Abstract:
The present disclosure is directed to a method of detecting at least one variable associated with at least one joint or a machine of an assembled pipeline system ( 100 ). The example method includes assembling, via the machine having at least one pulling cylinder, at least two pipe sections to form at least one joint of the assembled pipeline system. The example method includes measuring, by at least one sensor ( 102,104 ), at least one variable selected from the group consisting of time, temperature and hydraulic pressure of the pulling cylinder during assembly of the pipelines system ( 100 ). The example method includes determining a location of the at least one joint of the assembled pipeline system. The example method includes recording a serial number associated with each of the at least two pipe sections of the assembled pipeline system. Corresponding systems and a computer-readable media are also disclosed.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 61/656,514, filed 6 Jun. 2012, the contents of which are incorporated herein by reference in their entirety. 
     
    
     FIELD 
       [0002]    The present embodiments relates generally to detecting at least one variable associated with the formation of at least one joint and/or a machine during assembly of a pipeline system. 
       BACKGROUND 
       [0003]    1. Technical Field 
         [0004]    The present disclosure relates to pipeline systems and more specifically to detecting and tracking variable data associated with the formation of joints of an assembled pipeline system, and to archiving and subsequently retrieving the variable data at a later date in the event of a failure. 
         [0005]    2. Introduction 
         [0006]    Pipeline systems are used for transfer of various industrial fluids, such as oil, coolant, lubricants, water, or other fluids. Given the relatively large size and weight of such industrial pipeline systems, assembly of industrial pipeline systems typically occurs at remote locations that are convenient to processing facilities, such as rural fields for oil drilling, deep ocean floors, etc. Additionally, these pipeline systems are typically situated at locations that alternatively support both origination and receipt of shipment of such industrial commodities, such as ports supporting transport by truck, railway, and water shipment. 
         [0007]    Such pipeline systems typically include an assembly of individual pipe sections, which are assembled by hydraulically pulling a pipe section having a pin end into another pipe section having a bell end, thereby creating an interference fit at the joint. Manufacturers will typically supply these pipe sections with some form of unique part identifier, such as a pipe section serial number, and these pipe sections will be delivered to a particular geographic location for subsequent on-site pipeline assembly. 
         [0008]    Numerous environmental variables or pipeline system assembly parameters can influence its mechanical outcome and performance, as well as the resulting physical integrity of such assembled pipeline systems. Such variables can include, for example, any combination of one or more of variations in mechanical tolerances associated with the respective pin end and bell end of mating pipe sections, ambient temperature and humidity conditions at time of assembly, hydraulic pressing or pulling forces generated by pipeline assembly equipment while mating the pipe sections, as well as other variations affecting pipe quality or reliability. 
         [0009]    Because of the remote locations where these pipeline systems are typically assembled and deployed for use, experienced or qualified machine operators and related equipment are frequently unavailable. Given the complex nature and enormous capital expense for installation of such pipeline systems, as well as the high value associated with the commodities potentially being piped therein, it is desirable that such pipeline systems perform for several years without failure or required maintenance. Thus, determining whether the interference fit is proper during the pipeline assembly process and that a fluid-tight joint is established before these resources leave the pipeline assembly location can be important. 
         [0010]    In the event of a pipeline system failure, such as a failed connection (i.e., leakage) between a particular pin end and bell end of adjacent pipe sections, establishing some form or archival record during original assembly which documents the various assembly parameters and variables may be desirable. This would allow for both dynamic and retrospective analyses of the pipeline. 
         [0011]    Therefore, a need exists for detecting and tracking multiple variables associated with the formation of at least one joint of an assembled pipeline system at the time of assembly. A need also exists for archiving and subsequently retrieving variable data associated with the formation of at least one joint at a later date in the event of a subsequent failure of the at least one joint. The embodiments described below are believed to meet these needs. 
       SUMMARY 
       [0012]    Additional features and advantages of the disclosure will be set forth in the description that follows, and in part will be obvious from the description, or can be learned by practice of the herein disclosed principles. The features and advantages of the disclosure can be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. These and other features of the disclosure will become more fully apparent from the following description and appended claims, or can be learned by the practice of the principles set forth herein. The steps outlined in these methods can be arranged in any order, combination, or permutation thereof. The methods can include fewer steps or more steps. 
         [0013]    Disclosed herein is a method of detecting at least one variable associated with at least one joint and/or a machine of an assembled pipeline system. A system configured to practice this method can assemble, via the machine including at least one pulling cylinder, at least two pipe sections to form at least one joint of the assembled pipe system. The system can measure, by at least one sensor, at least one variable selected from the group consisting of time, temperature and hydraulic pressure of the pulling cylinder during assembly of the pipe system. The system can determine a location of the at least one joint of the assembled pipeline system. The system can record a serial number associated with each of the at least two pipe sections of the assembled pipeline system. 
         [0014]    In another aspect, a system for detecting at least one variable associated with at least one joint and/or a machine of an assembled pipeline system, includes a machine including at least one sensor for measuring at least one of a variable selected from the group consisting of time, temperature and hydraulic pressure of a pulling cylinder during assembly of the pipe system. The system can include a data controller communicatively coupled to the at least one sensor, the data controller configured to receive information from the sensor. The system can include a processor for executing computer-executable instructions for analyzing information obtained from the data collector. 
         [0015]    Also disclosed herein is a non-transitory computer-readable medium for use on a computer system, the computer-readable medium including computer-executable instructions for performing, when executed by a processor, a method for detecting at least one variable associated with at least one joint and/or a machine. The method can include receiving a measurement, via at least one sensor, of at least one variable selected from the group consisting of time, temperature, and hydraulic pressure during assembly of a pipe system. The method can include determining a location of at least one joint. The method can include generating a notification, status, or alert regarding the received measurement. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    Various embodiments of the invention will be understood from the following description, the appended claims and the accompanying drawings, in which: 
           [0017]      FIG. 1  provides a schematic diagram of a working environment of the present invention. 
           [0018]      FIG. 2  provides a schematic diagram illustrating certain components associated with the embodiments of  FIG. 1 ; and 
           [0019]      FIG. 3  provides a flowchart depicting an exemplary method for detecting at least one variable, consistent with the disclosed embodiments of  FIGS. 1-2 . 
       
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0020]    Before explaining the present embodiments in detail, it is to be understood that the embodiments are not limited to the particular embodiments and that they can be practiced or carried out in various ways. The steps and modules outlined and illustrated herein are exemplary, and can be combined in multiple configurations, including configurations in different orders, with different functional links, or with more or fewer steps or modules. 
         [0021]      FIG. 1  illustrates pipeline assembly equipment  100  for assembling a first tubular pipe section  102  together with a second tubular pipe section  104 . While the examples provided herein refer to tubular pipe sections  102 ,  104 , the same principles can be applied to other, non-tubular pipe sections as well, including but not limited to square, rectangular, octagonal, or trigonal pipes. These pipe sections will be typically be fabricated with specially-formed, mating ends for assembly by interference fit, and will be shipped in such form to the site for assembly using the present invention. The pipe sections can be fabricated of any suitable material, including but not limited to steel, ductile iron, PVC, non-rigid plastic, copper, and other materials. 
         [0022]    In one example, the first pipe section  102  incorporates an expanded bell end  102   a , and further includes an interior region  102   b  defined within the bell end. Prior to assembly of the two pipe sections, the interior region  102   b  may be coated with a fast setting epoxy compound, or other adhesive material or materials, disposed along its interior surface, which can include a smooth powder fusion epoxy, or alternatively can include a multi-layer (e.g., three-layer) polyethylene coating. 
         [0023]    The second pipe section  104  incorporates a pin end  104   a  which is tapered inwardly at the tapered portion  104   b  in order to provide a mating seal with the interior region  102   b  of the first pipe section  102 . Adjacent the pin end  104   a , an annular groove  104   b  may be pre-formed into the outer surface of the second pipe section, such as by a hydraulic groover or otherwise machined into the pipe, in order to receive additional epoxy for an improved fluid seal following pipe assembly. The pin end  104   a  may be coated with a fast setting epoxy compound disposed along its interior surface, which can include a smooth powder fusion epoxy, or alternatively can include a multi-layer (e.g., three-layer) polyethylene coating. However, it may be desirable that the most distal portion of the pin end  104   a  remains partially uncoated with the polyethylene coating to optimize the coupling of the first and second pipe sections. 
         [0024]    The pipe assembly equipment  100  includes a housing  106 . The housing incorporates inwardly-projecting pipe guides  108  and  109  which can be positioned after insertion of the bell end  10  of the first pipe section  102  into the housing, to stabilize the first pipe section for assembly. Additionally, the housing incorporates inwardly-projecting pipe guides  110  and  111  which can be positioned after insertion of the pin end  10  of the second pipe section  104  into the housing, to stabilize the second pipe section for assembly. 
         [0025]    Additionally, each of the projecting pipe guides  108 ,  109 ,  110  and  111  are respectively provided with sensors  108   a ,  109   a ,  110   a  and  111   a , for purposes of monitoring and acquiring at least one of several variables representative of pipe assembly conditions, including without limitation, hydraulic pressing or pulling forces generated by pipe assembly equipment while mating the pipe sections, time of assembly, and the like. Additionally, these sensors may also monitor and acquire at least one of several variables representative of pipe assembly conditions in the environment during pipeline installation, including without limitation, ambient temperature, barometric pressure and humidity conditions at time of assembly, and the like. The sensors can be incorporated into the projecting pipe guides  108 ,  109 ,  110 , and  111 , or can be incorporated at other locations, such as the exterior surface of the housing  106 , within the pipe sections  102 ,  104 , or in the cavity within the housing  106  between the projecting pipe guides  108 ,  109 ,  110  and  111 . In one embodiment, the sensors are of different types. In another embodiment, multiples sensors of a same type at several positions or locations can detect a difference or a gradient in sensed values. 
         [0026]    During assembly, the first pipe section  102  and the second pipe section  104  are concentrically aligned within the housing  106  of the pipe assembly equipment  100  with respect to a common longitudinal axis, and are stabilized by the pipe guides  108 ,  109 ,  100  and  111 , to ensure effective assembly at the mating joint. 
         [0027]    As a result, the pin end  104   a  is inserted into the bell end  102   a , such as by a hydraulic press (not shown), or in the alternative a hydraulic pulling cylinder (not shown), which moves the pin end in the general direction depicted by arrow A toward the bell end. In this manner, the two pipe sections are coupled together to create an interference fit. When in an interference fit, the interior surface of the bell end  102   a  exerts a compressive force upon the exterior surface of the pin end  104   a , which force is engineered by choice of design and materials to be less than the yield strength of the pin end. 
         [0028]    The pipeline assembly equipment  100  is illustrated in  FIG. 1  as being situated in an environment  112  for assembly and installation of pipeline systems, and is coupled to a pipeline machine management system  114  via a wired or wireless network  116 . In one example, the sensors  108   a ,  109   a ,  110   a  and  111   a  communicate with a central data collector, discussed below with respect to  FIG. 2 , which gathers the sensor data and reports the sensor data to the pipeline machine management system  114 . 
         [0029]    The subscriber  118  is depicted as connected to the pipeline machine management system  114 , to receive updates on information being acquired during pipeline assembly, as hereinafter described below. Subscriber  118  may be one or more entities with an interest or stake in the performance or electromechanical condition of pipeline assembly equipment  100 , and the subscriber may have duties or responsibilities to maintain the performance of or condition of pipeline assembly equipment  100 . Subscriber  118  may receive information on the at least one variable, such as the hydraulic pressure of the pulling cylinder (not shown) on pipeline assembly equipment  100 . Subscriber  118  may receive the information from pipeline machine management system  114 . Subscriber  118  may include, for example, operators of pipeline assembly equipment  100 , project managers, repair technicians, shift managers, human resource personnel, or any other person or entity that may be designated. 
         [0030]    In one variation, the subscriber  118  is a human entity, but the subscriber  118  can also be an electronic repository, such as a log file or a pipeline machine management history or record repository. The log file can include information such as a date, time, sensor readings, serial numbers of the pipe sections, sensor status, or any other available and relevant information. The subscriber  118  can enroll with the pipeline machine management system  114  to receive notifications of sensor data that exceeds a threshold, such as a sensed temperature outside of a desired temperature range for safe operation of the resulting pipe joint. Thus, while the pipeline machine management system  114  can record a large set of data, which can be made available upon request of the subscriber  118 , the pipeline machine management system  114  may only generate notifications for the subscriber  118  based on one or more conditions or sensor data ranges. The subscriber  118  can also enroll with the pipeline machine management system  114  to receive a periodic update or report of all data performed within a certain time period or within a certain number of pipe join operations, such as a daily report or a report for every 500 pipe join operations. 
         [0031]    The location of the at least one joint associated with each such pipeline assembly can be dynamically determined. According to one embodiment, GPS or another positioning system, alone or in combination with an internal tracking system of the pipeline machine management system  114 , may track or periodically update the position of pipeline assembly equipment  100 . In another exemplary embodiment, RFID tags located on-board the pipeline assembly equipment  100  may be detected by RFID receivers distributed throughout work environment  112  to determine relative positions of such equipment  100 . In another exemplary embodiment, a combination of GPS and RFID methodologies may be employed to determine the location of pipeline assembly equipment  100  in work environment  112 . In another embodiment, unique serial numbers can be imprinted directly on the pipeline assembly equipment which can be recognized and retrieved from a database to identify the equipment  100 . In yet another embodiment, some optically readable code, such as a QR code or other form of barcode, is affixed to or included on the equipment  100  for identification via an automatic means or via a human manually scanning the code, such as with a handheld barcode scanner. 
         [0032]    As illustrated in  FIG. 2 , the pipeline assembly equipment  100  is connected via network  116  to pipeline machine management system  114 , which is described in more detail below. 
         [0033]    Pipeline assembly equipment  100  can further incorporate a data collector  120  which may be configured to receive, collect, package, format, and/or distribute variable data acquired by each of the respective pipe sensors  108   a ,  109   a ,  110   a  and  111   a . In one embodiment, pipeline assembly equipment  100  may include on-board data collection and communication equipment to monitor, collect, and/or distribute information associated at least one variable sensed by at least one of the sensors  108   a ,  109   a ,  110   a  and  111   a . In particular, pipeline assembly equipment  100  may include electronic sensors  108   a ,  109   a ,  110   a  and  111   a  and control modules that are coupled to one or more data collectors  120  via communication lines  122 . Additionally, the data collector  120  may include one or more transceiver devices  124  and/or any other components for monitoring, collecting, and communicating information associated with the operation of pipeline assembly equipment  100 . 
         [0034]    Pipeline assembly equipment  100  may also be configured to receive information, warning signals, operator instructions, or other messages or commands from off-board systems, such as from pipeline machine management system  114 . The components described above are exemplary and not intended to be limiting. Accordingly, the disclosed embodiments contemplate pipeline assembly equipment  100  including additional and/or different components than those listed above. 
         [0035]    Referring to  FIG. 2 , pipeline machine management system  114  may include one or more hardware components and/or software applications that cooperate to improve performance of pipeline assembly equipment  100  in work environment  112  by monitoring, analyzing, and/or measuring variables during assembly of at least one joint during assembly of a pipeline system. For example, pipeline machine management system  114  may include a variable monitoring system  126  for collecting, distributing, analyzing, and/or otherwise managing variable data collected from pipeline assembly equipment  100 . In one exemplary embodiment, variable monitoring system  126  may determine hydraulic pressure of at least two pipe sections during assembly of at least one joint. 
         [0036]    Variable monitoring system  126  may include any computing system configured to receive, analyze, transmit, and/or distribute variable data associated with pipeline assembly equipment  100 . Variable monitoring system  126  may be communicatively coupled to pipeline assembly equipment  100  via communication network  116 . Data collector  120  may receive variable data from at least one of the sensors  108   a ,  109   a ,  110   a  and  111   a  via communication lines  122  during operation of the pipeline assembly equipment  100 , and may transmit the received data to pipeline machine management system  114  via communication network  116 . Alternatively or additionally, data collector  120  may store the received data in memory for a predetermined time period, for later transmission to pipeline machine management system  114 . For example, if a communication channel between the pipeline assembly equipment  100  and pipeline machine management system  114  becomes temporarily unavailable, the performance data may be stored in memory for subsequent retrieval and transmission when the communication channel has been restored. 
         [0037]    In an alternate embodiment, variable monitoring system  126  may be located on pipeline assembly equipment  100 . Variable monitoring system  126  may embody a centralized server and/or database adapted to collect and disseminate variable data associated with forming at least one joint of the assembled pipeline system and/or pipeline assembly equipment  100 . 
         [0038]    Variable monitoring system  126  may include hardware and/or software components that perform processes consistent with certain disclosed embodiments. For example, as illustrated in  FIG. 2 , variable monitoring system  126  may include one or more transceiver devices  128 , a central processing unit (CPU)  130 , a communication interface  132 , one or more computer-readable memory devices, such as a storage device  134 , a random access memory (RAM)  136  and a read-only memory (ROM)  138 , a common information bus  140 , a display unit  142 , and/or an input device  144 . The components described above are exemplary and not intended to be limiting. Furthermore, variable monitoring system  126  may include alternative and/or additional components than those listed above. 
         [0039]    CPU  130  may be one or more processors that execute instructions and process data to perform one or more processes consistent with certain disclosed embodiments. For instance, CPU  130  may execute software that enables variable monitoring system  126  to request and/or receive variable data from data collector  120  of pipeline assembly equipment  100 . CPU  130  may also execute software that stores collected variable data in storage device  134 . In addition, CPU  130  may execute software that enables variable monitoring system  126  to analyze variable data collected from pipeline assembly equipment  100 , perform diagnostic and/or prognostic analysis to identify potential problems with the at least one joint formed from at least two pipe sections, notify a machine operator or subscriber  118  of any potential problems, and/or provide customized analysis reports. 
         [0040]    CPU  130  may be connected to a common information bus  140  that may be configured to provide a communication medium between one or more components associated with variable monitoring system  126 . For example, common information bus  140  may include one or more components for communicating information to a plurality of devices. According to one embodiment, CPU  130  may access, using common information bus  140 , computer program instructions stored in memory. CPU  130  may then execute sequences of computer program instructions stored in computer-readable medium devices such as, for example, storage device  134 , RAM  136 , and/or ROM  136 , in order to perform methods consistent with certain disclosed embodiments, as will be described below. 
         [0041]    Communication interface  132  may include one or more elements configured for two-way data communication between variable monitoring system  126  and remote systems (e.g., pipeline assembly equipment  100 ) via transceiver device  128 . For example, communication interface  132  may include one or more modulators, demodulators, multiplexers, demultiplexers, network communication devices, wireless devices, antennas, modems, or any other devices configured to support a two-way communication interface between variable monitoring system  126  and remote systems or components. 
         [0042]    One or more computer-readable medium devices may include storage device  134 , a RAM  136 , ROM  138 , and/or any other magnetic, electronic, flash, or optical data computer-readable medium devices configured to store information, instructions, and/or program code used by CPU  130  of variable monitoring system  126 . Storage device  134  may include magnetic hard-drives, optical disc drives, floppy drives, flash drives, or any other such information storing device. RAM  136  may include any dynamic storage device for storing information and instructions by CPU  130 . RAM  136  also may be used for storing temporary variables or other intermediate information during execution of instructions to be executed by CPU  130 . During operation, some or all portions of an operating system (not shown) may be loaded into RAM  136 . In addition, ROM  138  may include any static storage device for storing information and instructions by CPU  130 . 
         [0043]    Variable monitoring system  126  may be configured to analyze variable data associated with at least one joint formed by assembling at least two pipe sections. According to one embodiment, variable monitoring system  126  may include diagnostic software for analyzing variable data associated with at least one joint based on threshold levels (which may be factory set, manufacturer recommended, and/or user configured). For example, diagnostic software associated with variable monitoring system  126  may compare an ambient temperature measurement received from a particular machine with a predetermined threshold temperature. If the measured ambient temperature exceeds the threshold temperature, variable monitoring system  126  may generate an alarm and notify one or more of the machine operator, job-site manager, repair technician, dispatcher, or any other appropriate entity, such as subscriber  118 . 
         [0044]    Variable monitoring system  126  may determine a physical location for the at least one joint of the assembled pipeline system. The physical location may be determined based on monitored GPS data associated with the machine, or other positioning systems, such as an internal machine system. For example, the physical location may be determined using the latitude, longitude, and elevation of the machine derived from GPS data gathered from on-board GPS equipment. Four or more remote positioning devices (or GPS satellites) may be used to determine elevation. 
         [0045]      FIG. 3  provides a flowchart  200  depicting an exemplary method for detecting at least one variable, consistent with the disclosed embodiments. 
         [0046]    As described above, the pipeline assembly equipment  100  is used to assemble a pipeline consisting of at least a first pipe section  102  and a second pipe section  104 , thereby forming at least one pipe joint therebetween (Step  210 ). 
         [0047]    Pipeline machine management system  114  records at least one sensor variable associated with the pipeline assembly process, such as hydraulic pressing or pulling parameters, pipeline temperature, ambient temperature, barometric pressure, humidity, time of assembly, etc. (Step  220 ). These measured pipeline assembly variables may be expressed as a number, a range of values around a number, a range of values between two numbers, a range of values, a maximum value, a minimum value, and the like. The range of values, for example, may include a predetermined amount or percentage of a value, or may be determined at the time the variable is measured. The range of values can be determined in advance and established in a memory, firmware, or other storage location of the system. Alternatively, an operator, administrator, or other user can enter or modify ranges of values. 
         [0048]    The location of the at least one pipe joint associated with each such pipeline assembly can then be dynamically determined (Step  230 ). 
         [0049]    A serial number associated with each of the at least two pipe sections of the assembled pipe system may then be recorded (Step  240 ). A subscriber  118  may use an input device  144 , such as a keyboard, to enter the serial number as the pipe section are fitted to form the at least one pipe joint. The serial number can be associated with the material, location and date of manufacturer of the respective pipe sections. Alternatively, Step  240  may be performed prior to any of Steps  210 ,  220  and  230 , or in any order therebetween. 
         [0050]    After the variables have been acquired in Step  220 , the variables are compared to standard and/or threshold values (Step  250 ). As an example to illustrate use of an embodiment of the present invention, the measured hydraulic pressure associated with the pulling cylinder of pipeline assembly equipment  100  can be compared to a standard hydraulic pressure, in order to determine whether the formed pipe joint, or the respectively-joined pipe sections, are faulty. For example, if the measured hydraulic pressure is greater or less than the standard value, then the data may suggest a variety of problems, such as a defect in the material of the pipe section (i.e., steel pipe section), improper dimensional tolerances in the bell and/or pin ends of the pipe sections, defective coatings or epoxy adhesives at the joint, and the like. 
         [0051]    Variable monitoring system  126  may be configured to generate a status or alert and provide the status or alert to pipeline machine management system  114  and/or one or more subscribers  118  (Step  260 ). A status or alert may indicate the comparison of Step  250  was out of tolerance, or may be information, such, as for example, the hydraulic pressure of the pulling cylinder during formation of the at least one joint was normal. A status or alert may embody any type of signal or message notifying pipeline machine management system  114  and/or one or more subscribers  118  of a variable measured by at least one sensor. For example, variable monitoring system  126  may output hydraulic pressure data on a display console  142  associated with the variable monitoring system  126 . Alternatively or additionally, variable monitoring system  126  may provide an electronic message (e.g., electronic page, text message, fax, e-mail, etc.) indicative of the status or alert to a respective machine operator and/or a project manager, or any other person or entity established as a subscriber  118 . In response to the status notification, subscribers  118  may take appropriate responsive action to investigate the variable to ensure that the at least one joint of the assembled pipe system is properly formed. 
         [0052]    In another embodiment, variable monitoring system  126  may be configured to archive at least one of the following, namely: the measured variables; the location of the at least one joint; the recorded serial number of each of the at least two pipe sections of the assembled pipe, and the like (Step  135 ). This archived data may later be retrieved in order to evaluate a cause of a latter failure of at least one joint. 
         [0053]    While certain aspects and features associated with the method described above may be described as being performed by one or more particular components of pipeline machine management system  114 , it is contemplated that these features may be performed by any suitable computing system. Also, while the method may describe variable monitoring system  126  as being part of pipeline machine management system  114 , variable monitoring system  126  may instead be located on-board pipeline assembly equipment  100 . Furthermore, the order of steps in  FIG. 3  is exemplary only, and that certain steps may be performed before, after, or substantially simultaneously with other steps illustrated in  FIG. 3 .