Abstract:
Method and apparatus for coiling long lengths of substantially rigid pipe. Sections of pipe can be welded into a length several thousand feet long which is then bent to form a continuous spiral. Preferably, the pipe is stored in a vertical coil, with the weight being carried solely by the lowermost coil.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention pertains to coiling, storage and uncoiling of large-diameter, heavy-wall pipe in long lengths. 
     2. Description of the Prior Art 
     The customary technique for storing large-diameter, heavy-wall pipe, particularly when laying the pipe on the ocean floor, is to take sections of pipe and weld them to the end of the pipe catenary. It has long been a problem in such practice to handle and weld the sections of pipe on the crowded deck of a ship. 
     Another storing technique is to coil the pipe on the vessel. Various patented techniques for coiling and uncoiling pipe are shown in U.S. Pat. Nos. 2,219,811; 3,116,781; 3,685,306; 3,680,342; 3,641,778; 3,512,367; 3,237,438; 3,372,461; 3,331,212; and 928,220 and British Pat. No. 601,103. U.S. Pat. No. 3,237,438, to Tesson, basically exemplary. The technique disclosed by the Tesson patent is basicaly to form a bend in the pipe approximately of the curvature of the average diameter of the coil on a reel and then to rotate the reel to pull the pipe onto the coil. The reel in such a technique must be driven and of great strength in order to pull the bent pipe into a firm coil on the reel, primarily since the bending occurs at a location spaced from the point of tangency of the coil. 
     SUMMARY OF THE INVENTION 
     It is an object of this invention to provide a method and apparatus for laying large-diameter pipe in long lengths on the ocean floor. 
     It is another object of this invention to provide a method and apparatus for storing long lengths of substantially rigid pipe. 
     It is another object of this invention to provide method and apparatus for coiling, storing and uncoiling long lengths of heavy-wall pipe or the like. 
     Basically, the method of this invention is to bend an elongated member at the point of tangency of a prospective coil around a central core, pushing the bent member axially along its length to form a loop, and guiding the loop axially of the central core to form the member into a coil around the central core. The axial movement (relative to the core) of the loop can be accomplished by an axial bend simultaneously with the loop-forming bend or in a subsequent bending operation. 
     Basically, the apparatus is to combine a storage spool, preferably rotatable about a vertical axis, with powered support rolls at the base of the spool which are set in an inclined spiral pattern, and a bending and straightening apparatus using multiple rolls set at the base of the storage reel and tangent to the periphery of the formed coil. 
     The advantages of the method and apparatus are that the spool need not react against bending loads because bending occurs at the point of tangency of the coil, but rather, provides only lateral guidance and stability for the spool, particularly in the case of a spool having a vertical axis. The upper loops of the coil will all rest on the lowermost loops, which are supported by the coil-supporting rollers. While the preferred apparatus is best utilized when the axis of the spool is vertical, the axis can also be horizontal, with the loops supported on rollers lying parallel to the horizontal axis of the spool or on a spool supported by end bearings, as in conventional reels. 
     The term &#34;spool&#34; is used herein arbitrarily to distinguish from conventional reels of the type requiring structural strength sufficient to withstand bending stresses to or from the pipe, and need not rotate. Also, as used herein, a &#34;spool&#34; need not have a solid shell, but may have, for example, the general configuration of a lantern pinion having its circumferentially spaced rods stationary or rotatable. &#34;Pipe&#34;, when used herein, is intended to cover thick or thin-walled pipe or tube, heavy cable or the like. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS 
     FIG. 1 is a schematic side elevation of a pipe-laying vessel having a storage rack embodying the principles of the invention. 
     FIG. 2 is a fragmentary schematic illustrating a preferred apparatus embodying the principles of the invention. 
     FIG. 3 is a fragmentary view of the embodiment shown in FIG. 2 with the rollers in coiling position. 
     FIG. 4 is a fragmentary view of the embodiment shown in FIG. 2, with the pipe-bending rolls shifted into an uncoiling position. 
     FIG. 5 is a modified form of the apparatus. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As best illustrated in FIG. 1, the coiling, storage and uncoiling apparatus 10 is mounted on the deck of a pipe-laying barge 12. Pipe from a shore-based welding and assembly area is fed to the apparatus 10 in a continuous length by powered conveyor rolls 14 or a conventional pipe-laying tensioning machine. In FIG. 1, the pipe being fed to the coiling apparatus is illustrated in phantom lines. The pipe is also shown in solid lines in a pipe-discharging position after it has passed through a pipe-laying tension machine 16. 
     The coiling, storing and uncoiling apparatus preferably bends the pipe transversely and slightly axially of a spool 18 to an inside radius slightly larger than the outside radius of the storage spool. The lower edge 20 of the spool passes directly over the inner bending or straightening rolls. The spool 18 includes a substantially lightweight shell held substantially vertical by a plurality of arms 22. The arms are joined to a hub 24 that is supported by a bearing 26 on a stub shaft 28 of a large base 30. Although the spool 18 is free to rotate about a vertical axis, it is not independently powered. 
     A plurality of powered support rolls 30a-30e are set in an inclined spiral pattern so that one wrap of the bent pipe moves vertically of the spool axis one pipe diameter. That is, powered roller 30a is at the lowest vertical height, substantially aligned with the pipe P as it leaves a bending apparatus 13. Each next successive roll is slightly higher in elevation so that a formed loop or wrap of the pipe is guided vertically upwardly along the spool one loop thickness for each revolution of the spool. As additional pipe is bent, the succeeding coils of pipe are forced upward over the outer shell of the spool. The spool does not support the weight of the pipe nor participate in the bending operation but merely guides the coils so that they lie in an orderly, vertical pattern. Further advancing of the pipe will produce a coil of pipe a single layer (radially of the spool) in thickness and as long as is desired, being limited only by the height of the spool and the ability of the bottom wrap of pipe to support the rest of the coil without flattening where it is engaged by the support rollers. 
     The pipe can be bent transversely while being fed through the bending apparatus 13 on an incline equal to the helix angle of the coil on the spool. Alternatively, the pipe can be fed through the bending apparatus horizontally and the rollers 30a-30e will deflect the pipe elastically, within its elastic limit, upwardly to form a spiral. As the rollers 30a-30e deflect the pipe upwardly, it will also twist slightly in the bending apparatus and, as a result, a compound transverse and slightly vertical bend will result to assist in forming the coil. 
     As an example, a coil 100 feet in diameter of 12-inch diameter steel pipe will contain 3,140 feet in each 10 feet of its length and will weigh at least 120 short tons, based on 5/8-inch wall thickness. A 100 foot high coil, therefore, would weigh 1200 tons. Larger diameter pipe will be heavier for the same height of a single layer coil. 
     The pipe is pulled and formed into the coil by the bending apparatus 13. The bending apparatus can be of the type described in said earlier-mentioned patents, such as U.S. Pat. No. 928,220, for example, or otherwise of conventional construction. In the preferred embodiment, the bending apparatus includes three outer bending rolls 40a-40c and two inner bending rolls 41a and 41b. The rolls are power driven through a gear box 42 and and a motor 43 or by any other conventional manner. Preferably, the rollers are each set independently in tracks 44 so that the bending apparatus can be converted to a straightening apparatus merely by shifting rollers 40b and 40c to the right, as viewed in FIG. 2, moving roller 40c out of contact with the pipe, and bringing into contact with the pipe an additional roller 41c. In this manner, and with the rollers rotated in the reverse direction, pipe will be pulled from the storage coil and straightened simultaneously. Straightening is facilitated in this manner since the bottom of the pipe coil extends downwardly below the lower end of the storage spool, making the space available for bending rolls on the inside of the pipe coil. The straightening apparatus can also be employed to grip the pipe at a desired tension to maintain the tension on the pipe string to the ocean bottom, if desired. 
     While the benefit of reduced spool costs is best employed with a spool mounted about a vertical axis, the spool can also be rotated about a horizontal axis. The embodiment shown in FIG. 5 illustrates bending apparatus 13 and spirally arranged, end support rollers 30a-30e. The spool 18 in this embodiment, however, is rotatably supported at opposite ends on bearing posts 60. While the bearings of the bearing post will have to support the weight of the spool and pipe, the spool and bearings will not have to be of the greater strength necessary to withstand the pipe-bending forces such as in conventional reels. 
     While the preferred embodiments of the invention have been illustrated and described, it should be understood that variations will be apparent to one skilled in the art without departing from the principles herein. Accordingly, the invention is not to be limited to the specific embodiments described.