Abstract
A transportable system and method for the in situ eccentric manufacturing of reinforced thermoplastic pipelines in continuous lengths up to 10 miles and from 8 to 60 inches in diameter having a rotating frame assembly with a eccentric spools for application of reinforcing tapes and other components to a polyolefin core pipe, and further having a forming machine for cross sectional shape reduction of the reinforced thermoplastic pipelines to facilitate pulling the reinforced thermoplastic pipelines inside a host pipeline. Also provided are continuous monitoring and marking with application of tape in the hoop stress direction and the axial stress direction as well as saturated tape feeding stations for impregnation of the reinforcing tape for in situ curing.
Claims
1. An apparatus for the eccentric wrapping of a core pipe for the in situ manufacture of reinforced thermoplastic pipelines in continuous lengths up to 10 miles and from 8 to 60 inches in diameter comprising a portable rotating frame assembly with a motorized driving mechanism with at least a first and second eccentric spool each having a cantilevered arm for application of a plurality of reinforcing tape layers under tension to the core pipe in helical and contra helical direction.
2. The apparatus of claim 1 wherein additional spools are provided for application of a plurality of reinforcing tape layers under tension to the core pipe in the hoop stress direction and the axial stress direction.
3. The apparatus of claim 1 wherein at least one additional rotational frame assembly is added to work in tandem with the first rotating frame assembly to increase the application of a plurality of reinforcing tape layers under tension to core pipe.
4. The apparatus of claim 1 where the rotating frame assembly further comprises a support frame with wheels to travel on railings.
5. The apparatus of claim 3 where all rotating frame assemblies further comprise support frames with wheels to travel on railings.
6. The apparatus of claim 1 where the core pipe is polyolefin.
7. The apparatus of claim 1 where the core pipe is HDPE.
8. The apparatus of claim 3 where the core pipe is polyolefin.
9. The apparatus of claim 3 where the core pipe is HDPE.
10. The apparatus of claim 1 where in addition to the application of a plurality of reinforcing tape layers under tension to the core pipe, continuous monitoring equipment is added.
11. The apparatus of claim 3 wherein in addition to the application of a plurality of reinforcing tape layers under tension to the core pipe, continuous monitoring equipment is added.
12. The apparatus of claim 1 wherein in addition to the application of a plurality of reinforcing tape layers under tension to the core pipe continuous marking is added.
13. The apparatus of claim 3 wherein in addition to the application of a plurality of reinforcing tape layers under tension to the core pipe continuous marking is added.
14. The apparatus of claim 1 further comprising saturated tape feeding stations for impregnation of the reinforcing tape for in situ curing.
15. The apparatus of claim 3 further comprising saturated tape feeding stations for impregnation of the reinforcing tape for in situ curing.
16. A method for the eccentric wrapping of a core pipe for the in situ manufacture of reinforced thermoplastic pipelines in continuous lengths up to 10 miles and from 8 to 60 inches in diameter comprising the steps of: transport and assemble on site an apparatus comprising a rotating frame assembly with a motorized driving mechanism with at least a first and second eccentric spool each having a cantilevered arm for application of a plurality of reinforcing tape layers under tension to the core pipe in helical and contra helical direction.; move rotating frame assembly over the core pipe with application of a plurality of reinforcing tape layers under tension.
17. The method of claim 16 wherein additional spools are provided for the apparatus for application of a plurality of reinforcing tape layers under tension to the core pipe in the hoop stress direction and the axial stress direction.
18. The method of claim 16 wherein at least one additional rotational frame assembly is added to work in tandem with the first rotating frame assembly to increase the application of a plurality of reinforcing tape layers under tension to the core pipe.
19. The method of claim 16 where the core pipe is polyolefin.
20. The method of claim 16 where the core pipe is HDPE.
21. The method of claim 18 where the core pipe is polyolefin.
22. The method of claim 18 where the core pipe is HDPE.
23. The method of claim 16 comprising the additional steps of application of continuous monitoring equipment and continuous marking to the core pipe.
24. The method of claim 18 comprising the additional steps of application of continuous monitoring equipment and continuous marking to the core pipe.
25. The method of claim 16 comprising the additional step of impregnation of the reinforcing tape for in situ curing.
26. The method of claim 18 comprising the additional step of impregnation of the reinforcing tape for in situ curing.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0052] FIG. 1 shows the front entry, and side elevations showing the positions of the eccentric use of the frame assembly.
[0053] FIG. 2 shows a rotating position of the frame assembly from the front view of the operation and from an exit elevation.
[0054] FIG. 3 is a depiction of the assembled eccentric equipment showing the front, side and back views.
[0055] FIG. 4 is a depiction of the cross sections in comparison of the sizes showing how the same size of the round pipe is reduced in its cross section.
[0056] FIG. 5 is the typical composite Smart pipe's isometric detail.
[0057] FIG. 6 is showing a typical cross section of the shape formed Smart pipe which is the primary product of this invention.
[0058] FIG. 7 is the isometric view of the two eccentric machines operating in tandem whereby a process of the doubling of the tape application is shown. For more applications there are the other possibilities, not shown on this drawing, whereby more spools are added or more units are in a simultaneous operation.
[0059] FIG. 7a shows the left eccentric machine depicted in FIG. 7.
[0060] FIG. 7b shows the right eccentric machine depicted in FIG. 7 working in tandem with the eccentric machine of FIG. 7a.
[0061] FIG. 8 is the plan of the two eccentric machines in operation while travelling over the rails.
[0062] FIG. 9 is the plan showing of the total factory in its one configuration showing the line of the equipment necessary for a production in situ. The arrangement of the equipment is a novelty of this invention since there are the features in such composition of the equipment necessary for accomplishing the work of the eccentric equipment, shape reduction equipment, pulling and control monitoring of the production.
[0063] FIG. 10 is the plan and front view showing multiple heads of the eccentric equipment which represent an alternative production for the Smart pipe where more layers would be applied in the process of making the pipe.
[0064] FIG. 11 is the plan view showing a saturation components of the eccentric equipment and helical and contra helical application of the saturated tapes ready to be installed over the core pipe.
[0065] FIG. 12 is the isometric view showing saturation components as an assembly on the core pipe.
[0066] FIG. 13 is the cross section and the list of the saturation components in the assembly on the core pipe in the reduced cross section of C shape but also applicable to W and other shapes.
[0067] FIG. 14 is the cross section showing saturation components as an assembly on the core pipe in the finished cured and rigid type assembly as one pipe.
[0068] FIG. 15 is the plan and the view showing augmented components to the helical and counter helical equipment, in a tandem assembly, where the horizontal head movements and the diverting aims are arranged for the application for the hoop stress tapes.
[0069] FIG. 16 is the plan showing augmented components to the helical and counter helical equipment, within the same assembly, where the horizontal head movements and the diverting arms are arranged for the application for the hoop stress tapes.
[0070] FIG. 17 is the isometric display of the pipe components and the list of the parts in the assembly on the core pipe.
DETAILED DESCRIPTION OF THE INVENTION
[0071] FIG. 1 shows the front entry and side elevations showing the positions of the eccentric use of the frame assembly 1 but does not show the supports within which this frame assembly 1 is put in motion. Also shown are the positions of two spools 3 in application of helical and contra helical tapes 2 over the core pipe and also showing the superimposed cross sections of the same round pipe in its reduced form. The helical and contra helical application tapes 2 on the spools are shown with cantilevered arms positioned in relationship to the core pipe, equipped with a mechanism for rotating the eccentric cage the frame 1, and mounted with arms for loading and unloading of the tapes 3. The dimensions A, B and C are suitable dimensions for installation on flat bed trucks, barges and other means of the transportation. This frame assembly 1 was specifically designed to be portable with the two spools 3 and frame structure as compact one piece equipment. The addition of more spools 3, which are the part of this invention, are in the same context, changed in the assembly whereby the spool components, the frame and the frame supports are re-assembled for transportation purposes and at the site composed together where the space is allowing for such larger type of the equipment to be operated. The frame assembly 1 is suitable for the transport to a site ready for manufacturing of large size composite RTP Smart pipe by movable and/or stationary eccentric tapers which can be expanded to multiple tapers.
[0072] In FIG. 2 is shown a rotating position of the frame assembly 1 from the front view of the operation and from an exit elevation , describing the extent of the circular motion of the frame and from which is determined the maximum height of the assembly 1 for the purpose of the environmentally conditioned manufacturing by means of enclosures, or tenting, for the purpose of handling in reloading of the spools 3 unto the equipment, and generally for the purpose of providing the equipment's limitation size as related to the transportation needs. FIG. 2 shows only one size of pipe but the other features will accommodate pipe sizes up to 60 inches in diameter and with modifications of the same principal equipment up to 60 inches in diameter are accomplished within the system of eccentric manufacturing by adding more spools at the site within the same limitations suitable for the site production. FIG. 1 only shows two coils 3 but double and quadruple coils can be mounted. The possibility of unobstructed space is indicated by the circular pattern 4.
[0073] In FIG. 3 is a depiction of the assembled eccentric equipment showing front, side and back views, and indicating a driving mechanism 5 to rotate the eccentric cage-frame by controlled speed and power in coordination with the type of motion in manufacturing the RTP product where the operation is strictly controlled by the computerized programs proprietary to this application for the reinforced structural layers of the pipe. Shown are two side-attachable frames 7a upon which the rotating cage is resting on the roller type bearings, as those attachable frames are also the compact components transportable and assembled at the site. The general sizes as A and D are length and the height of the equipment in operation. Also depicted in FIG. 3 is a motorized driving mechanism 6 mounted on the support frames and providing torsional force for the eccentric frame rotation. The motorized driving mechanism 6 may be installed on both sides of the assembly as required for more power and torque. A support frame 10 with wheels is also shown.
[0074] FIG. 4 shows a reduction of cross sections in composite pipes and is a comparison of cross sections of pipe sizes showing how the same size of the round pipe is reduced in its cross section and how these compact sections represent the two structurally suitable elements when subjected to the pulling forces in installation in long Smart pipes. This drawing depicts the standard formation of the shape C 8 and the shape W 9 in comparison, so that the benefit of their relationship to a large size pipes can be appreciated. The two technically advanced features of these cross sections are considered the most favorable, among others showing in the previous invention for the Smart Pipe, in light of the subject operation. As such this inventive system provides for the efficiency of the use of the large size diameters of the pipe and its conversion to manageable sections capable to be installed in the very long Smart pipes. This comparison is a technical part of this invention that provides the solution of the pulling the large size pipe inside a host pipeline or conduits or as stand-alone conducive for pulling in the process of the installation. This geometric feature is the inventive part of the handling of the large size pipes and their suitable conversion.
[0075] FIG. 5 shows an isometric view of high strength light type pressure pipe in one form of manufacturing practice for composite pipe types. Shown are the components of the Smart pipe construction including the monitoring inventive systems, pulling inventive systems, and all other features of such smart pipe designs including the novelty of monitoring the stored Smart pipes in all conditions. Additional sensors may be also used within the structure of the assembly such as at the frame structures used in manufacturing, and for the purpose of the application of the tapes under design tension. The components are depicted as follows: [0076] a. Core pipe (polyolefin). [0077] b. Wrapping layers helical and circular. [0078] Application in first and second orders as per the design for strength with embedded woven sensors within the fabric. [0079] c. High strength pulling tapes with embedded woven fabric sensors. [0080] d. Tows with embedded woven fabric sensors. [0081] e. Covering assembly tapes, Mylar or other temporary security for the pipe shape forming and installation. [0082] f. Sensors and readers for the various pipeline functions.
[0083] FIG. 6 shows the formation of the C shape reduction 8 of the pipe incorporating sensors, on or woven inside the fabric of the pipe, pulling tapes and strength added tapes. Other pipe shapes reduction is a prior art used in the manufacturing of composite pipes. The subject of the W shape reduction 9 is also considered similar to this C form presentation, but not shown in FIG. 6.
[0084] In FIGS. 7, 7a and 7b is depicted an isometric view of two eccentric machines operating in tandem whereby a process of the doubling of the tape application is shown. For more applications there are other possibilities, not shown on these drawings, whereby more spools are added or more units are in a simultaneous operation. There are three modes of operation: [0085] 1. Pipe turns in eccentric application by means of the machine moving over the pipe. [0086] 2. Pipe moves through; eccentric application by means of the machine in the static position. [0087] 3. Pipe is static; eccentric application by means of the machine in motion.
[0088] The machine 11 depicted in FIG. 7a indicates the tandem operation of the machines and application of the tapes over the core pipe in the first passage while the overlay of the second machine 12 depicted in FIG. 7b immediately follows the first machine 11 in strict coordination to meet the technical demands for tape application in terms of angle of repose and tension. The extended arms 13 holding the spools 3 of the tapes 2 are dismountable and flexible in adjustment so that they can provide for the calculated angles of repose in the tape applications and also for the exchange of the spools in a continuous process of the manufacturing. The dismountable assembly mechanism 14 can be either static or mobile as required and is suitably designed to be flexible in transportation and assembly at the site. Control stations 15 are mounted on the drive mechanism, providing for direct and remote control of the operations. Also shown is a control station 16 used for a direct guiding and alignment in the process of the production, which is also coordinated into the entire control operation.
[0089] FIG. 8 shows a plan of the tandem operation 17 of two eccentric machines where helical and contra helical applications are repeated in overlays, where the number of overlays can be added as per the design for the strength and internal pressure is specified. Also diagrammatically indicated are two additional spools 18 that can be attached to the same frame assembly to multiply the application of the layers per each machine. These can be made active spools in simultaneous operation or they can be used as a replacement of the active spools when in need of the replacement. The detail shows the assembly of the wheels 19 which are provided for the movement of the equipment in such arrangement suitable for the most stable and the least friction resistant operation. This system of the driving wheels at the angled position towards the railings provides for a minimum friction and maximum stability of movement, and in turn the system provides for a steady control of the machinery in coordination during the manufacturing.
[0090] A plan of the assembly line 20 for a typical production of composite pipe using minimum equipment layout is shown in FIG. 9. This plan layout 20 provides one assembly of the entire operation necessary for the production of the composite pipe RTP. The novelty of the system is that it is site portable, it can operate under different weather conditions, it is self sustainable in the overall operation in terms of the power and logistics of the operation and it is environmentally friendly without any emissions and no discharges requiring any treatment or associated permits The system operates with no hazardous or detrimental materials but with the product components all pre-made and pre-possessed for this type of the manufacturing.
[0091] As shown in FIG. 9, there is a prime mover caterpuller 36, a buffer caterpuller 31, a longitudinal wrapper 29, double eccentric Mylar taper 30, a counter helical tape head 35, a helical tape head 34, tape feeding stations 33, and saturated tape feeding stations 32. In connection with the tape feeding stations are containers 22 prepared for impregnation of the tapes which are in a continuous way applied on the core pipe. Also shown is a pipe rack and delivery 37, welding equipment 38 and a control station 28.
[0092] A plan and front view of the assembly line 21 with multiple head diverters for the eccentric machine is shown in FIG. 10. This represents an alternative production for the Smart pipe where more layers would be applied in the process of making the pipe. Such modifications are showing the packing of the spools, diagrammatically noted here, to indicate the same principle of this invention, namely, to be a large size eccentric application in making of the RTP composite products. The multiple eccentric systems where the equipment is under the operation of producing shorter sections can be used under the same principle of the eccentric manufacturing. The novelty of this system is also related to its portability in transportation by means of dismountable parts being used in the reduction of the height and width of the equipment needed to fit the transportation requirements to the site, and also the ergonomics at the site in assembling the entire equipment for production.
[0093] FIG. 11 shows a plan of the assembly line with the head diverters and the saturation equipment. In FIG. 11 is shown saturated tape feeding stations 32, containers 22 prepared for impregnation of the tapes and the saturated tapes 23 applied on the core pipe in helical and contra helical motions.
[0094] FIG. 12 shows an isometric view of the high strength light type pressure pipe composed of the solid wall thickness made by combined and impregnated and cured assembly.
[0095] FIG. 13 shows the formation of the C (W) shape reductions of the pipe incorporating sensors, on or woven inside the fabric of the pipe, pulling tapes and strength added tapes and forming assembly of the solid walls before curing of the saturated assembly. The components as depicted are: [0096] a. Core pipe (polyolefin). [0097] Items b, c, d, f represent one assembly cured in solid wall [0098] b. Wrapping layers helical and circular. [0099] Application in first and second orders as per the design for strength with embedded woven sensors within the fabric. [0100] c. High strength pulling tapes with embedded woven fabric sensors. [0101] d. Tows with embedded woven fabric sensors. [0102] e. Covering assembly tapes, Mylar or other temporary security for the pipe shape forming and installation. [0103] f. Sensors and readers for the various pipeline functions.
[0104] In the cross section shown in FIG. 14, the saturated and cured assembly 24 is shown as applied on the core pipe in the installed stage.
[0105] FIG. 15 shows a plan of the assembly line 25 with multiple head diverters for the eccentric machine for variable directional stress applications, from the hoop direction to axial configuration. This assembly line shows the variable installation 26 of the tapes by use of the application arms for the hoop stress configuration and the horizontal movement installation 27 of the application arms for the hoop stress configuration.
[0106] FIG. 16 shows a plan of the assembly line with multiple head diverters for the eccentric combined machine for variable directional stress applications, from the hoop direction to axial configuration.
[0107] FIG. 17 shows an isometric view of the high strength light type pressure pipe in one form of the manufacturing practice for the composite pipe types. Also shown if the formation of the C shape reduction of the pipe incorporating sensors, on or woven inside the fabric of the pipe, pulling tapes and strength added tapes depicting the hoop and axis modes of the composite pipes. The components as depicted are: [0108] a. Core pipe (polyolefin). [0109] b. Wrapping layers helical and circular. [0110] Application in first and second orders as per the design for strength with embedded woven sensors within the fabric. [0111] c. High strength pulling tapes with embedded woven fabric sensors. [0112] d. Tows with embedded woven fabric sensors. [0113] e. Covering assembly tapes, Mylar or other temporary security for the pipe shape forming and installation. [0114] f. Sensors and readers for the various pipeline functions. [0115] g. wrapping layers in the hoop direction application in several applications as per the design for strength.
