Method of cutting target members using a cutting saw device
09919370 ยท 2018-03-20
Assignee
Inventors
Cpc classification
Y10T83/9292
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
E21B29/12
FIXED CONSTRUCTIONS
Y10T83/472
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B26D1/547
PERFORMING OPERATIONS; TRANSPORTING
B23D57/0061
PERFORMING OPERATIONS; TRANSPORTING
B23D57/0084
PERFORMING OPERATIONS; TRANSPORTING
Y10T83/4722
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y10T83/424
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F16L1/166
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
E21B29/007
FIXED CONSTRUCTIONS
International classification
E03F3/06
FIXED CONSTRUCTIONS
E21B29/12
FIXED CONSTRUCTIONS
F16L1/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A diamond wire saw and method provides a frame that includes a clamp that attaches to a target (e.g. piling, beam, tubular), an elongated toothed rack extending away from the mount and target, and a moving portion that carries the diamond wire and motor drives that advance the moving portion toward the target and along the toothed rack while driving the wire around roller guides.
Claims
1. A wire saw apparatus comprising: a) a frame having first and second sections configured to attach the first section to a target that is to be cut and a moving portion operatively connected to the frame; b) a beam mounted to the first section of the frame and extending away from the first section and target, the beam including a detachable connector that detachably connects the beam to the target to be cut wherein, when connected, the target to be cut supports both the beam and the moving portion; c) the moving portion including a pair of arms disposed on opposing sides of the beam, an open end positioned near the first section and a transverse bar that connects the arms opposite the open end, the moving portion including a sleeve movably connecting the moving portion to the beam and restricting relative motion between the beam and the moving portion to relative linear motion; d) the moving portion having a powered driver operably connected to the beam which driver effects non-rotational movement of the moving portion of the frame along the beam, the moving portion having a single degree of freedom relative to the beam; e) a plurality of roller guides on the moving portion of the frame including at least one roller guide mounted at the free end of each arm; f) a drive roller on the moving portion, the drive roller being rotatable by a powered motor drive; and g) a diamond wire wound upon the drive roller and guide rollers so that when the drive roller is rotated, the diamond wire travels around the moving portion and from one roller to another roller.
2. The wire saw apparatus of claim 1, wherein the powered driver travels with the moving portion.
3. The wire saw apparatus of claim 1, further comprising a tensioning mechanism that enables adjustment of the tension of the diamond wire.
4. The wire saw apparatus of claim 1, wherein the diamond wire travels at a speed of between about 20 and 30 feet per second.
5. The wire saw apparatus of claim 1, wherein at least one of the rollers is marked with different patterns so that rotation of the rollers is visible even via underwater camera and remote monitor.
6. The wire saw apparatus of claim 1, wherein the arm free ends are connected with a section of wire that cuts through the target as the moving portion of the frame travels along the beam and towards the first section.
7. The wire saw apparatus of claim 1, wherein the guide rollers on the arm free ends are connected with a section of wire that extends across the open end of the moving portion.
8. The wire saw apparatus of claim 1, wherein the moving portion carries a camera and light mount.
9. The wire saw apparatus of claim 1, wherein the guide rollers are removably attached to the moving portion of the frame.
10. The wire saw apparatus of claim 1, wherein rollers and wire define a cutting plane and the linear beam includes a toothed rack and is below the cutting plane and a drive motor is operably connected to the toothed rack and also positioned below the cutting plane.
11. The wire saw apparatus of claim 1, wherein the arms are spaced apart a distance that defines the maximum thickness of a target that can be cut.
12. The wire saw apparatus of claim 1, wherein the arm free ends and transverse bar are spaced apart a distance that defines the maximum thickness of a target that can be cut.
13. A wire saw apparatus comprising: a) a frame having first and second sections configured with a detachable connector to attach to a target that is to be cut, wherein after attachment the target supports the frame; b) a beam mounted to the first section and extending away from the first section and target; c) a moving frame having a sleeve, the sleeve being mounted on the beam and being movable along the beam with a single degree of freedom, the frame including a pair of arms disposed on opposing sides of the beam, an open end positioned near the detachable connector and a transverse bar that connects the arms opposite the open end; d) a motor operably connected to the beam which motor effects non-rotational movement of the moving frame along the beam; e) a plurality of roller guides on the moving portion of the frame including at least one roller guide mounted at the free end of each arm; f) a drive roller on the moving portion, the drive roller being rotatable by a second motor drive; g) a diamond wire wound upon the drive roller and guide rollers so that when the drive roller is rotated with the second motor drive, the diamond wire travels around the moving portion and from one roller to another roller.
14. The wire saw apparatus of claim 13, wherein the the sleeve movably connecting the moving portion to the beam and restricting relative motion between the beam and the moving portion to relative linear motion.
15. The wire saw apparatus of claim 13, wherein the diamond wire travels at a speed of between about 20 and 30 feet per second.
16. A method of cutting an underwater target, comprising the steps of: a) lowering a cutting apparatus to a position that is next to an underwater target to be cut, the target having a longitudinal axis; b) attaching the cutting apparatus to the target; c) wherein in step b the cutting apparatus includes a frame that has first and second sections, the first section including a beam and detachable connector attached to the beam which detachable connector is configured to attach to the target, wherein when so attached the target supports the frame, and a moving portion having first and second moving ends, and mounting to the first section for movement relative to the first section limited to a single degree of freedom relative to the beam, the moving portion includes a pair of arms disposed on opposing sides of the beam and an open end at the first end of the moving portion and a transverse section that connects the arms opposite the open end and wherein a diamond wire is supported for travel upon the frame, the wire connected to a plurality of rollers including at least one powered drive roller that moves the wire; d) advancing the moving portion toward the target while the diamond wire is traveling upon the rollers; and e) wherein in step d a driver engages the beam, which engagement causes the advancement of the moving portion linearly in a direction generally perpendicular to the longitudinal axis of the target.
17. The method of claim 16, wherein the moving portion having a sleeve, and the sleeve movably connecting the moving portion to the beam and restricting relative motion between the beam and the moving portion to relative linear motion.
18. The method of claim 17, wherein remote operation includes monitoring the cutting with an underwater camera that transmits a signal to a monitor on the vessel.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
(1) For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:
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DETAILED DESCRIPTION OF THE INVENTION
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(26) Cutting apparatus 10 can be employed to cut a target for above water cutting when fitted with optional cooling system (
(27) A feed shaft 20 extends from mounting clamp 17 as shown in
(28) Frame 13 includes mounting clamp 17, feed shaft 20 and moving portion or section 23. Moving portion 23 includes transverse section 60 and arms 24, 25 which are spaced apart. Arms 24, 25 can be generally parallel. An open end 26 is provided to moving portion 23 in between arms 24, 25 generally opposite drive roller 31. Moving portion 23 provides sleeve 61 at transverse section 60. Sleeve 61 is receptive of feed shaft 20 and forms a sliding connection therewith.
(29) A plurality of sheaves or roller guides 27-30 are mounted to moving portion 23. A tensioner 32 is mounted to moving portion 23 and includes roller guide 74. An endless diamond wire 16 is wound about the roller guides/sheaves 27-30, drive roller 31 and tensioner 32 roller guide 74 as shown. Larger diameter roller 31 is a drive roller 31 drives diamond wire 16 clockwise when viewed in plan (see
(30) Rollers 27-30 can be painted or marked to divide each roller 27-30 into semi-circular areas 51-52 of different color and thus easily show rotational movement during operation, such as when viewed with a remote, underwater camera 81. Each roller 27-30 is removable from moving section 23 for ease of replacement. Each roller 27-30 rotates upon a vertical shaft 53, which rotation can be facility by one or more bearings such as two sets of 3 centimeter stainless steel sealed bearings. Each shaft 53 is held in vertical tube 54 with one or more set screws 55. Set screws 55 enable replacement of a selected roller 27-30 and its shaft 53 as well as vertical adjustment (see arrows 62,
(31) Support vessel 35 at water surface 36 can provide a crane 37 that lifts and lowers cable 15 and any needed rigging (e.g. slings). Hydraulic fluid supply lines 33 are provided for supplying hydraulic fluid from support vessel 35 and hydraulic control unit 34 to hydraulic motor drives 40, 44.
(32) The apparatus 10 of the present invention can be remotely operated underwater from a vessel 35. Support vessel 35 can provide a hydraulic control unit 34 that enables remote operation of cutting apparatus 10. Arrow 38 in
(33) A pair of motor drives 40-44 are each provided with hydraulic flow lines. These hydraulic flow lines are a part of the hydraulic fluid supply 33. The motor drive 40 is provided with hydraulic lines 41, 42. The motor drive 44 is provided with hydraulic lines 45, 46. Motor drive 44 powers drive roller 31. Motor drive 40 powers pinion gear 49. The motor drive 40 powers smaller gear 47 which powers larger gear 48 using belt drive 43. Pinion 49 is attached to larger gear 48 and rotates therewith. The pinion 49 engages toothed rack 21 of feed shaft 20.
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(42) Typical Method of Subsea Operation
(43) The following includes steps in one embodiment for operating the cutting saw in a subsea environment:
(44) 1. Job to be performed can be discussed at length with customer. Details of the job can include tooling placement on vessel 35, shipboard power requirements, water depth, casing sizes to be cut, offshore location, departure dock and safety orientation.
(45) 2. Cutting saw 10 and support equipment is prepared and function tested prior to transport to job site.
(46) 3. Cutting saw 10 and support equipment is transported to job site such as through customer's supply vessel 35 and to the work location that could be a platform, drilling rig, drill ship, work barge, dive boat, or lift boat.
(47) 4. Cutting saw 10 and support equipment is offloaded via work platform crane 37 and placed on the deck in accordance with vessel Captain, tool pusher, and/or Customer representative's instructions.
(48) 5. Cutting saw 10 hydraulic control 113 is connected to hydraulic power supply unit.
(49) 6. Hoses are used to connect control panel 113 and cutting saw 10 via either a single, 4-hose, umbilical hose bundle or two 2-hose umbilical hose bundles. All umbilical hoses are stored on powered reels for ease of transport, unspooling, and reclaiming hoses from the sea floor.
(50) 7. 1 hose is connected to the main drive wheel motor 40 of the cutting saw 10 and (or ) hose connected to drive motor for cutting saw's axial feed system (rack and pinion system 20/21).
(51) 8. Loop of cutting wire 16 is placed around the alignment wheels or sheaves (10 idler pulley wheels 27-30 and the 24 main wire drive wheel 31). In one embodiment alignment wheels or sheaves 27-30 are painted to be black to allow their rotation to be viewed underwater via a saw mounted camera. When viewing of the rotating wheels substantially appears solid, the wheel speed, and cutting wire 16 speed can be considered adequate for cutting.
(52) 9. The tension of the cutting wire loop 16 is applied via the axial tension arm 32 using a wrench (
(53) 10. Operators start the hydraulic power unit, adjust appropriate output pressure and gallons per minute flow rate and test the cutting saw 10 operation while the cutting saw 10 is above water (e.g., on the surface of the deck of the ship 35).
(54) 11. Once test is deemed good, diver support crews attach sonar positioning beacons, observation camera 81 and light, visual illumination/indication (cylalume glow sticks) and any necessary hand tools for wire changes sub-sea.
(55) 12. Deck rigging crews connect the furnished three part sling to the big or small block of the vessel crane 37.
(56) 13. Once a diver is in the water and at depth, the vessel crane 37 lowers the cutting saw 10 to the depth and location of the target 11 to be cut. Air bags and/or foam floatation modules 110 can be attached or added to the cutting saw 10 to approximate a neutral buoyancy condition for the cutting saw 10, and to increase the diver's ability to manipulate the cutting saw 10.
(57) 14. Diver manually manipulates cutting saw 10 to the desired cut area on target to be cut and provides directions (e.g., oral or verbal such as through a transmitter) to the crane operator to assist in vertically positioning the cutting saw 10 as needed.
(58) 15. Once the desired cut position is reached, the diver secures (clamp 17) the cutting saw 10 to the target to be cut (e.g., using manual chain binders or come-along or a hydraulically operated clamp 100 can be used in place of the manual chain binder assembly 17.
(59) 16. Once the cutting saw 10 is mounted, the diver removes all attached slings, tooling and handling ropes. The diver ensures that any umbilical and hydraulic lines are clear of all mechanical moving items to ensure unimpeded operation of the cutting saw 10.
(60) 17. The diver affixes the crane block with slings and shackles to the item 11 being cut to provide safe holding of the work piece 11 during and after cutting. This step also provides lifting tension on the item to open the cut and aid in the cutting process.
(61) 18. The diver returns to a dive bell or to surface prior to initiating saw operation.
(62) 19. Once instructed to commence cutting by the Dive Supervisor, the hydraulic power unit is started and adjusted for the appropriate pressure and flow rate.
(63) 20. The observation camera 81 and light is turned on to monitor the cut. All cutting is recorded on digital video disk for later assessment.
(64) 21. The hydraulic power unit is engaged providing pressure to the system. The operator having verified all parameters starts the cutting machine with the control panel 113.
(65) 22. Once a free-spinning drive motor 40 baseline pressure is reached, the diamond wire saw drive motor 40 pressure is monitored for increased pressure indicating that the diamond wire 16 is cutting.
(66) 23. An optimum increased pressure on the cutting wire 16 drive motor 40 is approximately 100-300 psi and may be adjusted by incremental movement of the rack and pinion axial wire feed mechanism 20/21.
(67) 24. Pressure is monitored throughout the cut. Increased pressure spikes can indicate movement in the target 11 being cut giving the operator 116 an indication of pinching of the diamond wire 16 or a complete drop in pressure, indicating a broken wire 16 or that the cut is complete. Visual indications are provided through the camera 81 and light monitoring system if water clarity allows.
(68) 25. If the cut is not complete, a new diamond cutting wire 16 is placed on the 10 idler pulleys 27-30 and tensioned manually by the diver 118 with verbal instruction from a Technician via the Dive Supervisor.
(69) 26. All hydraulics are disengaged via the control panel 113 once the cut is complete, or in the event that there is a diamond wire 16 breakage.
(70) 27. Once the cut is complete, the vessel 37 crane operator moves the extracted cut piece 11 to the sea floor or returns the piece to the work deck for offloading at a later time.
(71) 28. Following a diver survey of the area to ensure no damage to outlying structures or equipment has occurred; the vessel crane 37 block is lowered to the diver and reattached to the diamond wire saw 10 via the supplied three part sling.
(72) 29. The diver 118 removes the manual chain clamping system 17 and gives verbal guidance to the crane operator for returning the diamond wire saw 10 to surface.
(73) 30. Once the cutting saw 10 is on the vessel 35 work deck, all hydraulic hoses from the hose reel to the saw are disconnected.
(74) 31. The cutting saw 10 is thoroughly rinsed with a freshwater solution and all moving components are lubricated.
(75) 32. Cutting saw 10 is maintained on standby until further use is needed.
(76) 33. All video footage recorded is reviewed for analysis and improvement.
(77) 34. A cutting report can be provided to the customer which can include the video footage.
(78) Using Cutting Wire Resistance to Determine Advancement of Cutting Wire
(79) In one embodiment the operator 116 of the saw device can be above water and the cutting saw 10 be below water. In one embodiment the operator can use the resistance on the cutting wire 16 to determine when to advance the cutting wire 16 of the cutting saw 10. In one embodiment the resistance on the cutting wire 16 can be relatively determined based on the back pressure (e.g., hydraulic back pressure) to the driving motor 40 for the cutting wire 16. In one embodiment the cutting process includes the step of advancing the cutting wire 16 a short distance, and watching the resistance on the cutting wire 16 increase and then over time decrease (as the cut on the target 11 is made), and after noting the decrease in wire 16 resistance, again advancing the cutting wire 16 and watching the resistance on the cutting 16 wire again increase. In one embodiment these two steps of advancing the cutting wire 16 a short distance, and watching the resistance on the cutting wire 16 first increase and then decrease before again advancing the cutting wire 16 are repeated a plurality of times until the cut is made through the target 11.
(80) Replacement of Cutting Wire and Alignment Wheels Underwater
(81) In one embodiment the wire 16 can be replaced while the cutting saw 10 is underwater, such as during the middle of a cut and without moving the cutting saw 10 above water (e.g., see
(82) In one embodiment while underwater after a first cutting wire 16 has broken a second cutting wire 16 can be placed on the saw device 10 and properly tensioning without having to first return the saw device 10 to the surface (e.g., see
(83) In one embodiment one or more of the alignment wheels or sheaves 27-30 and 32 can be replaced while the saw device 10 is underwater, such as during the middle of a cut and without moving the saw device 10 above water.
(84) Using Both a Push and a Pull Types of Cuts on a Single Cut
(85) In one embodiment the method includes the step of:
(86) (a) starting a cut with a pushing (or pulling) type cut;
(87) (b) before the cut is completed, stopping the cutting wire 16 and at least partially removing the cutting wire 16 from the alignment wheels or sheaves 27-30;
(88) (c) moving the saw device 10 into a different pulling (or pushing) type cut position but without bringing the cutting saw 10 above;
(89) (d) placing cutting wire 16 on the alignment wheels or sheaves 27-30; and
(90) (e) completing the remaining portion of the cut in the other type of cutting mode.
(91) In one embodiment step c is completed without repositioning the clamp 17 holding the cutting saw 10 on the target 11.
(92) In one embodiment step c is performed by moving the cutting frame 23 to a substantially extended position. In one embodiment the cutting frame 23 is moved to a completely extended position.
(93) In one embodiment step c is performed by moving the cutting frame 23 to a substantially retracted position. In one embodiment the cutting frame 23 is moved to a completely retracted position.
(94) In one embodiment the same cutting wire 16 is used during steps a and e.
(95) In one embodiment a different cutting wire 16 is in step e as that cutting wire 16 used in step a.
(96) In one embodiment the cutting wire 16 used in step a is a loop which is broken into a wire string with two ends and during step d the two ends are reconnected to form a loop.
(97) In one embodiment the cutting wire 16 used in step a remains in a loop and is placed around the target 11 being cut before step d such as by being run down the top 11 of target 11.
(98) In one embodiment the tensioning mechanism 32 is used to loosen the cutting wire 16 in step b.
(99) In one embodiment the tensioning mechanism 32 is used to tension the cutting wire 16 in step d.
(100) In one embodiment the method includes the step of:
(101) (a) starting a cut with a pushing (or pulling) type cut;
(102) (b) before the cut is completed, the first cutting wire 16 breaking;
(103) (c) removing the first cutting wire 16 from the alignment wheels or sheaves 27-30;
(104) (d) without bringing the cutting saw 10 above water installing a second cutting wire 16 on the alignment wheels or sheaves 27-30; and
(105) (e) completing the remaining portion of the cut with the second cutting wire 16.
(106) In one embodiment the tensioning mechanism 32 is used to loosen the first cutting wire 16 in step c.
(107) In one embodiment the tensioning mechanism is used to tension the second cutting wire 16 in step d.
(108) In one embodiment the method includes the step of vertically adjusting at least one of the alignment wheels or sheaves (27-30 and/or 32) while the cutting saw 10 remains underwater.
(109) The following is a list of Reference numerals which are used in this application.
LIST OF REFERENCE NUMERALS
(110) TABLE-US-00001 Reference Number Description 10 cutting apparatus 11 target 12 seabed 13 frame 14 shackle 15 lift cable 16 diamond wire 16A cutting point of diamond wire 17 mounting clamp 18 cable/chain attachment 19 cable/chain attachment 20 feed shaft 21 toothed rack 22 receiver 23 moving portion 24 arm 25 arm 26 open end 27 sheave/roller guide 28 sheave/roller guide 29 sheave/roller guide 30 sheave/roller guide 31 drive roller 32 tensioner mechanism 33 hydraulic fluid supply 34 hydraulic control unit 35 support vessel 36 water surface 37 crane 38 arrow 39 cut 40 motor drive 41 hydraulic line 42 hydraulic line 43 drive belt 44 motor drive 45 hydraulic line 46 hydraulic line 47 smaller gear 48 larger gear 49 pinion 50 arrow 51 section 52 section 53 shaft 54 tube 55 set screw 56 arrow 57 arrow 58 arrow 59 arrow 60 transverse section 61 sleeve 62 arrow 63 web 64 flange 65 end plate 66 adjustment head 67 plate opening 68 threaded rod 69 nut 70 intervally threaded opening 71 bearing/slide 72 arrow 73 curved arrow 74 roller guide 75 annular grove 76 annular flange/stop 77 arrow 78 set screw 79 cable 80 camera mount 81 camera 82 post 83 tube 84 cooling system 85 flow line/header 86 nozzle 87 water jet 88 water supply conduit 89 tee fitting 90 arrow 92 light 93 arrow 94 arrow 95 arrow 100 hydraulic clamp 101 receiver 102 opening 103 body 104 hinge 105 pivoting arm 106 cylinder 107 pushrod 108 pinned connection 109 arrow 110 floatation material 111 bolted connection 112 pinned connection 113 control panel 114 instrument 115 control valve/lever 116 operator 117 monitor 118 diver 119 wrench 120 lift line 121 wire rope body 122 abrasive member
(111) All measurements disclosed herein are at standard temperature and pressure, at sea level on Earth, unless indicated otherwise. All materials used or intended to be used in a human being are biocompatible, unless indicated otherwise.
(112) The foregoing embodiments are presented by way of example only; the scope of the present invention is to be limited only by the following claims.