, with button 140 also used to prime the system, button 152 used to purge the system, and button 148 used to retract the cylinder. A large, easy to access emergency stop button 158 is also provided.

[0102] Once the cutback region 15 has been sprayed in its entirety, the apparatus 10 returns automatically to its start position relative to the pipe, and the user can remove the now depleted cartridge 48, 50 and the mixer 126; in the case of disposable cartridge 48, 50 and/or mixer 126, disposing of them; in the case of a re-usable cartridge 48, 50 and/or mixer 126, placing them in a storage location for cleaning. The user can then unlock the apparatus 10 from the track 12 by disengaging clamping cam handle 26, and remove the apparatus 10 from the pipe. The track 12 can also be removed from the pipe and moved to the next cutback region.

[0103] As would be understood to a person of skill in the art, an automated cutback coating apparatus such as that herein described also has the advantage that it can collect data, such as confirmation that a coating was properly applied, the protocol it was applied with, and the type of component (for example, epoxy) used on the cutback. In this manner, the apparatus can provide objective, standardized, real time data regarding the integrity of the cutback region coating. For example, each cartridge could have a bar code or RFID tag, which would be read by a bar code reader/RFID reader located on an appropriate position on the apparatus. Part of the application protocol might require reading such a bar code before the application of coating can take place. This would reduce the risk of field substitution of inferior components, for example. The bar code reading would be sent, through controller 40 to the control box 102, and confirmation of an appropriate cartridge would be necessary before a user could apply the coating to the pipe. Similarly, a bar code or RFID reading can be taken off the pipe at or proximal to the cutback region, which would provide a unique identification of the specific cutback to which the apparatus is applying coating. This information, as well as confirmation of a successful (i.e. error-free) coating, and the time and date the cutback was coated, the size of the pipe, the temperature of the coating components when leaving the reservoir housing (by having a temperature sensor located proximal to that point, or in the case of heated cartridges as described further below) can be recorded at the control box 102 or on memory (for example, a removable SD card) right on the apparatus, for audit or documentary purposes.

[0104] It would be understood that, although pneumatic or electrical driving of circumferential travel and/or lateral arm travel are shown, these could also be operated through hydraulic means. It would also be understood that although an external source of compressed gas and an external electric source are shown, in certain embodiments, the compressed gas, compressed fluid, and/or electrical source could be incorporated within the apparatus. For example, the apparatus may further comprise a battery or capacitor, which may be rechargeable, for example, a solar panel-charged battery or capacitor; a canister of compressed air, an electric or gas driven air compressor, or any other known means. For example, a disposable or refillable compressed air canister (not shown) can be connected to the back of cartridge gun body 56 to be used as a source of energy for compressing the pistons 52, 54 and thus displacing first coating component and second coating component out of the cartridges 48, 50.

[0105] Accordingly, in certain embodiments, the entire apparatus 10 can be self-contained, and does not require additional generators, coating containers, hoses, or connections, making the apparatus 10 both more efficient and less dangerous to use.

[0106] For some coating components, it is advantageous to heat the components before application. Therefore, in certain embodiments, apparatus frame 20 may also comprise a heating means for heating the coating components in the reservoir. Alternatively or in addition, a plurality of reservoir housings can be stored in a separate, self-contained, heated container, and pulled out and affixed to the apparatus frame 20 immediately before application.

[0107] Although not shown, coating systems containing more than two components may also be used, by providing a cartridge carriage 46 capable of containing more than two cartridges 48, 50. In some cases, this may require minor modifications to the coating actuator, for example, additional pistons or alternate displacement means may be required. In certain embodiments, the individual pistons (or other displacement means) are housed and a component of the reservoir housing itself, providing a universal connection with the coating actuator.

[0108] Rotational travel speed of the apparatus may be variable or constant, and typically may be anywhere from 0-1500 mm/s, depending on the pipeline application, the coating to be applied, and the geographic conditions.

[0109] The embodiments of the present disclosure described above are intended to be examples only. The present disclosure may be embodied in other specific forms. Alterations, modifications and variations to the disclosure may be made without departing from the intended scope of the present disclosure. While the systems, devices and processes disclosed and shown herein may comprise a specific number of elements/components, the systems, devices and assemblies could be modified to include additional or fewer of such elements/components. For example, while any of the elements/components disclosed may be referenced as being singular, the embodiments disclosed herein could be modified to include a plurality of such elements/components. Selected features from one or more of the above-described embodiments may be combined to create alternative embodiments not explicitly described. All values and sub-ranges within disclosed ranges are also disclosed. The subject matter described herein intends to cover and embrace all suitable changes in technology. All references mentioned are hereby incorporated by reference in their entirety.