Apparatus, work station and method for applying protective sheeting of polymer material to a pipeline, and computer program for implementing the method

Abstract

An apparatus configured to apply protective sheeting of polymer material around a cutback on a pipeline has a frame located close to a pipeline extending along a longitudinal axis; a manipulator fitted to the frame and having a guide system movable between a rest position at a distance from the pipeline, and a work position in which the guide system is fitted around the pipeline; and an extrusion die movable selectively along the guide system and around the pipeline to supply and apply protective sheeting around the cutback on the pipeline.

Claims

1. A pipeline protective sheeting application apparatus comprising: a frame locatable a designated distance from a pipeline extending along a longitudinal axis transverse to a bed of a body of water; a manipulator fittable to the frame and movable with respect to the frame, the manipulator including a guide system separately movable between a rest position a first distance from the pipeline, and a work position a second distance from the pipeline, wherein in the work position, the guide system is fittable around the pipeline; and an extrusion die comprising an extrusion outlet defining a cross section corresponding in size and shape to a cross section of a protective sheeting, the extrusion die selectively movable: (i) along the guide system via a carriage of the guide system which supports the extrusion die and is selectively moveable along a guide of the guide system, and (ii) around the pipeline to supply and apply the protective sheeting around a cutback on the pipeline.

2. The pipeline protective sheeting application apparatus of claim 1, wherein the guide system includes a plurality of spacers which, in the work position, are positionable in contact with the pipeline to center the guide system around the pipeline by permitting axial movement of the guide system with respect to the pipeline.

3. The pipeline protective sheeting application apparatus of claim 2, wherein the spacers are divided into two axially spaced groups, each including at least three spacers arranged around the longitudinal axis.

4. The pipeline protective sheeting application apparatus of claim 2, wherein each spacer includes a roller configured to contact the pipeline and assist in the axial movement between the guide system and the pipeline.

5. The pipeline protective sheeting application apparatus of claim 1, wherein the manipulator is selectively movable with respect to the frame to axially adjust a position of the guide system with respect to the cutback on the pipeline.

6. The pipeline protective sheeting application apparatus of claim 1, wherein the guide system includes at least one sensor configured to determine an axial position of the guide system with respect to the cutback.

7. The pipeline protective sheeting application apparatus of claim 1, wherein the manipulator includes: an articulated system configured to move the guide system between the work position and the rest position, and a universal joint to connect the articulated system to the guide system and permit angular movement of the guide system with respect to the articulated system when the guide system is fittable around the pipeline.

8. The pipeline protective sheeting application apparatus of claim 1, which includes an extrusion device which is fittable to the guide system and is connectable, by a hose, to the extrusion die to permit relative movement between the extrusion die and the extrusion device.

9. The pipeline protective sheeting application apparatus of claim 8, which includes a winder configured to wind and unwind the hose according to a position of the extrusion die.

10. The pipeline protective sheeting application apparatus of claim 9, wherein the winder includes a reel rotatable about a rotation axis to wind and unwind the hose according to the position of the extrusion die with respect to the guide system.

11. The pipeline protective sheeting application apparatus of claim 10, which includes a rotary hydraulic joint having: a rotating portion that is rotatable about a rotation axis and is connectable to the hose, and a fixed portion rigidly connected to the extrusion outlet of the extrusion device.

12. The pipeline protective sheeting application apparatus of claim 11, wherein the reel and the rotating portion of the rotary hydraulic joint are powered to rotate both directions about the rotation axis.

13. The pipeline protective sheeting application apparatus of claim 8, which includes: a plastifying device; and a further hose configured to connect the plastifying device to the extrusion device to enable relative movement between the plastifying device and the extrusion device.

14. The pipeline protective sheeting application apparatus of claim 13, wherein the plastifying device is mounted on an articulated system.

15. The pipeline protective sheeting application apparatus of claim 1, wherein the protective sheeting includes a protective sheeting of a polymer material.

16. A pipeline protective sheeting application work station comprising: a pipeline protective sheeting application apparatus configured to apply a protective sheeting around a cutback on a pipeline and including: a frame locatable a designated distance from the pipeline extending along a longitudinal axis transverse to a bed of a body of water, a manipulator fittable to the frame and movable with respect to the frame, the manipulator including a guide system separately movable between a rest position a first distance from the pipeline, and a work position a second distance from the pipeline, wherein in the work position, the guide system is fittable around the pipeline, and an extrusion die comprising an extrusion outlet defining a cross section corresponding in size and shape to a cross section of the protective sheeting, the extrusion die selectively movable: (i) along the guide system via a carriage of the guide system which supports the extrusion die and is selectively moveable along a guide of the guide system, and (ii) around the pipeline to supply and apply the protective sheeting around a cutback on the pipeline.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Certain embodiments of the present disclosure will be described with reference to the attached drawings, in which:

(2) FIG. 1 shows a partly sectioned side view, with parts removed for clarity, of a pipeline and protective sheeting;

(3) FIG. 2 shows a partly sectioned side view, with parts removed for clarity, of the pipeline with the protective sheeting applied;

(4) FIG. 3 shows a partly sectioned, schematic side view, with parts removed for clarity, of the pipeline, and a protective sheeting application apparatus fitted around the FIG. 1 pipeline;

(5) FIG. 4 shows a side view, with parts removed for clarity, of a laying vessel for laying the pipeline on the bed of a body of water;

(6) FIG. 5 shows a plan view, with parts removed for clarity, of a work station on a line for constructing the FIG. 1 pipeline;

(7) FIG. 6 shows a larger-scale, partly sectioned plan view, with parts removed for clarity, of an apparatus for applying protective sheeting to the pipeline;

(8) FIG. 7 shows a partly sectioned plan view, with parts removed for clarity, of the FIG. 6 apparatus in a work position, fitted around the pipeline;

(9) FIG. 8 shows a view in perspective, with parts removed for clarity, of a detail of the FIG. 6 apparatus;

(10) FIG. 9 shows a view in perspective, with parts removed for clarity, of a detail of the FIG. 6 apparatus;

(11) FIG. 10 shows a larger-scale view in perspective, with parts removed for clarity, of a component part of the FIGS. 6 and 7 apparatus; and

(12) FIGS. 11 to 13 show schematic plan views of three successive operating stages of the apparatus according to the present disclosure.

DETAILED DESCRIPTION

(13) The Pipeline

(14) Referring now to the example embodiments of the present disclosure illustrated in FIGS. 1 to 13, number 1 in FIGS. 1 and 2 indicates as a whole a pipeline extending along a longitudinal axis A1. In the FIG. 1 example, pipeline 1 comprises two pipes 2 aligned along longitudinal axis A1. Each pipe 2 comprises a metal cylinder 3; and a polymer coating 4, normally of polyethylene or polypropylene, contacting and for corrosion-proofing metal cylinder 3.

(15) Each pipe 2 has two opposite free ends 5 (only one of which is shown in FIG. 1) with no coating 4, which has a bevel 6 at each free end 5. Two consecutive pipes 2 aligned along longitudinal axis A1 are positioned with their free ends 5 contacting, and are welded, possibly with a number or quantity of weld passes, to form an annular weld bead 7 between pipes 2. The two welded pipes 2 define a cutback 8, which extends along longitudinal axis A1, between the two consecutive bevels 6 of coatings 4, and comprises annular weld bead 7.

(16) Joining pipes 2 forms pipeline 1. In this description, pipeline 1 is also intended to mean the pipeline as the pipeline is being constructed, and even only comprising, for example, two joined pipes 2.

(17) In addition to welding metal cylinders 3, joining pipes 2 also comprises forming a covering seamlessly connecting existing coatings 4. This comprises applying protective sheeting 9 around cutback 8 and two end portions 10 of coatings 4; and causing the protective sheeting 9 to adhere to cutback 8 and end portions 10 of coatings 4.

(18) Applying protective sheeting 9 normally involves preparing the surfaces of cutback 8 and end portions 10 to improve adhesion of protective sheeting 9. Which surface-preparation work comprises cleaning (e.g., grit-blasting), and heating (e.g., induction heating) cutback 8.

(19) Protective sheeting 9 is 1-7 mm thick and made of a polymer, such as polyolefins, and, in certain embodiments, CMPE or CMPP.

(20) Protective sheeting 9 is wider than cutback 8 (measured along longitudinal axis A1), so as to overlap respective end portions 10 of coatings 4, and is long enough to cover the perimeter of cutback 8 and to overlap the end portions of protective sheeting 9.

(21) Protective sheeting 9 is extruded as protective sheeting is applied around pipeline 1. This technique produces protective sheeting 9 which, at the application stage, is highly flexible, adapts closely to the shape of coatings 4 and cutback 8, and adheres firmly to pipeline 1, as shown in FIG. 2.

(22) Number 20 in FIG. 3 indicates an apparatus configured to apply protective sheeting 9 to pipeline 1.

(23) Pipeline 1 so formed is suitable for various applications, such as, for example, underwater piping hydrocarbons.

(24) The Laying Vessel

(25) The joining process described to construct pipeline 1 may be carried out at land-based installations, or on laying vessels, such as laying vessel 11 in FIG. 4.

(26) Laying vessel 11 is configured to construct and lay pipeline 1 on the bed 12 of a body of water 13.

(27) Vessel 11 comprises a floating structure 14; and a J-laying rig 15 configured to assemble and lay pipeline 1. Though shown upright, J-laying rig 15 may be tilted at an angle of up to 30 to the vertical when laying pipeline 1.

(28) Laying rig 15 comprises a top portion 16 where pipeline 1 is assembled; an intermediate portion 17 where a tensioning device (not shown) is operated; and a bottom portion 18 housing a work station 19 where pipeline 1 is stopped, and protective sheeting 9 is applied by an apparatus 20 (FIG. 3).

(29) Protective Sheeting Application Apparatus

(30) With reference to FIG. 5, apparatus 20 is configured to apply protective sheeting 9 (FIGS. 1, 2 and 3) to cutbacks 8 fed successively into work station 19 as pipeline 1 is fed forward in steps. Apparatus 20 as a whole is configured to perform work cycles, each of which comprises plastifying the polymer material of which protective sheeting 9 (FIGS. 1, 2 and 3) is made; engaging pipeline 1, around cutback 8 (FIG. 3); and extruding and simultaneously applying protective sheeting 9 (FIGS. 1, 2 and 3) around cutback 8 on pipeline 1. For this reason, apparatus 20 is configured to move into a work position, in which apparatus is fitted around pipeline 1 (FIG. 7), and a rest position (FIG. 5), in which the whole of apparatus 20 is positioned at a distance from pipeline 1.

(31) Constructing pipeline 1 comprises feeding pipeline 1 in steps in a direction D1 parallel to longitudinal axis A1, which is substantially vertical or at any rate tilted sharply to the horizontal; and fitting apparatus 20 (FIG. 7) around pipeline 1, at cutback 8. In this description, the term axial refers to longitudinal axis A1.

(32) With reference to FIGS. 6 and 7, apparatus 20 comprises: a frame 21; an extrusion line 22 configured to plastify solid polymer material, and configured to extrude and apply soft protective sheeting 9; a mechanical manipulator 23 mounted on frame 21 to connect extrusion line 22 selectively to pipeline 1; a control system 24 including a computer and configured to coordinate the movements of manipulator 23 with the movement of pipeline 1, and to control the plastifying and extrusion processes on extrusion line 22.

(33) Frame 21 is straight and serves to support manipulator 23 slidably in a direction D2 which, in the example shown, but not necessarily, is parallel to D1 and to longitudinal axis A1. That is, in certain embodiments, pipeline 1 and frame 21 can practically never be perfectly parallel to each other. In some cases, frame 21 is mounted on a rocking platform 21a, which is movable with respect to J-laying rig 15 (FIG. 4) so as to remain horizontal regardless of the tilt angle of the J-laying rig (FIG. 4).

(34) Extrusion line 22 comprises a plastifying device 25, an extrusion device 26, and an extrusion die 27.

(35) In the embodiment shown in the attached drawings, plastifying device 25 is connected to extrusion device 26 by a hose 28, so plastifying device 25 and extrusion device 26 can be located on parts movable with respect to each other.

(36) Likewise, extrusion die 27 and extrusion device 26 are connected by a hose 29, so extrusion die and extrusion device 26 can be mounted on parts movable with respect to each other.

(37) In certain embodiments, plastifying device 25 is a screw type, and comprises an inlet 30 configured to receive solid polymer material; and an outlet 31 configured to feed soft polymer material along hose 28 to extrusion device 26.

(38) In certain embodiments, extrusion device 26 comprises a cylindrical tank 32 having an inlet 33 configured to receive soft polymer material from hose 28, and an outlet 34 configured to feed soft polymer material along hose 29 to extrusion die 27.

(39) Extrusion device 26 comprises a piston 35 configured to expel the soft polymer material rapidly from tank 32.

(40) Extrusion die 27 substantially comprises an extrusion outlet 36 with a cross section configured to form the exact cross section shape and size of protective sheeting 9 (FIGS. 1, 2 and 3); and a cavity (not shown) configured to guide the soft polymer material to extrusion outlet 36.

(41) Manipulator 23 comprises a guide system 37 configured to guide extrusion die 27 along an annular path; an articulated mechanism 38 configured to move guide system 37 selectively between a work position around pipeline 1 (FIG. 7), and a rest position relatively distant from pipeline 1 (FIG. 5); and a slide 39 mounted on frame 21 and movable selectively along frame 21 in direction D2.

(42) With reference to FIG. 8, guide system 37 comprises: a supporting structure 40; two facing, parallel guides 41 and 42 integral with supporting structure 40; two facing, parallel, movable guides 43 and 44 hinged to supporting structure 40 and complementary to guides 41 and 42; an actuator 45 configured to open and close movable guides 43 and 44; a winder 46 configured to wind and unwind hose 29 in controlled manner; and a carriage 47 movable selectively along guides 41 and 42, and configured to support extrusion die 27, a roller 48, and lateral heaters 49 (FIGS. 7 and 10).

(43) With reference to FIG. 9, supporting structure 40 is connected to articulated system 38 by a universal joint 50 and two actuators 51 and 52.

(44) With reference to FIG. 8, supporting structure 40 supports extrusion device 26 (FIG. 7) and winder 46, which comprises a rotary joint 53 and a reel 54 which rotates about a rotation axis A2. Rotary joint 53 and reel 54 are aligned along rotation axis A2. Rotary joint 53 comprises a fixed part connected to extrusion device 26; and a rotating portion integral with reel 54 and communicating with hose 29. Rotation of reel 54 about rotation axis A2 is powered, reversible, and coordinated with the movement of carriage 47.

(45) Reel 54 substantially comprises an annular seat 55 configured to wind at most one turn of hose 29, and which is coplanar with guide 41 and movable guide 43.

(46) With reference to FIGS. 6 and 7, guides 41 and 42 are arc-shaped and extend to an angle of over 180; and movable guides 43 and 44 are complementary to respective guides 41 and 42, and so extend to an angle of less than 180. Movable guides 43 and 44 open sufficiently to insert pipeline 1 between guides 41, 42 and movable guides 43, 44.

(47) In the closed position, guide 41 and movable guide 43 define an outer annular seat 56 configured to house hose 29.

(48) With reference to FIG. 3, in the closed position, guides 41 and 42 and movable guides 43 and 44 define respective inner annular seats 57. Guide 42 and movable guide 44 support an annular rack 58, and a housing 59 for electric cables (not shown in the drawings).

(49) With reference to FIG. 10, carriage 47 comprises two facing, annular-sector-shaped plates 60; bars 61 connecting facing plates 60; rollers 62 which engage and are guided by inner annular seats 57 (FIG. 3); a pinion 63 which meshes with annular rack 58; an actuator 64 configured to activate pinion 63; and a control device 65. Extrusion die 27, roller 48, and lateral heaters 49 are mounted on carriage 47, between plates 60, so as to be movable selectively to and from pipeline 1 (FIGS. 6 and 7).

(50) Extrusion die 27 is connected to a rotary joint 66 connectable to hose 29 (FIG. 8).

(51) With reference to FIG. 3, guide system 37 is fitted around pipeline 1, and is centered with respect to pipeline 1 by spacers 67 enabling axial movement (in direction D1 parallel to longitudinal axis A1) of guide system 37 with respect to pipeline 1.

(52) In certain embodiments, each spacer 67 comprises a wheel with its axis crosswise to longitudinal axis A1. At least one of spacers 67 comprises a sensor 68 configured to determine the movement of guide system 37 with respect to pipeline 1 in direction D1.

(53) In the example shown, carriage 47 comprises a sensor 69 configured to identify a reference such as, for example, annular weld bead 7.

(54) Control system 24 (FIGS. 6 and 7), control device 65 (FIG. 10), and sensor 69 provide for checking the correct axial position of guide system 37 along pipeline 1. If positioned wrongly, guide system 37 is moved along longitudinal axis A1 and centered with respect to cutback 8. In certain embodiments, guide system 37 is moved by moving the whole of manipulator 23 with respect to frame 21 in direction D2 by an actuator 70 (FIG. 7).

(55) With reference to FIGS. 6 and 7, the articulated system is operated by actuators (not shown) configured to determine the position of guide system 37 in a plane perpendicular to direction D2. With reference to FIG. 5, in addition to apparatus 20 configured to apply protective sheeting 9, work station 19 also comprises a cleaning apparatus 71 and a heating apparatus 72.

(56) Cleaning apparatus 71 comprises a manipulator 73; and an applicator 74 comprising two shells 75 configured to selectively close applicator 74 around cutback 8.

(57) Heating apparatus 72 comprises a manipulator 76; and an applicator 77 comprising two shells 78 configured to selectively close applicator 77 around cutback 8.

(58) Manipulators 73, 76 and shells 75, 78 provide for grit-blasting and induction heating in rapid succession, so as to prepare cutback 8 to adhere to protective sheeting 9 (FIG. 1).

(59) In actual use, as shown in FIG. 5, apparatus 20 is positioned well away from pipeline 1, so as not to interfere with apparatuses 71 and 72.

(60) With reference to FIG. 6, plastifying device 25 is fed with polymer granules, and plastifies and transfers the material to tank 32 of extrusion device 26.

(61) Once apparatuses 71 and 72 (FIG. 5) finish working on cutback 8, manipulator 23 moves guide system 37, with movable guides 43 and 44 open, up to pipeline 1, to position guides 41, 42 and movable guides 43, 44 around pipeline 1.

(62) With reference to FIG. 7, movable guides 43 and 44 are then closed to connect apparatus 20 to pipeline 1.

(63) With reference to FIG. 9, just before guide system 37 is closed completely around pipeline 1, actuators 51 and 52 are deactivated to enable universal joint 50 to move freely. In other words, just before being connected to pipeline 1, guide system 37 centers automatically with respect to pipeline 1, by being freely orientable with respect to articulated system 38 supporting it.

(64) With reference to FIG. 3, guide system 37 is positioned axially with respect to cutback 8, if necessary, so that the position of carriage 47 enables protective sheeting 9 to be positioned fairly accurately over the end portions of coatings 4.

(65) The axial position (in direction D1 parallel to longitudinal axis A1) of guide system 37 is adjusted by actuator 70 (FIG. 7) moving slide 39 along frame 21 in direction D2.

(66) With reference to FIG. 7, pipeline 1 and frame 21 are not guaranteed parallel, so universal joint 50 and articulated system 38 enable guide system 37 to move freely and so center and align perfectly with pipeline 1. Once guide system 37 is centered on pipeline 1 and positioned axially with respect to cutback 8, extrusion and application of protective sheeting 9 around pipeline 1 are commenced (FIG. 7).

(67) Extruding and applying protective sheeting 9 involve rotating carriage 47 over 360 around pipeline 1. In certain embodiments, the carriage is rotated 390 around pipeline 1 to achieve a wide overlap of the opposite ends of protective sheeting 9. At this stage, lateral heaters 49 heat end portions 10 (FIGS. 1, 2 and 3), and roller 48 presses protective sheeting 9 against pipeline 1 to ensure protective sheeting adheres firmly to pipeline 1, and to prevent the formation of air bubbles. At this point, carriage 47 is restored to its starting position, by reversing carriage along the same path traveled to apply protective sheeting 9; during which movement, protective sheeting 9 may optionally be rolled further.

(68) With reference to FIGS. 11 to 13, hose 29 is guided by guide system 37 and winder 46.

(69) At the start of the extrusion operation, carriage 47 and extrusion die 27 are located on the opposite side to winder 46. As carriage 47 begins travelling anticlockwise around longitudinal axis A1, hose 29 is housed inside outer annular seat 56, and is gathered inside annular seat 55 by powered reel 54 rotating clockwise about rotation axis A2, together with rotary hydraulic joint 53.

(70) In FIG. 12, carriage 47 is located at the point closest to winder 46, and hose 29 is wound almost completely around reel 54.

(71) In FIG. 13, carriage 47 is close to its limit position. To enable carriage 47 to reach this position, winder 46 has released most of the hose in time with the travel of carriage 47.

(72) Winder 46 tracks the reverse travel of carriage 47 to return carriage 47 and hose 29 to the configuration shown in FIG. 11.

(73) Clearly, changes may be made to the embodiments of the present disclosure described with reference to the attached drawings without, however, departing from the protective scope of the accompanying Claims. In particular, though the present description refers specifically to a laying vessel equipped with a J-laying rig, the apparatus, work station and method in the Claims also apply to substantially horizontal assembly lines on laying vessels equipped with S-laying ramps. Accordingly, various changes and modifications to the presently disclosed embodiments will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.