Electrofusion of pipe liners

Abstract

A method of joining together liner sections within a polymer-lined pipe energises an induction coil inside the pipe to spot-heat part of a circumferential interface between the liner sections. This melts and fuses the polymer material locally. The induction coil is then moved along the interface to heat other parts of the interface successively above the melting temperature. An apparatus for performing the method has a power supply for energising the induction coil and a drive system for moving the energised induction coil relative to a body of the apparatus. The apparatus may be configured as a carriage that is movable along the pipe.

Claims

1. A method of joining together liner sections of polymer material within a lined pipe comprises: energising an induction coil disposed within the pipe to heat a portion of an elongate interface between the liner sections by generating heat locally in at least one heating element positioned at the interface; heating said portion of the interface above a melting temperature of the polymer material, at which the polymer material of the liner sections melts and fuses locally; and moving the induction coil circumferentially along the interface within the pipe to heat successive portions of the interface above the melting temperature by generating heat locally in at least one heating element positioned at each of said successive portions of the interface.

2. The method of claim 1, comprising allowing a previously heated portion of the interface to cool below the melting temperature while the induction coil heats another portion of the interface above the melting temperature.

3. The method of claim 1, comprising pivoting the induction coil around a central longitudinal axis of the pipe.

4. The method of claim 1, wherein the induction coil is coiled around a coil axis and is supported such that the coil axis is substantially orthogonal to the interface.

5. The method of claim 4, wherein the interface is curved and the induction coil is mounted pivotally to keep the axis substantially orthogonal to that interface as the induction coil moves along the interface.

6. The method of claim 1, comprising determining a degree of longitudinal alignment between the induction coil and the interface by sensing magnetic field fluctuations of the induction coil.

7. The method of claim 6, comprising moving the induction coil longitudinal within the pipe in response to the determined degree of longitudinal alignment.

8. The method of claim 1, comprising advancing the induction coil longitudinally along the pipe between separate interfaces.

9. The method of claim 1, performed simultaneously at two or more interfaces by a plurality of induction coils each moving along a respective one of the interfaces.

10. The method of claim 1, comprising: supporting the induction coil a carriage; moving the carriage along and within the pipe; aligning the induction coil with the interface; and moving the energised induction coil relative to the carriage to follow the interface.

11. The method of claim 1, comprising: interposing a liner bridge between parent liners of lengths of the lined pipe, the liner bridge and the parent liners being said liner sections; bringing together the lined pipe lengths around the liner bridge at a closed bevel; and joining the liner bridge to the parent liners along respective interfaces.

12. The method of claim 1, further comprising welding together lengths of the lined pipe.

13. The method of claim 12, comprising welding together the lined pipe lengths while joining the liner sections along the interface.

14. An apparatus for joining together liner sections of polymer material within a lined pipe comprises: a body; an induction coil supported by the body; a power supply for energising the induction coil to heat a portion of an elongate interface between the liner sections by generating heat locally in at least one heating element positioned at the interface; and a drive system for moving the energised induction coil relative to the body.

15. The apparatus of claim 14, wherein the drive system is arranged to pivot the induction coil about a pivot axis relative to the body.

16. The apparatus of claim 15, wherein the induction coil is coiled about a coil axis that is substantially orthogonal to the pivot axis.

17. The apparatus of claim 15, wherein the body is configured to fit within and to move longitudinally along a surrounding pipe substantially without lateral movement, while maintaining the pivot axis substantially coincident with the central longitudinal axis of the pipe.

18. The apparatus of claim 14, wherein the induction coil is supported by an arm extending from an end of the body.

19. The apparatus of claim 14, further comprising an alignment sensor that is arranged to sense magnetic field fluctuations of the induction coil.

20. The apparatus of claim 14, wherein the body supports a plurality of longitudinally spaced induction coils.

Description

(1) In order that the invention may be more readily understood, reference will now be made, by way of example, to the accompanying drawings, in which:

(2) FIG. 1 is a schematic side view, in partial longitudinal section, of a joint between abutting lengths of lined pipe, including a tool in accordance with the invention for fusing a liner bridge between parent liners of the pipe lengths;

(3) FIG. 2 corresponds to FIG. 1 but shows a variant of the tool being used to fuse the liner bridge between parent liners when a weld has been, or is being, made between the abutting lengths of lined pipe;

(4) FIG. 3 is an enlarged detail view of an overlapping interface between the liner bridge and a parent liner, corresponding to Detail III of FIG. 1; and

(5) FIG. 4 corresponds to FIG. 3 but shows a variant of the interface.

(6) FIG. 1 of the drawings shows two lined pipes 20 of carbon steel abutting end-to-end at a closed bevel 22 between the pipes 20, ready to be joined by a circumferential girth weld 24 as shown in the variant of FIG. 2. Each pipe 20 contains a parent liner 26 of thermoplastics material, for example HDPE.

(7) The abutting pipes 20 enclose a generally tubular electrofusion fitting 28 that extends between, and will be fused to, their parent liners 26 to maintain a substantially continuous corrosion-resistant inner surface. For this purpose, the electrofusion fitting 28 comprises an elongate tube that is machined or moulded from a polymer material. The polymer material of the electrofusion fitting 28 is preferably the same as, or at least compatible with, the material of the parent liners 26, thus for example also being of HDPE.

(8) As best appreciated in the enlarged detail view of FIG. 3, the parent liners 26 have interface formations machined into their opposed ends. The interface formations of the parent liners 26 mate with inverse complementary interface formations on the opposed ends of the electrofusion fitting 28.

(9) All of the interface formations of the parent liners 28 and the electrofusion fitting 28 are rotationally symmetrical around a common central longitudinal axis 30 of the pipes 20. All of those interface formations are also in mirrored relation about a central transverse plane 32 that is orthogonal to the central longitudinal axis 30, that plane 32 being aligned with the interface between the pipes 20 when the electrofusion fitting 28 is in situ as shown in FIGS. 1 and 2.

(10) Specifically, each parent liner 26 terminates short of an end of the associated pipe 20 and has a stepped profile in longitudinal section. The stepped shape is defined by a full-thickness body portion 34 and a reduced-thickness end portion 36. This creates an annular step 38 between the body portion 34 and the end portion 36 of the parent liner 26 and another annular step 40 between the end portion 32 and the inner wall of the pipe 20. In cross-section, the steps 38, 40 are concentric with respect to the central longitudinal axis 30.

(11) The electrofusion fitting 28 has a complementarily-stepped profile in longitudinal section. Internally, the electrofusion fitting 28 is plain and parallel-walled. Externally, the electrofusion fitting 28 has a pair of circumferential integral hoops 42 that protrude radially from the tubular body 44 of the electrofusion fitting 28 inboard of its ends. The hoops 42 are parallel to, and spaced symmetrically from, each other about the central transverse plane 32.

(12) An annular insulator recess 46 is defined between the hoops 42 in alignment with the bevel 22 and hence the weld 24. Thermally-insulating material may be positioned in the insulator recess 46 to protect the electrofusion fitting 28 from radiant heat during weld preparation and the welding process itself.

(13) An outboard side of each hoop 42 defines an outer annular step 48 that opposes the step 40 between the end portion 32 of a parent liner 24 and the inner wall of the associated pipe 20. Each end of the body 44 of the electrofusion fitting 28 defines an inner annular step 50 that opposes the step 38 between the body portion 34 and the end portion 36 of the parent liner 26. In cross-section, the steps 48, 50 are also concentric with respect to the central longitudinal axis 30.

(14) The steps 38, 40, 48, 50 are preferably radiused or chamfered as shown in the drawings to ease insertion of the electrofusion fitting 28 into the ends of the pipes 20.

(15) End portions 52 of the body 44 of the electrofusion fitting 28, which extend longitudinally between the steps 48, 50 outboard of the hoops 42, are received telescopically within the reduced-thickness end portions 36 of the parent liners 26. Here, circumferential heating elements 54 extend continuously around the end portions 52 of the body 44, hence facing radially outwardly toward the end portions 36 of the parent liners 26.

(16) It will therefore be apparent that the interface formations of the opposed parent liners 26 comprise female interface elements that mate telescopically with male interface elements defined by the complementary formations of the electrofusion fitting 26. The heating elements 54 are positioned where there is a substantial male-female overlap between the electrofusion fitting 28 and the parent liners 26, specifically where the projecting end portions 52 of the electrofusion fitting 28 extend axially outwardly beyond the hoops 42.

(17) When assembling a pipeline for welding, the electrofusion fitting 28 is inserted into the end of a pipe 20 whose parent liner 26 has been prepared as shown in FIG. 1, with half of the electrofusion fitting 28 protruding from the pipe 20. Then, a second similarly-prepared pipe 20 is brought together into end-to-end abutment with the first pipe 20 while surrounding and locating the electrofusion fitting 26 as shown in FIG. 1. Subsequently, the pipes 20 are welded together at the bevel 22 after any necessary further preparation.

(18) FIG. 1 also shows a fusing tool 56 of the invention advanced within the abutting pipes 20 to be positioned at least partially within the electrofusion fitting 28. The tool 56 may be self-propelled or may be advanced into the pipes 20 by, or integrated with, other apparatus that moves within the pipe, such as a line-up clamp.

(19) In this much-simplified view, the fusing tool 56 is represented schematically as a self-contained unit that runs along the inside of the pipes 20 by virtue of wheels 58 that bear against the inner surface of the parent liners 26 and the electrofusion fitting 28. The wheels 58 facilitate longitudinal movement of the fusing tool 56 but resist angular movement of a body 60 of the fusing tool 56 around the central longitudinal axis 30.

(20) The body 60 of the fusing tool 56 supports a rotary drive system 62 that is driven around the central longitudinal axis 30 by an on-board motor/gearbox unit 64. A radially-extending support arm 66 fixed to the rotary drive system 62 at one end of the body 60 supports an induction coil 68. The induction coil 68 therefore turns with the rotary drive system 62 about the central longitudinal axis 30 to sweep circumferentially around the inside of the electrofusion fitting 28.

(21) The induction coil 68 is coiled around a substantially radial coil axis 70 that is, therefore, substantially orthogonal to the central longitudinal axis 30. The induction coil 68 is fitted with a field concentrator 72. When the induction coil 68 is energised, the field concentrator 72 concentrates and projects the magnetic field of the induction coil 68 radially outwardly along the axis 70.

(22) A radially outer end of the induction coil 68 is held close to the inner surface of an end portion 52 of the electrofusion fitting 28, in longitudinal alignment with the heating elements 54 that are supported by that end portion 52. Thus, the axis 70 of the induction coil 68 is substantially orthogonal to the opposed part of the electrofusion fitting 28.

(23) Aided by the field concentrator 72, the energised induction coil 68 promotes strong local heating in the heating elements 54 of the electrofusion fitting 28 that are opposed to the induction coil 68 along the axis 70. Heat generated in that part of the heating elements 54 is conducted into the adjacent parts of the electrofusion fitting 28 and the associated parent liner 26, which thereby melt and fuse together.

(24) The induction coil 68 is held at a circumferential position for long enough to initiate fusing and is then advanced circumferentially at a speed determined to promote and extend fusing along the interface between the electrofusion fitting 28 and the associated parent liner 26. In this way, when the induction coil 68 completes a full circumferential circuit, the electrofusion fitting 28 is sealed to the parent liner 26.

(25) As its circumferential sweep progresses, the induction coil 68 moves away from an already-fused part of the interface. The already-fused part of the interface is thereby left to cool and harden. Applying heat locally and progressively along the interface in this way therefore saves electrical power and reduces cooling time, to the benefit of cycle times during pipeline fabrication.

(26) The fusing tool 56 can then be moved longitudinally to fuse another interface in a similar manner, in particular the interface between the electrofusion fitting 28 and the parent liner 26 of the other pipe 20.

(27) The body 60 of the fusing tool 56 contains a power supply 74 that powers the motor/gearbox unit 64 and that energises the induction coil 68. A controller 76 controls the fusing process by controlling the operation and speed of the motor/gearbox unit 64 and the power supplied to the induction coil 68.

(28) The controller 76 is responsive to a set of sensors 78 that provide control feedback signals. The sensors 78 may, for example, include a temperature sensor that measures the local temperature of the interface between the electrofusion fitting 28 and the associated parent liner 26. The sensors 78 may also include a magnetic field sensor that senses variation of magnetic field in the induction coil 68.

(29) Fluctuation of the magnetic field in the induction coil 68 may be used to detect longitudinal alignment, or misalignment, of the induction coil 68 with the heating elements 54 of the electrofusion fitting 28. This enables the controller 76 to control an optional on-board drive system 80 that may drive at least one of the wheels 58 to move the fusing tool 56 longitudinally to position the induction coil 68 as appropriate. Alternatively, the controller 76 can provide positional feedback to an external control system so that an external drive system can position the fusing tool 56 appropriately instead.

(30) FIG. 2 shows a variant in which the fusing tool 56 is fitted with induction coils 68 at both ends of the body 60. The induction coils 68 can be moved individually or together to fuse and seal the electrofusion fitting 28 to both of the parent liners 26 simultaneously.

(31) As noted above, FIG. 2 shows the weld 24 between the pipes 20 now completed. The weld 24 may be completed before, during or after fusing together the electrofusion fitting 28 and the parent liners 26. FIG. 2 also shows fused regions 82 around the heating elements 54 that join the electrofusion fitting 28 and the parent liners 26.

(32) In the detail shown in FIG. 3, the heating elements 54 are located in circumferential locating grooves 84 to protrude radially outwardly from the end portions 52 of the body 44. This holds the heating elements 54 in direct contact with both the electrofusion fitting 28 and the surrounding end portion 36 of the parent liner 26. Direct contact maximises thermal conduction between the heating elements 54 and the materials of the electrofusion fitting 28 and the parent liners 26.

(33) In the variant shown in similar detail in FIG. 4, the heating elements 54 are embedded shallowly in the end portions 52 of the body 44. This places the heating elements 54 close to the surface of each end portion 52 and hence close to the surrounding end portion 36 of the parent liner 26. This positioning protects the heating elements 54 but is close enough to ensure adequate thermal conduction between the heating elements 54 and the material of the parent liner 26.

(34) Many other variations are possible within the inventive concept. For example, the fusing tool could move along the abutting pipes on articulated tracks instead of, or in addition to, wheels. Also, the fusing tool could be equipped with clamp shoes that move radially outwardly into engagement with the surrounding parent liners and the electrofusion fitting. Such shoes would lock the fusing tool against longitudinal or angular movement along or around the central longitudinal axis when the tool is being used to fuse the electrofusion fitting to the parent liners.

(35) It is also possible to apply internal cooling within the abutting pipes to control the temperature of the electrofusion fitting. Cooling the electrofusion fitting during the welding process may not be necessary if welding variables are chosen appropriately. However, internal cooling of the electrofusion fitting may be advantageous to allow faster welding while keeping the thermoplastics material of the fitting well below its softening temperature. In principle, such cooling could be provided via the fusing tool of the invention.