Method of Installing a Heat Tube on Pre-Insulated Piping

Abstract

A method is shown for installing a heat tube on a section of pre-insulated piping. A metal carrier pipe is covered with a first layer of foam insulation. Next, a routing device is used to cut a longitudinal slot along the length of the pipe so that the pipe exterior surface is exposed from the insulation. A heat tube is then installed within the longitudinal slot, whereby the heat tube contacts the exterior surface of the metal carrier pipe. A second layer of foam insulation is then sprayed onto the exterior of the metal carrier pipe, covering the previously formed longitudinal slot and installed heat tube. A polyolefin coating is then applied over the insulation to form a protective outer jacket for the insulated pipe.

Claims

1. A method for installing a heat tube on a section of pre-insulated piping where the piping is made up of first and second lengths of insulated and jacketed pipe, each having a joining end to be joined to an end of the other length, each pipe length comprising an inner metal carrier pipe having an interior surface and an exterior surface, an envelope of foamed insulation surrounding the inner metal carrier pipe exterior surface, and an outer protective jacket surrounding the envelope of insulation, the joining ends of adjacent metal carrier pipe lengths being welded together to form fixed joints, whereby the adjacent pipe lengths provide a continuous length of fluid conduit for conveying fluids, the method comprising the steps of: providing a metal carrier pipe having an exterior surface, an interior surface and a given length extending along a central longitudinal axis; applying a first layer of foam insulation onto the exterior surface of the metal carrier pipe; using a wire brush to cut a longitudinal slot through the first layer of foam insulation at one point on the circumference of the metal carrier pipe; installing a heat tube within the longitudinal slot whereby the heat tube contacts the exterior surface of the metal carrier pipe; applying a second layer of foam insulation onto the exterior of the metal carrier pipe, covering the previously formed longitudinal slot and installed heat tube; installing a polyolefin coating around at least a portion of the pipe with the insulation thereon to thereby form an outer protective jacket for the insulated pipe.

2. The method of claim 1, wherein the heat tube is formed of a material selected from the group of metals and plastics.

3. The method of Claim 1, wherein the foam insulation is selected from the group consisting of polyurethane foams and polyisocyanurate foam.

4. The method of claim 3, wherein the lengths of insulated piping being joined are part of a pipeline conveying process fluids, heating water and petroleum products.

5. The method of claim 4, wherein the carrier pipe being insulated is a metal pipe formed of steel of a given gauge.

6. The method of claim 4, wherein the outer protective jacket is a high density polyethylene jacket material.

7. A method for installing a heat tube on a section of pre-insulated piping where the piping is made up of first and second lengths of insulated and jacketed pipe, each having a joining end to be joined to an end of the other length, each pipe length comprising an inner metal carrier pipe having an interior surface and an exterior surface, an envelope of foamed insulation surrounding the inner metal carrier pipe exterior surface, and an outer protective jacket surrounding the envelope of insulation, the joining ends of adjacent metal carrier pipe lengths being welded together to form fixed joints, whereby the adjacent pipe lengths provide a continuous length of fluid conduit for conveying fluids, the method comprising the steps of: providing a steel carrier pipe having an exterior surface, an interior surface and a given length extending along a central longitudinal axis; placing the steel carrier pipe on a conveyor and rotating the steel carrier pipe while simultaneously moving it past a first foam application station and while spraying a first layer of foam insulation onto the exterior surface of the metal carrier pipe; passing the foam covered pipe through a curing station and allowing the foam insulation to cure to a given radial thickness to thereby form a foam insulated pipe; mounting a routing device in a suitable fixture adjacent the conveyor and moving the foam insulated pipe past the fixture in linear fashion, whereby the routing device cuts a longitudinal slot through the first layer of foam insulation along the length of the steel carrier pipe, exposing the exterior surface of the steel carrier pipe; installing a metal heat tube within the longitudinal slot whereby the heat tube contacts the exposed exterior surface of the metal carrier pipe; passing the pipe past a second foam application station while spraying a second layer of foam insulation onto the exterior of the metal carrier pipe, thereby covering the previously formed longitudinal slot and installed heat tube; applying a polyolefin coating around the insulated pipe to thereby form an outer protective jacket for the insulated pipe.

8. The method of claim 7, wherein the routing device is a wire brush.

9. The method of claim 7, wherein the routing device is a blade.

10. The method of claim 7, wherein the foam insulation is selected from the group consisting of polyurethane foams and polyisocyanurate foam.

11. The method of claim 7, wherein the lengths of insulated piping being joined are part of a pipeline conveying process fluids, heating water and petroleum products.

12. The method of claim 7, wherein the outer protective jacket is a high density polyethylene jacket material.

13. The method of claim 12, wherein the outer protective jacket is spirally wrapped about the previously insulated pipe.

14. A method for installing a heat tube on a section of pre-insulated piping where the piping is made up of first and second lengths of insulated and jacketed pipe, each having a joining end to be joined to an end of the other length, each pipe length comprising an inner metal carrier pipe having an interior surface and an exterior surface, an envelope of foamed insulation surrounding the inner metal carrier pipe exterior surface, and an outer protective jacket surrounding the envelope of insulation, the joining ends of adjacent metal carrier pipe lengths being welded together to form fixed joints, whereby the adjacent, pipe lengths provide a continuous length of fluid conduit for conveying fluids, the method comprising the steps of: providing a steel carrier pipe having an exterior surface, an interior surface and a given length extending along a central longitudinal axis; placing the carrier pipe on a conveyor which rotates the steel carrier pipe while simultaneously moving the pipe in a longitudinal direction past a first foam application station where a first layer of foam insulation is sprayed onto the exterior surface of the metal carrier pipe; passing the foam covered pipe through a curing station located on the conveyor line and allowing the foam insulation to cure to a given radial thickness to thereby form a foam insulated pipe as it is being moved longitudinally down the conveyor line; passing the foam covered pipe to another section of straight line conveyor where it continues to be moved in a longitudinal direction; mounting a routing device in a suitable fixture adjacent the section of straight line conveyor and moving the foam insulated pipe past the fixture in linear fashion, whereby the routing device cuts a longitudinal slot through the first layer of foam insulation, along the length of the steel carrier pipe, exposing the exterior surface of the steel carrier pipe; installing a metal heat tube within the longitudinal slot whereby the heat tube contacts the exposed exterior surface of the metal carrier pipe; moving the pipe to another section of conveyor which moves the pipe in a longitudinal direction while simultaneously rotating the pipe; passing the pipe past a second foam application station while spraying a second layer of than insulation onto the exterior of the metal carrier pipe, thereby covering the previously formed longitudinal slot and installed heat tube; continuing to move the pipe down a final section of conveyor while applying a polyolefin coating around the insulated pipe to thereby form an outer protective jacket for the insulated pipe; rolling the pipe off the final section of conveyor into a finished pipe area.

14. method of claim 14, wherein the routing device is a wire brush.

16. The method of claim 14, wherein the routing device is a blade.

14. method of claim 14, wherein the foam insulation is selected from the group consisting of polyurethane foams and polyisocyanurate foam.

18. The method of claim 14, wherein the lengths of insulated piping being joined are part of a pipeline conveying process fluids, heating water and petroleum products.

19. The method of claim 14, wherein the outer protective jacket is a high density polyethylene jacket material.

20. The method of claim 19, wherein the outer protective jacket is spirally wrapped about the previously insulated pipe.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a simplified representation of a typical prior art pre-insulated electric heat traced steel piping installation.

[0026] FIG. 2 is a simplified, schematic view of the first step in the manufacturing process of the invention in which an inner metal carrier pipe is coated with a layer of foam insulation.

[0027] FIG. 3 is a simplified view, similar to FIG. 2, showing the next step in the process in which a wire electric brush is used to cut a longitudinal slot in the previously applied layer of foam insulation.

[0028] FIG. 3A is a simplified, isolated view of a blade fixture which can also be used as the routing device in the process of the invention.

[0029] FIG. 4 is a view of the next step in the process of the invention in which a steel heat tube is installed in the previously cut slot.

[0030] FIG. 5 is illustrates the next step in the process in which an additional layer of foam insulation is applied to the partly insulated pipe, covering the steel heat tube and longitudinal slot.

[0031] FIG. 6 is illustrates the final step in the process of the invention in which an outer protective synthetic jacket is applied about the exterior of the previously insulated pipe and steel heat tube.

[0032] FIGS. 7A and 7B are simplified, partly schematic views of a continuous manufacturing process for installing a heat tube on pre-insulated piping.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The preferred version of the invention presented in the following written description and the various features and advantageous details thereof are explained more fully with reference to the non-limiting examples included in the accompanying drawings and as detailed in the description which follows. Descriptions of well-known components and processes and manufacturing techniques are omitted so as to not unnecessarily obscure the principle features of the invention as described herein. The examples used in the description which follows are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples should not be construed as limiting the scope of the claimed invention.

[0034] As has been briefly described, the particular type of piping system under consideration includes lengths of insulated and jacketed pre-insulated piping and, more specifically to a bonded foam pre-insulated piping system; i.e., the piping is made up of an inner carrier pipe having an interior surface and an exterior surface with an envelope of foamed insulation surrounding the inner pipe exterior surface. The envelope of foamed insulation can be, for example, an insulating material selected from the group consisting of polyurethane foams and high temperature polyisocyanurate foams. An outer protective jacket surrounds the envelope of insulation. The outer jacket can conveniently be formed from a polyolefin, such as a high density polyethylene. Each length of piping has a joining end for joining to an adjacent length of piping, whereby the adjacent lengths of piping provide a continuous length of fluid conduit for conveying high temperature fluids. The section of piping, as previously described, is installed in a piping system made up of other sections of piping.

[0035] One example of a commercially available pre-insulated piping system of the above type is the HT-406 High Temp Steel Piping System sold by Thermacor Process, Inc., 1670 Hicks Field Road East, Fort Worth, Tex. 76179. The following references, among others, teach the manufacture of such prior art systems: U.S. Pat. No. 3,793,4111; U.S. Pat. No. 4,084,842; and U.S. Pat. No. 4,221,405, all to Stonitsch et al.; as well as U.S. Pat. No. 6,547,908; U.S. Pat. No. 5,736,715; U.S. Pat. No. 7,037,557; U.S. Pat. No. 7,418.979; and U.S. Pat. No. 9,377,150, all assigned to Thermacor Process, Inc., the assignee of the present invention.

[0036] Any reference in this discussion to sections or lengths of pipe is intended to refer to standard available factory pre-insulated piping of the type previously described having an inner metal pipe surrounded by an envelope of foamed insulation, which in turn, is contained within a polyolefin jacket. As referred to briefly above, typical commercial practice involves the use of steel, copper, aluminum or alloy metal material for the inner carrier pipes. The typical pipe diameters will be, for example, 4 inches to 12 inches. The insulating foam may be, for example, a suitable polyurethane foam. For high temperature systems, the surrounding envelope of foam insulation is typically formed of closed cell polyisocyanurate. The outer protective jacket in such systems can be formed of a suitable polyolefin, such as polypropylene, polybutylene, polyethylene, polyvinylchloride and similar protective jackets.

[0037] The term high temperature as used in this discussion, means that the pipelines are conveying fluids at temperatures above ambient, typically at temperatures of 212 F. and above. In some cases, temperatures of 350-400 F. and higher will be encountered. The expected operating temperature of the pipeline will determine the type of outer foam insulation utilized. For example, 250 F. is generally accepted as the present temperature limitation at which polyurethane foam is used in bonded foam systems. Temperatures above about 250 F. generally require the use of higher temperature foams, such as the previously mentioned polyisocyanurate foam. For example, a typical steam line might be conveying fluid at, for example, 250-350 F. In the case of the heat tracing systems of the type to be described, the piping system may be used, for example, as a part of a pipeline conveying process fluids, heating water or petroleum products. In such cases, the fluid being conveyed may be at a lower temperature, so that a polyurethane foam insulation is sufficient.

[0038] Several types of electric heat tracing methods are available, depending upon the end application. For example, one type is known as skin effect tracing. Electric skin effect current tracing can be thought of as combining the engineering principles of skin effect and proximity effect.

[0039] Skin effect is an alternating current phenomena whereby AC current flows in the outer surface of a steel conductor. Proximity effect is an electromagnetic force which operates based upon the fact that equal currents in opposite directions attract. By placing the electric cable inside the heat tube, the current is drawn to a thin section of the heat tube inner wall. Heat generated from the current passes through the heat tube wall and into the steel carrier pipe by conduction. Exterior surfaces of skin effect current systems are electrically grounded. The voltage is impressed between the cable and the inner surface of the heat tube.

[0040] Skin effect heating allows a single point connection to provide heat for distances as long as 15 miles and even greater. Since electricity only flows on the inside of the heat tube, any residual voltage is eliminated. Since skin effect heating allows the heat applied to be evenly dissipated over long distances, an even temperature profile can be achieved.

[0041] One skin effect heating system is sold by Thermacor Process, Inc., Fort Worth, Tex., as the Ferro-Therm HDPE Skin Effect Heating System. Exemplary Specifications, somewhat simplified for ease of explanation, include the following:

[0042] A. Carrier Pipe shall be steel ASTM A-53, Grade B, ERW (Type e) or seamless (Type S), standard weight Piping shall generally be provided in 40 foot double random lengths where feasible. Straight sections of factory insulated piping shall have 6 of exposed pipe at each end for field joint fabrication.

[0043] B. A steel heat tube (cylindrical conduit) of A106, Seamless Sch. 40 pipe will be installed along the entire length of the carrier pipe. This could also be a channel member to accomplish the same purpose.

[0044] C. An electric skin effect heat trace system will be custom designed for the specific application and installation conditions.

[0045] D. Polyurethane foam insulation shall be used to cover the carrier pipe in the annular space between the carrier pipe and the ultimate outer HDPE jacket with a minimum thickness of one inch. Insulation shall be rigid 90-95% closed cell polyurethane with a 2.0-3.0 pounds per cubic foot density and coefficient of thermal conductivity 9K-factor) of 0.14 and shall conform to ASTM C-591.

[0046] E. The outer jacketing material shall be extruded black, high density polyethylene (HDPE) manufactured in accordance with ASTM D-1248 having a minimum wail thickness of 150 mils.

[0047] The above specification extracts are intended to be exemplary only as the specifications may vary to some extent, depending upon the end application for the heat trace system. These specifications are intended to provide some understanding of the basic types of materials used in a typical system of the type under consideration.

[0048] Turning now to FIG. 1, there is shown in somewhat simplified fashion a heat tracing system, which in this case happens to be an electric skin effect heat trace system. There are typically six main components in most skin effect systems. A control panel 11 is used to monitor the process temperature and to adjust the power input. A transformer 13 is used to regulate the voltage applied to the system. Various temperature sensors 15 are used to monitor the process temperatures. Skin effect electrical wires or cabling 17 are used to carry the voltage over the length of the pipeline system. Tubing or channeling 19 provides protection for the electrical wires 17 and dissipates the heat energy to the pipeline. Junction boxes, such as pull box 21 and end termination box 23 are used for wire connection and wire pulling points.

[0049] This somewhat schematic illustration of a typical skin effect heat tracing system is intended to be exemplary only of one type of heat traced piping system. However, for whatever type heat traced system happens to be under consideration, there is generally the need to provide a heat tube to house the various electrical wires or cabling used in the system. FIGS. 2-6 which follow illustrate the improved method of the invention which is used to install such a heat tube on a section of pre-insulated piping.

[0050] Turning to FIG. 2, there is shown, in simplified fashion, the first step in the manufacturing process of the invention. The method is used for installing a heat tube on a section of pre-insulated piping where the piping is made up of first and second lengths of insulated and jacketed pipe, each having a joining end to be joined to an end of the other length. Each pipe length comprises an inner metal carrier pipe having an interior surface and an exterior surface. An envelope of foamed insulation surrounds the inner metal carrier pipe exterior surface, and an outer protective jacket surrounds the envelope of insulation. The joining ends of adjacent metal carrier pipe lengths are eventually welded together to form fixed joints, whereby the adjacent pipe lengths provide a continuous length of fluid conduit for conveying fluids, as has been described.

[0051] In the first step of the method illustrated in FIG. 2, a section of steel carrier pipe 25 has an exterior surface 27, an interior surface 29 and a given length (l in FIG. 3) extending along a central longitudinal axis 31. The carrier pipe is placed on a helical conveyor system which rotates the pipe as it translates down the conveyor. A fixed foam dispensing head 35 sprays a layer of insulating foam 38 on the carrier pipe as it passes through the spray head path. As has been discussed, this might be a polyurethane foam sprayed to a depth of, for example, one inch thick. This part of the process is conventional and will be familiar to those skilled in the relevant arts.

[0052] The first layer of insulating foam will generally be sprayed to a depth which corresponds approximately with the height of the heat tube to be installed later. The layer of foam insulation is allowed to cure to a given radial thickness to thereby form a foam insulated pipe. It may be necessary to utilize more than one dispensing head 35, for example, one head above the pipe and one head below the pipe for evenly injecting foaming material as the heads move down the length of the rotating pipe.

[0053] In the next step in the method, shown in FIG. 3, a routing device is used to cut a longitudinal channel or opening down a selected length of the foam covered pipe. For example, a wire brush 37 can be mounted in a suitable jig fixture 39 on the side of the foam insulated pipe 25. The pipe 25 is drawn past the wire brush 37 in a linear direction of travel to thereby cut a longitudinal slot 41 through the first layer of foam insulation at one point on the circumference of the steel carrier pipe, thereby exposing the exterior surface 27 of the steel carrier pipe 25. The slot may be, for example, about one inch by one inch in dimension. The wire brush can be something as simple as a typical wire wheel brush mounted on an electric drill body. Suitable wire wheels and drill bodies are available at Home Depot, Lowes and similar stores.

[0054] The routing device could also assume other forms, for example, FIG. 3A shows a simple stationary blade 34 mounted in a suitable fixture 36. As the foam covered pipe passes longitudinally past the routing station, the blade cuts a longitudinal slot such as the slot 41 shown in FIG. 3.

[0055] FIG. 4 illustrates the next step in the method in which a metal or plastic heat tube 43 is installed within the longitudinal slot 41, whereby the heat tube 43 contacts the exposed exterior surface 27 of the metal carrier pipe 25. The heat tube 43 may be temporarily affixed to the pipe exterior surface in some manner, but it is typically not necessary to weld the heat tube in place. The heat tube 43 is shown as being a cylindrical conduit in the drawings, but it will be understood that the heat tube could have other shapes, such as a square or rectangular channel member, for example.

[0056] FIG. 5 illustrates the next step in the method in which a second layer of foam insulation 42 is sprayed onto the exterior of the metal carrier pipe and first layer of foam insulation 38, thereby covering the previously formed longitudinal slot 41 and installed heat tube 43.

[0057] In the final step in the process, shown in FIG. 6, an outer protective synthetic jacket 45 is applied to the carrier pipe and two layers of foam insulation. This can be accomplished, as by applying a polyolefin coating (HDPE) around the insulated pipe to thereby form an outer protective jacket for the insulated pipe. In the example illustrated in FIG. 6, an extruder head 47 extrudes the HDPE coating from an extrusion nozzle 49 as the extrusion head passes longitudinally along the exterior of the pipe. Alternatively, the extruder head can be stationary with the pipe being placed on a helical conveyor system which rotates the pipe as it translates down the conveyor.

[0058] The steps in the method which have previously been described could apply to a batch, stepwise process, or to a continuous or semi-continuous process. FIGS. 7A and 7B illustrate one embodiment of such a continuous process.

[0059] With reference to FIG. 7A, a steel pipe 51 rolls off onto a conveyor line 53 and moves from right to left, as viewed in the top portion of FIG. 7A. The pipe is being translated in a longitudinal direction and also simultaneously rotated as it travels down the conveyor line. After traveling down a given length of the conveyor line 53, the pipe passes a foam application station 55 where a dispensing head 57 sprays a first layer of insulating foam onto the steel pipe. The foam may be sprayed, for example, to a depth of about 1.5 inches to match the general height of the heat tube to be installed.

[0060] With reference to the top portion of FIG. 7B, the pipe then enters the curing oven section 59 of the conveyor line and continues to move to the left as viewed in the top portion of FIG. 7B. At the far left end of the drawing, the pipe is rolled off onto the second, straight line section of a conveyor line 61. The now foam covered pipe 63 moves from left to right, as viewed in the mid-section of FIG. 7B and continues over to a routing station (shown as 65 in FIG. 7A). The previously described wire brush or blade routing processes are then used to cut a longitudinal channel down the length of the foam covered pipe 63, as described with respect to FIGS. 3 and 3A.

[0061] The foam covered pipe 63, having the routed longitudinal channel or groove previously described, then rolls off the end section 67 of the straight line conveyor onto a work station (designated as 69 in FIG. 7A). The previously described length of heat tube is then installed, in this case by hand, into the longitudinal channel cut in each length of pipe 71.

[0062] The lengths of pipe 71 then pass to another conveyor section 77 which both translates the lengths of pipe longitudinally and also simultaneously rotates the lengths of pipe. The lengths of pipe 71, having the installed heat tubes, are then moved from right to left, as viewed in the bottom portion of FIG. 7A, where they pass a second foam application station 73 where a dispending head 75 sprays a second layer of foam to cover the heat tube and open channel. The thickness of the second application of foam is determined by the required process specification thickness.

[0063] The lengths of pipe 71 then pass through an application station (79 in FIG. 7B) where they are sprayed by dispensers 81, 83, with a vapor barrier and wrapped with the polyethylene outer jacket previously described. The finished pipe lengths 85 then pass from right to left, as viewed in the bottom portion of FIG. 7B and roll off to a finishing area 87. The process line used in the continuous, or semi-continuous process described can easily run on the order of fifteen feet per minute.

[0064] An invention has been provided with several advantages. The method of the invention can be used to manufacture a length of pre-insulated piping where the lengths of insulated piping being joined are part of a pipeline conveying, for example, process fluids, heating water and petroleum products. The process accommodates the installation of a heat tube of the type used in a heat tracing system used for temperature maintenance and freeze protection. The process is simple in nature and economical to practice requiring the addition of only simple hand tool type implements.

[0065] While the invention has been shown in only one of its forms, it is not thus limited but s susceptible to various change and modifications without departing from the spirit thereof.