Systems and methods for making pipe, and method of installing the pipe in a pipeline

A method for restoring a degraded pipeline, the method comprising: removing a degraded part of an inner flow pipe of a pipeline leaving a space between two spaced-apart sections of the inner flow pipe; positioning a new pipe in the space; connecting the new pipe to the two spaced-apart sections of the inner flow pipe thereby re-establishing a flow channel through the inner flow pipe; the new pipe having a core pipe with a first strengthening wrap thereon, a second strengthening wrap around the first strengthening wrap, and a protective outer wrap on the second strengthening wrap.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention in certain aspects, is directed to non-metallic pipe; to systems and methods for making such pipe; to pipe for installation in a pipeline; to pipelines with such pipe; in certain particular aspects, to continuous reinforced thermoplastic pipe for use as a stand alone pipe within a pipeline to restore a degraded pipeline; and to methods for installing such a pipe in a pipeline.

2. Description of Related Art

Pipeline and/or underground transport of liquids and gases has been utilized for many years. Such pipeline and/or underground transport has proven to be an efficient and safe manner in which to transport potentially explosive, flammable, and/or toxic liquids (e.g. crude oil) and gases (e.g. methane and propane) over long distances. One method for providing such long distance underground transport has been through metal tubes and pipes. In the past, the utilization of metals (such as steel, copper, lead, and the like) was effective from cost and raw material supply perspectives. However, with the population growing throughout the world and the necessity for transporting liquids and gases to more locations increases, the continued utilization of such metal articles has become more and more difficult. Metal pipes and tubes have the potential for internal and external corrosion (which may contaminate the transported liquid or gas), the low threshold of earth-shifting resistance which could cause a break within the pipeline, and the difficulty in replacing worn out metal pipes in sections, again due to the metal pipe weight, metal pipe length, and connection welds.

Although there is a need to produce new pipelines in various locations around the world, there is also a growing need to replace the degrading pipelines already in use.

Known pipe liners have been used in a variety of applications to stop further degradation of a pipeline due to internal corrosion, to provide improved resistance to abrasion, and to stop leakage at joints. Examples of known pipe liners are disclosed in U.S. Pat. Nos. 2,502,638; 4,000,759; 4,384,595; 5,072,622; and 6,305,423; 4,064,211; 4,863,365; 4,985,196; 4,998,871 and 6,058,978; and 6,708,729 (and in prior art cited therein). The use of such pipe liners is well documented in the industry literature and is not applicable to high-pressure applications. Another type of prior art pipe liner is the extruded thermoplastic pipe-liner. A wide variety of pipe, pipe liners, systems and methods are known for lining, manufacture, transport, and installation of continuous non-metallic pipe; including, and not by way of limitation, those disclosed in U.S. Pat. Nos. 7,160,409; 6,889,716; 6,357,485; 6,305,423; 6,286,557; 6,148,866; 6,065,400; 6,058,978; 5,828,003; 5,755,266; 5,072,622; 4,998,871; 4,985,196; 4,863,365; 4,384,595; 4,053,343; 4,000,759; 3,769,127; and 2,502,638. Pending patent applications co-owned with the present invention—U.S. Ser. No. 11/172,132 filed Jul. 1, 2005 and Ser. No. 12/455,582 filed Jun. 3, 2009—are incorporated fully herein for all purposes. U.S. Pat. No. 7,347,127, co-owned with the present invention, discloses, among other things, apparatus for wrapping material on a pipe.

One well-known pipe liner product and method for rehabilitation of pipelines is flexible yet rigid spoolable composite pipe which can be pulled or otherwise inserted into a host pipe (see, e.g. U.S. Pat. Nos. 3,769,127; 4,053,343, 5,755,266; 5,828,003 and 6,065,540).

Another well-known documented pipe liner product and method for the rehabilitation of pipelines is reinforced thermoplastic pipe which can be inserted or otherwise pulled into a host pipe.

Wound-fiber reinforced plastic pipe is commonly available in a variety of forms, including discrete length products in which a specific length of pipe, e.g. 9.14 m (30-feet), is produced and continuous length products, often referred to as “Spoolable Composite Pipe” or “SCP.” One common type of SCP utilizes a polymer liner or core pipe reinforced by layers of wound-fibers in a polymer matrix, e.g. epoxy or polyester, see, e.g. U.S. Pat. Nos. 6,782,932, 5,933,945, 5,921,285, 4,384,595, 4,142,352 and 4,120,324. Another common type of SCP has a polymer liner or core pipe reinforced by wound-tapes or fibers using an orbital process in which material is pulled from bobbins or rolls that orbit a polymer liner as it translates through the apparatus; see, e.g. U.S. Pat. Nos. 2,502,638, 3,616,072 4,259,139 and 4,495,018 and U.S. Patent Application Pub. No. 20040144440, U.S. Ser. No. 351,350 filed Jan. 27, 2003.

SUMMARY OF THE PRESENT INVENTION

The present invention, in at least certain embodiments, discloses pipe for installation within a degraded pipeline, methods to make the pipe, methods to install the pipe in a pipeline, and pipelines with such pipe.

In certain methods according to the present invention stand-alone pipe (or “core pipe”) is inserted into damaged or degraded underground pipelines restoring their designed capabilities without excavation and pipe replacement. In one aspect, the present invention discloses methods for making a core pipe suitable for insertion into a host pipe, the methods including: welding together a plurality of pieces to form a pipe (in one aspect, in situ at a site of use), a pipe made of temperature-resistant corrosion-resistant non-metallic material, the pipe having an outer surface, an inner surface, a first end and a second end and a flow channel therethrough from the first end to the second end; wrapping the pipe with a first strengthening wrap; wrapping the pipe with a second strengthening wrap; and wrapping the pipe with a protective outer wrap to protect the pipe during installation in a host pipe. In one aspect, the wrap is a fabric of high strength synthetic fibers (in one aspect, unidirectional fibers). In one aspect, a wrap is connected to a pipe or to a previously-installed wrap layer by taping an end of a wrap to a pipe (or to a wrap layer) with any suitable tape.

In one aspect, the present invention discloses pipe which is non-metallic and which is suitable for insertion into a host pipe, the pipe including: a pipe made of temperature-resistant corrosion-resistant material, the pipe having an outer surface, an inner surface, a first end and a second end and a flow channel therethrough from the first end to the second end; a first strengthening wrap around the pipe; a second strengthening wrap around the pipe; and a protective outer wrap on the pipe for protection installation and/or during insertion into the host pipe.

In certain aspects, the present invention discloses a stand-alone reinforced thermoplastic pipe of continuous length with: a layer of polymeric material; two or more layers of fabric reinforcement material; orbitally wound tapes and/or fibers to lock material and/or tapes in relationship to fabric reinforcement; optionally, one or a series of fiber optic cables; and, optionally such cables covered by a protective layer, e.g. a protective polymer layer.

In one aspect, a wrap layer is wrapped onto a pipe or onto an already-applied wrap layer using a gantry wrap system according to the present invention. In one aspect, wrapping is done first as the gantry wrap system moves forward over a pipe. Optionally, when the gantry wrap system reaches a first end of the pipe, the system is reoriented, wrap is connected to the wrap layer on the pipe (e.g. with duct tape), and the gantry wrap system moves in an opposite direction toward a second end of the pipe wrapping another layer onto the already-applied layer; or the gantry wrap system is moved back to the initial starting point at the second end of the pipe and another wrap layer is applied.

Pipe in accordance with certain embodiments of the present invention is stand-alone pipe which is capable of withstanding typical pipeline operating and installation loadings and, optionally, with embedded measurement and/or redundant sensing devices for monitoring the integrity of a restored pipeline on a continuous basis.

The present invention discloses, in at least certain aspects, a light-weight high-strength multi-component pipe that can be installed as a stand-alone pipe restoring a host pipeline to (or near) its original performance parameters and original service life, while providing increased internal and external corrosion protection and increased protection from damage, e.g. during earthquakes, accidents, and acts of terrorism. In certain aspects, a “stand-alone” pipe as used herein is a pipe that withstands all (or substantially all) installation and operational loads without assistance.

In certain aspects, the present invention discloses a stand-alone reinforced thermoplastic pipe of continuous length with: a layer of polymeric material; two or more layers of fabric reinforcement material; optionally, an axial strengthener [e.g. axial tapes (in one aspect, fiber tapes) or socks, or flattened tubes, e.g., in certain aspects, made from carbon fiber based material, or any suitable high strength fiber or material disclosed herein] for increasing strength; orbitally wound fibers to lock the tapes in relationship to the fabric reinforcement; optionally, one or a series of fiber optic cables; and, optionally such cables covered by a protective layer, e.g. a protective polymer layer, which, in certain aspects mitigates installation damage and provides structure for collecting and removing permeated fluids.

In certain aspects a pipe according to the present invention is designed for long term service (fifty years or more) at maximum allowable operating pressures up to 1.37×107Pa (˜2,000 psi, 136 bar) with safety factors in the range from 2.8 to 3.8 against Short Term Burst. In certain aspects, wrap materials of synthetic fiber are used as a unidirectional fabric wrapped at about plus and minus 65-degrees for hoop strength (internal pressure resistance) and, optionally, axial tapes of the same description (to take axial loads from hydrostatic testing or pulling a long line into place) are used. Optionally, the wrap(s) and/or the axial tapes are coated on at least one side with a thermoplastic hot melt, such as EVA or HDPE.

In one particular aspect a first layer of a pipe according to the present invention is a first polymeric layer which is an extruded cylindrical thermoplastic or modified thermosetting resin material, such as polyolefin, polyamides, polyvinyl chlorides and alloys thereof, HDPE and polymeric materials that have sufficient resistance to chemical attack and strength to be used in applications involving the transport of hydrocarbons and water. Such materials are readily available worldwide and have had extensive usage in the transportation of natural gas, hydrocarbons and water. An extruded cylinder is produced in long, yet transportable, lengths for ease of inspection and transport to the fabrication site. These discrete length cylinders of polymeric material are welded together, e.g. butt fusion welded, to form a continuous-length inner pressure barrier for the pipe. The weld is accomplished using existing technology in conjunction with, preferably, rapid cooling techniques, to increase the process speed. Both the external and internal weld beads are, optionally, removed during the process and each weld is subjected to a 100% volumetric non-destructive integrity test.

Reinforcement added to the first layer cylinder of the pipe is one layer, at least one layer, two or at least two layers of fabric (preferably, but not necessarily, unidirectional fabric) applied under tension (e.g. tension provided by rotating a core pipe beneath a fabric wrapping apparatus according to the present invention) and, in one aspect, at essentially equal but opposite angles (that is, plus and minus the same angle, with respect to the pipe liner axis). In certain aspects, each layer of reinforcement of the pipe is a single width of fabric. Each width of fabric can have several individual thicknesses of reinforcement material.

In certain aspects the material used is one of several advanced reinforcement fiber materials commonly referred to as “ballistic materials” or “extended chain polyethylene ballistic material”. This material is light weight, exhibits high specific strength, high specific stiffness and low elongation or stretch.

For certain aspects of the present invention, the desired coverage is 100 percent and the nominal value of a fabric winding angle ranges between 50 and 60 degrees or between 35 and 70 degrees, e.g., in one aspect, about 55 degrees, e.g. 54.7 degrees. The outside diameter of the pipe increases with each reinforcement layer resulting in a required increase in the fabric width for each layer. For certain aspects of the present invention, the angle φ may be adjusted slightly to produce 100 percent coverage using a single fabric width. In one aspect a thin polyolefin layer (e.g. a layer10as described below) resists pressure until the reinforcement becomes loaded and the further increase in pressure is transferred to the reinforcement. This transfer in loading appears to take place at approximately one third of the maximum allowable operating pressure.

The materials of construction may have extremely low coefficients of friction and the first reinforcement layer may, optionally, be locally bonded to the inner liner and the reinforcement layer(s) are bonded to each other, e.g. using any suitable adhesive, e.g. a glue or rapidly curing adhesive and/or tape. Bonding takes place at one, two, three, four or more independent narrow axial strips (or intermittent amounts of glue or adhesive) equally spaced on the circumference of the substrate. In certain aspects, the total width of the axial strips makes up no more than 10% of the circumference of the inner pipe (first layer cylinder). The limited bonding is used to maintain the flexibility of the pipe-liner while holding the reinforcements in place during subsequent manufacturing operations.

Optionally, components of a continuous measuring, monitoring and communications systems are bonded to the pipe surface. This system is intended, in certain aspects, to allow monitoring on a continuous or intermittent basis as determined by the pipeline operator. The system is a fiber optics system.

In addition to the monitoring system, additional fiber optic cables can be provided for use in a communications and control system. These fiber optic cables can be included within the tapes mentioned or within separate tap The monitoring system package and reinforcement is, optionally, protected by a polymeric cover or jacket. This placement can result in an annular space between the pipe reinforcement and the inside of the cover sheet due to the presence therebetween of the fiber optic sensors. Spacers are, optionally, placed between the sensor tapes as necessary to support the cover (e.g., separate spacers made of plastic, wood, extruded thermoplastic or thermosetting material or spacers that are integral to a cover). Additionally, in certain aspects, these spacers are, optionally, shaped to permit the accumulation of permeated fluids from the flowing fluid to be vacuumed at an external vent port so there is no accumulation of pressure that might result in damage to the pipe liner. Monitoring the amount of fluid removed and/or pressure relieved provides an additional indication of the integrity of the pipe liner.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A pipe liner12(or “pipe”) according to the present invention as shown inFIG. 1has an innermost first layer (which when formed is a hollow cylinder, in one aspect, a deformable/re-formable cylinder), a second layer20, a third layer30, fiber strands40, spacers50, fiber optic cables60, and a cover70.

As shown inFIGS. 1 and 2, the first layer10is a generally cylindrical member made of flexible material sufficiently strong to support the other layers and components and sufficiently flexible to be compressed, deformed, and re-formed. In one particular aspect the first layer10is extruded HDPE (e.g. any suitable grade; e.g. PE 3408, PE 100), with an outside-diameter-to wall-thickness ratio SDR of about 32.5 in hollow cylindrical form. In certain aspects the lined pipe is between 0.1 m and 0.76 m (4″ and 30″) in O.D. and, in other aspects, the pipe that is lined is standard size (iron pipe size or IPS) and has an O.D. between 0.15 m and 0.41 m (6″ and 16″). In one particular aspect, 15.24 m (fifty foot) lengths of such first layers are commercially available. In certain aspects a fluid-resistant thermoplastic material is used for the first layer that resists fluids being transported through a pipeline or pipe. NYLON 6 (Trademark) material, RILSAN (Trademark) material, or NYLON 11 (Trademark) material or other suitable thermoplastic material may be used for the first layer.

Pipe according to the present invention made by methods according to the present. invention, in certain aspects, has an outer diameter ranging between 0.025 m and 3.05 m (one inch and one hundred twenty inches).

In certain embodiments, lengths of the first layer10are welded together on-site at a location at which the liner12is to be installed within a pipe or pipeline. In one aspect the lengths of the first layer10are butt fusion welded and while the welds are still hot weld beads are smoothed out and/or removed both inside and outside the layer10. Optionally, the welded area is tested on-site for integrity, e.g., but not limited to, with known ultrasonic testing apparatus.

As shown inFIGS. 1 and 3, the first layer10is wrapped with the second layer20which is a layer of material for strengthening the liner12. Suitable materials for the second layer20include fabric with highly oriented HMPE fibers (“HMPE”: high molecular weight polyethylene); SPECTRA (Trademark) material; KEVLAR (Trademark) material; ARAMID (Trademark) material; VECTRAN (Trademark) material; liquid crystal polymer (“LCP”) material; DYNEEMA (Trademark) material; TWARON (Trademark) material; TECHNORA (Trademark) material; fiber-reinforcing material, e.g. carbon fibers, fiberglass fibers and/or hybrid fibers; fabric made from carbon fibers and/or glass fibers; and fabric made from carbon fibers and SPECTRA (Trademark) fibers. In certain particular aspects, SPECTRA (Trademark) material, commercially available from Honeywell Company is used because it has a weight-to-volume ratio of 0.035 lbs/in3. In certain particular aspects, commercially available para-aramid material is used which has a weight-to-volume ratio of 0.051 lbs/in3. In certain particular aspects, commercially available carbon-fiber reinforced material is used which has a weight-to-volume ratio of 0.051 lbs/in3. The thickness of layers20and30, in certain aspects, ranges between 0.25 mm and 6.10 mm (0.010″ and 0.240″) and in one particular aspect is 0.61 mm (0.024 inches). In one aspect the layer20and/or the layer30are highly oriented high molecular weight polyethylene (“HMWPE”).

The second layer20is wrapped around the first layer10, in certain aspects at a wrap angle (or wind angle) between 45 degrees and 70 degrees. In other aspects this wrap angle is between 50 degrees and 60 degrees and, in one particular aspect, this angle is 54.7 degrees. As shown inFIG. 3, the wind angle is designated “plus” to indicate its orientation with respect to a longitudinal axis A of the layer10and the wind angle is 56 degrees. Edges of each wrap are butted up against edges of adjacent wraps so no part of the second layer overlaps itself (see, e.g. butting up indicated by arrow W,FIG. 3). Alternatively, a minimal overlap is used; or there is a gap G as shown inFIG. 3. Each wrap of the layer20has a width H). Optionally, one, two, three, four, five, six, seven, eight or more tapes, strips, or lines of adhesive or glue21are applied on the liner10. It is to be understood that the entire layer20can, according to the present invention, be wrapped around the layer10with no gap between wrap edges; with an overlap of some edges; with a gap between all adjacent wrap edges; or with a combination of gap between some edges, overlap of some edges, and/or no gap between others. In certain aspects in which the layer20(and/or the layer30discussed below) have unidirectional (oriented at the same angle or in the same direction) fibers, the layer20is applied so that the fibers are oriented generally at an angle to the longitudinal axis A, in one aspect, at the same angle as the wind angle. By employing no such overlap, overall effective diameter of the liner12is reduced. Alternatively, the second layer20is wrapped with space between adjacent wrap edges, rather than butting edges against each other which also results in no overlap. In some such aspects, space between adjacent wrap edges is no more than 3% of the total liner surface area.

Optionally, as shown inFIGS. 3 and 6, one or more lines or strips of glue, adhesive, or tape21may be applied to the first layer10, either intermittently or from one end of the first layer10to the other, either in straight lines (as shown) or wrapped around the first layer10, to inhibit or prevent slippage of the second layer20on the first layer10. In an embodiment in which SPECTRA (Trademark) fiber material is used with axial carbon fibers, these lines21tie the axial carbon fibers to the SPECTRA (Trademark) fibers so the two function at the same strain rate which allows the carbon fibers to strengthen the fabric. In certain aspects a commercially available modified cyanoacrylate type of glue is used, from Loctite Company for the lines21. As shown in FIG.6, eight lines21are used; but any desired number (e.g. 1, 2, 3, 5, 10, etc.) may be used. In one aspect the lines21are sprayed on. In certain aspects the lines21(and31) are applied so that the liner12is still sufficiently flexible that it can be deformed and re-formed as desired. In one aspect two, three, four, five or more pairs of two lines are used spaced apart around the circumference.

As shown inFIGS. 1, 4 and 7the third layer30is wrapped over the second layer20and may be wrapped in any of the ways described for the second layer20and may be material as described for the second layer20, with or without lines, etc.21on the layer20as described for the layer10. In one aspect both the second layer20and the third layer30are SPECTRA (Trademark) material about 0.024 inches thick. In certain aspects the third layer30, as shown inFIG. 4, is wrapped at a wrap angle opposite to that of the second layer20(designated “minus” to illustrate its orientation with respect to the axis A and in a direction opposite to that of the layer20; and, as shown at a wind or wrap angle of minus 54 degrees). Also, as shown inFIG. 7(not to scale) in an end view, lines31(like the lines21) may be used between the second layer20and the third layer30.

Optionally, as shown inFIGS. 1, 5 and 8one, two, three, four, five twenty, thirty, thirty six, forty or more fiber strands (or “tows”)40are used, e.g. wound on the third layer30(and/or on the layer20and/or on the tapes50) to strengthen the liner12and/or to facilitate its integrity while it is being pulled into a pipeline. Any suitable fiber may be used. It is within the scope of the present invention to apply strands or tows40at different wind angles on a liner12. Strands40aare at a plus wind angle and strands40bare at a negative wind angle.

In certain particular aspects the strands40are commercially available fiber tows, which are wound on the liner12. With the fibers40glued or otherwise adhered in place, the fibers40and the remaining components form a single integral body which can react to and withstand strain so that creep (undesired movement) of the third layer30is reduced and axial loads on the liner12are partially absorbed by the tapes50thereby reducing strain on the other layers.

Optionally, as shown inFIGS. 1, 5 and 8, tapes50(or socks or tubes) (or stacks of two, three or more tapes50) may be applied to the third layer30. Optionally, one or some strands40are applied over the layer20, over the layer30, and/or over the tapes50. The strands40when used over the tapes50tie the tapes50to the lower layers. In one particular aspect a first tape or first tapes50are applied on the layer30then a layer of strands40(described below) ties the tapes50in place. Then one or more additional tapes50is applied over the strands40and additional (one or more) strands40tie the additional tapes50in place. These tapes50also enhance the ability of the liner12to be pulled into a pipeline. In one particular aspect the tape50is carbon fiber tape, about 1.50 inches wide, about 0.040 inches thick, and eight such tapes50are used equally spaced around the circumference of the liner and extending in straight lines from one end thereof to the other (or 4 pairs of 2 tapes stacked one on the other are used). The tapes50(and the fibers40) can be equally spaced around the liner circumference or not; e.g.FIGS. 8 and 9show a cross-section view with particular spacing for the tapes50. The spacing for the tapes50as shown inFIG. 9facilitates the maintenance of a folded liner12(insertable into a pipe or pipe line) in a general “C” shape as described below (seeFIG. 14).

As shown inFIGS. 1 and 9, fiber optic cables60(one, two, three, four, five, six, or more) are applied on the fibers40. It is within the scope of the present invention to apply the fiber optic cable(s) to the layers10,20, and/or30and/or on the tapes50and/or beneath a cover like the cover70. Any known suitable fiber optic cables may be used, including SmartProfile (Trademark) cables from Smartec S/A Company. In one particular aspect a SmartProfile (Trademark) fiber optic cable61is used as shown inFIG. 10which has a body62, e.g. made of HDPE which encases two fiber optic cables63,64in filler material69within a central space65and two additional fiber optic cables66,67. Either or both of the cables63,64is used to measure temperature on the liner12and either or both of the cables66,67are used to measure strain. The temperature measurements provide information regarding leaks in the liner12both regarding the existence of a leak and its location (temperature and strain measurements are done in prior art systems with cables on the outside of a pipe, e.g. a steel pipe). Either cable63or64may be deleted; but providing two such cables provides redundancy in the event one of them fails.

FIG. 11Ashows schematically a system100according to the present invention for receiving, processing, and transmitting information based on the signals from fiber optic cables. A pipeline (or pipe)110has a liner112(or “pipe”) (like the liner12described above or like any liner according to the present invention) with a fiber optic system114as described above with fiber optic cables160(like the cables60described above). The pipeline110has a variety of pipeline-associated devices and apparatuses104(two shown schematically), each with an operator or controller106. In one particular aspect, the pipeline110has a plurality of apparatuses104which are valves that selectively control the flow of fluid through the pipeline and each valve has a controller106which is in operational communication with the fiber optic system114. A measurement system120provides a communications interface between the pipeline110and a control system130(e.g. a pipeline operator's control room with a SCADA system136). The SCADA system136includes a computer system138which receives digitized signals from the system120which has converted the analog signals from the pipeline110into digital form) indicative of temperature and/or strain along the length of the pipeline110. Either the system120or the system138has a programmable medium programmed to note an anomaly or spike in either temperature or strain or both. Such an anomaly or spike can indicate a potential leak (temperature spike) or a potential overstress condition or impending liner failure (strain spike) in the pipeline110. In one aspect the system130activates an alarm or alarm system140when an alarm value for temperature, strain or both is reached. In one particular aspect, each of the apparatuses104is a pipeline valve; an alarm is provided by the system140in response to signals from the system114(temperature or strain or both measured and indicating a leak at a location between the valves104),120,130; controllers106on each valve104are activated to close both valves104; and both valves104are closed, isolating the length of the pipeline110between the valves.

FIG. 11Billustrates schematically one particular embodiment of a system120(e.g. a commercially available Model DiTest Model STA 201 from Smartec S/A company) connected to a pipeline110. Fiber optic cables160a,160bare looped as shown or terminated with a reflective end (as may be done with any cable of any system herein). In one aspect, instead of looping the cable, a mirror is provided at the end of the cables160a.160bfor beam bounce back in the same cable. As shown inFIG. 11B, the prior art measurement system120is, according to the present invention, used with the pipeline110. The measurement system120sends a signal (e.g. a laser beam) to and through the upper (as shown inFIG. 11B) fiber optic cable160aand receives a signal back through the lower (as shown inFIG. 11B) fiber optic cable160b. The system120inputs signals into the fiber optic cables; monitors the return signals; processes the return signals (including A/D conversion); produces digital signals indicative of measured parameters (temperature and/or strain of the pipeline110) e.g. temperature sensitivity within 4° F. and/or strain sensitivity within 0.002%.

It is old and well-known to use grooves or recesses71in a cover70as shown inFIG. 1(see, e.g. U.S. Pat. No. 6,220,079). Optionally, a cover70according to the present invention as shown inFIG. 1may have one, two, three, four, five, six, seven, eight or more interior grooves or recesses72. Such grooves or recesses are used within a pipeline lined with a pipe liner12to provide a space to hold gases from the fluid flowing through the pipeline which permeate through layers of the liner12.

Optionally, a cover70is provided with no grooves71and with no grooves72. As shown inFIG. 12a pipe liner12a(like the pipe liner12) has one, two, three, four, five, six, seven, eight or more spacers15(two shown) over which is applied a cover70a. The cover70ahas no grooves, interior or exterior, and spaces73formed adjacent the spacers15provide a volume that can be entered to vent accumulated gases. Alternatively, one or more grooves like the grooves72and/or like the grooves71may be used with the liner12a.

When gases permeate a liner10and enter into grooves71, grooves72and/or spaces73, this accumulated gas is removed from the spaces adjacent the grooves or from the spaces73, e.g. by vacuuming from ports provided along a pipe or pipe line. Such gas permeation is reduced by co-extruding with the first layer10a thin layer17(shown partially,FIG. 1; encompasses entire length and circumference of the pipe or pipeline) of impermeable material (e.g. 1.5 mm, 0.060 inches thick) which is on the wetted side (an interior side) of the first layer10and serves as a pressure barrier. In one aspect this layer17is EVOH (ethylene vinyl alcohol copolymer) or NYLON (Trademark) material. In another aspect, to reduce gas permeation, a thin layer19(seeFIG. 7; e.g. 1.5 mm, 0.060 inches thick) of HDPE is co-extruded with the first layer10. The layer19has a plurality of functionalized single wall nano tubes throughout the layer19which both inhibit gas permeation through the first layer10and which strengthen it. In one aspect, by volume, between about 1% to 5% of a layer is made of these nano tubes; and in one particular aspect about 2%.

In certain materials and certain ballistic materials, e.g. the SPECTRA (Trademark) material creeps (i.e., elongates under loading) which can result in a loss of strength of an overall layer. To strengthen such layers and to reduce creep therein, a plurality of functionalized single wall nano tubes is added to the second layer20and/or to the third layer30(and/or to any other layer or component). Using functionalized nano tubes from NanoRidge Materials, Inc. results in substantially no increase in weight of a layer or of a component, e.g. of a layer20or a layer30due to their small size. In certain aspects, by volume these nano tubes are about 1% to 5% of a component or of a layer's total volume and, in one particular aspect, are about 2% of this total volume.

In certain aspects for the layers10,20,30a mixture of fibers can be used instead of using, e.g. only SPECTRA (Trademark) material fibers. For example, carbon fibers (20% to 50% by volume) can be mixed with SPECTRA (Trademark).

FIG. 13illustrates schematically a method according to the present invention for producing a pipe12c(any pipe according to the present invention) which has fiber optic cables60a(like the fiber optic cables60or any fiber optic cables described above) which are applied to the pipe12cas the pipe12cis being made to monitor installation effects, e.g. location in a host pipe and/or applied tension. As the pipe12cexits a liner making machine in a production system F, a system MA (e.g. like the system120described above) is in communication with the fiber optic cables (as the system120is in such communication as described above). By employing mirrors MR at the distal end of the fiber optic cables and/or by using a GPS sensor apparatus GPS (which emits a GPS locator signal transmitted through the fiber optic cables) at the end of the pipe12c, the system MA can determine the distance from the end of the pipe12cat the machine exit to the distal end of the produced pipe, thereby providing a measurement of the length of the produced liner12c. Strain, if there is any on the pipe12cas it is produced is measured providing a measure of the pulling force. Similarly, using a system MA during a pipe installation procedure, a measurement is provided which indicates the length of pipe installed within a pipe or pipe line; and, in one aspect, a measurement of a strain on a pipe as it is pulled into a pipe or pipe line. Any pipe or pipeline herein may have a fiber optic cable or cables with a mirror MR and/or a GPS apparatus as described above.

FIG. 14illustrates one embodiment of a system200according to the present invention with a wrapping apparatus202according to the present invention (shown schematically) mounted on and supported by a movable base204.

Pipe supports208with a plurality of rollers208a, b, c, dsupport a core pipe206as the wrapping apparatus202is moved along the pipe206. The movable base204has rotatable rollers218for movement on tracks232on a support238. A motor234moves a chain or belt236around rods219which is attached to the base204to move the base204. Rotators230rotate the pipe206for wrapping. Only one rotator may be used. The motor234is activated and controlled by a control system CS which may also control the wrapping apparatus202. Optionally, a power system208p(shown schematically,FIG. 14) powers the rollers that support the pipe for selective powered rotation of the pipe. Such a power system may be used with any pipe-supporting roller herein. Optionally, a pipe in a system according to the present invention has a guide line thereon (e.g. see line206ton the pipe206) and an optional laser guidance system202gtracks and follows this line.

FIG. 15andFIGS. 16A-16dshow a system250according to the present invention for making a pipe for installation in a degraded pipeline. The pipe may be any pipe disclosed herein or any pipe according to the present invention (including, but not limited to a pipe as inFIGS. 1, 2, 3-9, 12 and 20).

The system250has pipe rotators252which rotate a core pipe210(e.g., but not limited to, a piece or section of HDPE pipe or pieces of HDPE pipe welded together). Pipe supports254(which may have rollers, not shown; e.g. like rollers208a-cor rollers294) support the pipe210. The pipe210extends through and is rotated beneath a gantry system260according to the present invention which includes wrapping apparatus280for wrapping material (fabric, tapes, etc.) onto the pipe210. In one aspect, a wrap layer is applied during forward motion (left-to-right,FIG. 15) of the system260. Then the motion of the system260is reversed (right-to-left,FIG. 15) and another layer is applied; or the system260is moved back to an initial starting point and another layer is again applied in a forward motion. Any second or additional layer (of wrap or of tape) can be applied at an angle the same as, or an angle different from, the application of a previously-applied layer (or tape). In one particular aspect, the winding angle of an additional layer is the reverse of the winding angle of an already-applied layer (or tape) onto which the additional layer (or tape) is applied.

A control system CT (seeFIG. 15) controls an on-board power generator262and motors264which provide power to move the gantry system along the pipe210. Fabric266or other material (e.g. tape) on a roll268is pulled onto the pipe210by the tension created by the rotation of the pipe210by the rotators252.

In one aspect the power generator262is a computer-controlled fuelled power generator (e.g. a gasoline engine system or an hydraulically-powered power system, either with suitable connections chains, gears, belts, drives, shafts, and/or gearing for transmitting power). One, two, three or four or more frame rollers are powered to move the system.

The gantry system260includes a brake apparatus261(which can also provide tension on the fabric266) and a pivotable frame263pivotably mounted on pivots265to a main frame267. The main frame267has rollers269and power transmission apparatus272(e.g. gear system or chain) connected with the motors264to move two of the rollers269(rollers269a,269b). In one aspect, the frame263is pivotable within a range between wrap angles of thirty-five to seventy degrees with a setting tolerance of plus or minus two degrees (or, preferably, plus-or-minus one degree) to position the roll268and thus the fabric266(or tape) at a desired angle with respect to the core pipe.

Optionally a pipe guide274connected to the frame267contacts and moves along the pipe210. Optionally the pipe guide274has rollers276. Optionally, one of the motors264is deleted.

Optionally, an encoder278is provided which is in communication with the control system CT to measure the speed of the gantry system260and controls (or the system CT controls) the rotational speed of the rotators252. This can be done with wires, cables, etc. or wirelessly.

FIG. 17illustrates a pipe support290according to the present invention which has a bar291, a beam292and roller apparatuses294with rollers296rotatably mounted on the beam292, e.g. with bolt/nut combinations295. Each roller296has multiple sub-rollers296srotatably mounted to the rollers296Optionally, a power system294pprovides power and power-transmitting apparatus and/or connections to selective rotate the rollers.

FIG. 18shows a system300according to the present invention for making a pipe for installation in a degraded pipeline. A wrapping machine according to the present invention (e.g. like the wrapping apparatus202or the gantry system260; not shown) wraps material (fabric, tape, etc.) onto a core pipe302held and rotated by rotators304. In one aspect, initially an end of the wrap material is adhered to, glued to and/or taped to the core pipe.

A base306beneath the pipe302has outer edges308which provide a guide for wheels or rollers (e.g. the rollers269,FIG. 15, abut these edges as the system moves down the pipe) to guide a wrapping machine as it moves along a pipe. Optionally, pipe guides312on the base306maintain the position of the pipe302. The guides312may have rollers thereon (e.g., any rollers disclosed herein).

FIG. 19illustrates installation of a pipe320according to the present invention within a degraded (rusted, damaged, fallen, severed, punctured, opened, deteriorated, sagging, leaking, etc.) pipeline322. The pipeline322has an inner flow pipe324from which a section has been removed. Access to the pipe line interior is established to position the pipe320between ends of pipe324. Connections326on the pipe320are connected to connections328on the pipe324. The outer pipeline322is then sealed, enclosed, and/or welded.

FIG. 20shows a pipe according to the present invention which can be made with apparatus according to the present invention (e.g. as inFIGS. 14, 15) by methods according to the present invention.

It is within the scope of the present invention to employ multiple wrapping systems according to the present invention side-by-side or end-to-end, each producing a pipe according to the present invention. These multiple pipes are then joined together to produce a pipe of desired length.FIG. 21shows multiple gantry wrap systems GWS according to the present invention making pipes to be joined end-to-end upon completion.

A system according to the present invention, e.g. as inFIG. 14 or 15, is used to make finite lengths of pipe for stand along applications (or for pull-in applications that have sufficient clearance to allow pull-in without folding or deformation of the pipe). Multiple passes are made over the finite length of pipe wrapping it with reinforcing fabric, laying axial components if desired, and optionally applying a protective outer covering. Systems according to the present invention may be used to lay fabric on the up stroke only (i.e. going in a first direction) or on the up and back stroke (going in the opposite direction). In one aspect, fabric is laid in one direction then the gantry system's direction is reversed and fabric is laid in the other direction. In another aspect, fabric is laid in one direction and cut and then either fabric is laid in the opposite direction or the system is moved to the original starting point and another layer is laid.

In one aspect a core pipe to be wrapped is made by butt fusion welding (e.g. by known methods, e.g. as in U.S. Pat. No. 7,347,127) with known inspection and bead removal. The ends of the pipe are sealed with aluminum inserts or weld-on HDPE end caps. The pipe is set up horizontally in commercially available weld positioner-rotators positioned at each end of the pipe. The pipe is leveled. Pipe supports and/or guides are positioned along the length (as required) to keep the pipe level and minimize sagging.

In one aspect, the core pipe is pressurized to about 50% of its quick burst pressure using a rotary connector. Optionally, the pipe is maintained under a cover (e.g., see cover307,FIG. 18, shown schematically) to prevent direct contact with sunlight to prevent heating of the pipe. Guide(s) for the gantry wheels are centered on the pipe.

The wrapping (e.g. gantry) system is driven over the weld positioner/rotator at one end and, when in position just inside the weld positioner/rotator, the pipe is rotated to pull fabric off the roll (see roll268,FIG. 15) at approximately 90-degrees for one or two wraps. Rotation is then stopped. The fabric is secured to the pipe with pieces of tape and/or with multiple (two or three as needed) clamps such as hose clamps. The orientation of the roll of fabric is manually changed to provide a desired wrap angle (e.g. plus-or-minus 55 degrees), and rotation of the pipe in the proper direction and at the proper speed begins simultaneously as the gantry system moves along the pipe.

The rotation of the pipe pulls fabric off of the roll against the resistance of the roll/brake to lay the fabric under tension on the pipe. As fabric wrapping occurs, the gantry system is travelling toward the second weld positioner at a controlled speed controlled by a control system (e.g. system CS or CT) to match the rotating speed and produce the wrap angle. As it reaches the end of the pipe, gantry system translation is stopped and rotation continues to lay one/two wraps of about 90-degree fabric, then rotation is stopped and the fabric is secured with clamps. In certain aspects the gantry system has hard wheels, hard rollers, inflatable tires, or flotation type tires.

In one aspect, the fabric comes off the pipe at about mid-point above where the guide rollers make contact. The rollers go over fabric already laid.

The fabric is cut or turned and the roll angle adjusted to a co-helical position and the gantry system reverses direction to lay a next layer of fabric. The process is repeated until the desired number of layers and/or pairs of fabric are laid. Optionally, when the fabric is cut, the gantry system returns to the starting point, the angle is adjusted and a second layer is applied co-helically.

Optionally axial pulling tapes are applied by the gantry system. If optical fibers are to be used they are loaded on the gantry system and laid down. Rollers may be used to guide optical fibers.

In one aspect, the fabric on the roll is replaced with a spool (or spools) of TEK-RAP (or equivalent) and a protective outer layer is applied. Optionally, seams of the TEK-RAP are orientated so that there is no edge to catch. The angle of wrapping of the outer layer may be different from the reinforcement layers. In one aspect, if axial components are applied, once they are in place, such a protective layer is applied.

In one aspect a system according to the present invention (e.g., as inFIG. 14or a gantry system260) is used to make pipe in relatively short lengths (e.g. about 121.9 m (400 feet); about 121.9 m (400 feet) that is then cut down to about 114.3 m (375 feet); e.g. 0 to 914.4 m (0 to 3,000 feet) in length). In one aspect using a system according to the present invention in a method according to the present invention, one wrapping pass is made down a length of rotating core pipe and at an end the fabric is secured. Optionally, the direction of the system is reversed and the angle of the roll is adjusted. The fabric (or tape) is secured and the system returns to a starting point to make another pass with the angle of the roll changed. In one aspect, a number of pairs of fabric are laid and secured in individual passes.

In one particular aspect of the present invention, a pipe line is restored by installing in it a pipe made as follows:

1. HDPE core pipe CP, butt fusion welded (using a machine according to the present invention or a system according to the present invention) is made.

2. High Strength braided fabric sleeve, Wrap1(WR1), is wrapped on the core pipe, CP.

3. High Strength braided fabric sleeve, Wrap2(WR2), is wrapped on the core pipe.

4. Fiber optic sensors ST are secured to the pipe (optional).

Optionally, one, two or more layers of strengthening material GF, e.g. glass fiber material, is applied over Wrap2. Optionally, a tape layer TL is wrapped around the core pipe to inhibit or prevent the diffusion of gases through the core pipe CP. In one aspect the layer TL is a foil layer. In one particular aspect, the layer TL is aluminium foil tape, e.g., but not limited to, commercially available 3M Aluminium Foil Tape 1450.

HDPE core pipe sections are brought together in line and butt fusion welded end-to-end, e.g. using a fusion welding machine, e.g. a commercially available TracStar fusion machine provided by McElroy Mfg. Inc. (Tulsa, Okla.). This is followed by welding inspection to verify that a leak-proof seal exists between core pipe components. Fabric material and/or sleeve material, e.g. in one aspect, SPECTRA (TRADEMARK) material braided sleeve and, in another aspect, high strength synthetic fiber material braided sleeve is used for Wraps1and2. Two layers of a high strength braided fabric material is co-helical wrapped around the pipe and controlled by a control systems, e.g., a system with one or more computers and/or PLC's. Any desirable wind angle may be used for Wraps1and2; and, in one particular aspect, positive and negative wind angles (in one aspect, plus-or-minus 65 degrees) are used. Wraps1and2may be of known fabric material; e.g. of VECTRAN (TRADEMARK) material which has no creep or very low creep) is made from liquid crystal polymer material run through a known fiber spinning process and supplied by Kuraray USA and braided by A&P Technology which provides a commercially available basket woven fabric made of this material. SPECTRA (TRADEMARK) material is made from ultrahigh molecular weight polyethylene run through a patented gel-spinning process, supplied by Honeywell Advanced Fibers and Composites (Colonial Heights, Va.). Hexcel (Dublin, Calif.) provides a commercially available basket-woven fabric made of this material. In one aspect, as used in methods according to the present invention, a coating is added to the woven fabric—e.g. in one aspect the commercially available EVA coating applied by JHRG LLC (Spring Hope, N.C.) and, in another aspect, a hot melt thermoplastic coating added to the fabric—to prevent unravelling and slipping, before it's finally wound around the pipe.

In one aspect the VECTRAN (TRADEMARK) material or the SPECTRA (TRADEMARK) material is used in its dry form only without the addition of a resin which does not increase the stiffness of the pipe. Any other suitable wrap material can be used for Wraps1and2; e.g. SPECTRA (TRADEMARK) material hybridized with materials that do not creep or a triaxial braided wrap material with unidirectional VECTRAN (TRADEMARK) or S-Glass and hot melt thermoplastic fibers, e.g. as commercially available from A&P Technologies.

Fiber optic sensors are, optionally, applied along the length of the core pipe as strips ST (seeFIG. 20) of encapsulated fiber optic sensors, optionally running the entire length of the liner. It is these sensors that provide signals indicative of applied tension which are processed by the control system to provide monitoring of the pipe as it is made. The fiber optic sensors also function during and after core pipe installation in a host pipe: During liner pulling (installation of core pipe) these sensors provide data on pipe tension and integrate with the pipe-pulling system, controlled by the control system, to adjust on-the-fly to increased and decreased tension. After installation, the sensors can (within a limited distance; e.g. in one aspect, within 3.1 feet) detect leaks, sense displacement and/or report temperature along the pipe, all of which help a pipeline manager monitor pipe integrity and anticipate potential failures.

A casing CG (seeFIG. 20), e.g. a thin sleeve of thermoplastic film or HDPE film is wrapped around the core pipe CP and the layers on it. In one aspect, this casing CG has a thermoplastic film carrier and a partially cured butyl rubber adhesive backing. In one aspect, this casing CG has an HDPE carrier and a partially cured butyl rubber adhesive. It protects the core pipe CP and its layers during installation in a host pipe or pipeline. In one aspect, this sleeve material is commercially available TER-RAP (trademark) material from Tek-Rap Inc. (Houston, Tex.).

The present invention, therefore, provides in some, but not necessarily all embodiments, a pipe (“core pipe”) which is suitable for insertion into a host pipe, the core pipe having: a pipe made of temperature-resistant corrosion-resistant material, the pipe having an outer surface, an inner surface, a first end and a second end and a flow channel therethrough from the first end to the second end; an optional foil tape wrap around the core pipe; a first strengthening wrap around the pipe; an optional second strengthening wrap around the pipe; and a protective outer wrap.

The present invention, therefore, provides methods for restoring a degraded pipeline, the methods including: removing a degraded part of an inner flow pipe of a pipeline leaving a space between two spaced-apart sections of the inner flow pipe; positioning a new pipe in the space; connecting the new pipe to the two spaced-apart sections of the inner flow pipe thereby re-establishing a flow channel through the inner flow pipe; the new pipe having a core pipe with a first strengthening wrap thereon, optionally, a second strengthening wrap around the first strengthening wrap; and a protective outer wrap on the outermost strengthening wrap.

The present invention provides, therefore, in at least certain embodiments, methods for restoring a degraded pipeline, the methods including: removing a degraded part of an inner flow pipe of a pipeline leaving a space between two spaced-apart sections of the inner flow pipe; positioning a new pipe in the space; connecting the new pipe to the two spaced-apart sections of the inner flow pipe thereby re-establishing a flow channel through the inner flow pipe; the new pipe having a core pipe wrapped by a wrapping system according to the present invention as any disclosed herein.

The present invention, therefore, provides, in at least certain embodiments, a core pipe wrapped with one or a plurality of layers with wrapping material applied from a wrapping system according to the present invention. Such a core pipe may have one or some, in any possible combination, of the following: the pipe is of a continuous length produced in-situ at a site of a degraded pipeline; the wrapping material is one of high strength material, fabric and tape; the wrapping material includes multiple layers of fabric and at least one layer of tape; the wrapping material includes at least one layer of fabric and an outer protective layer; the outer protective layer is adhesive backed thermoplastic tape; axial strength members on a layer on the core pipe; the axial strength members are unidirectional tapes made of synthetic fibers; the wrapping material is fabric material made of high strength synthetic fibers; a protective outer wrap on the core pipe for protection during installation of the pipe in a degraded pipeline.

The present invention, therefore, provides in at least certain embodiments, methods for making a pipe suitable for installation into a degraded pipeline, the methods including: using a wrapping system; wrapping a core pipe with at least one layer of wrapping material; the wrapping system movable adjacent the core pipe as the core pipe is rotated with respect to the wrapping system (e.g., but not limited to, core pipe beneath the wrapping system); the wrapping material dispensed from a roll on a frame of the wrapping system at a desired wrap angle.

The present invention, therefore, provides, in at least certain embodiments, a system for making a pipe suitable for installation into a degraded pipeline, the system having: a frame; a roll of wrapping material, the roll pivotably mounted to the frame; and movement apparatus on the frame for moving the frame with respect to a core pipe to be wrapped to form pipe to be installed in a degraded pipeline.