INTEGRATED MODULAR TOOL SYSTEM

Abstract: Apparatus and method for pipe end preparation and end to end welding of pipes. The apparatus comprises a stationary annular clamp (4) for both clamping and round up of pipes (2). It also has one or two rotating tool carrier rings (5) mounted at one or both sides of the clamp (4) on a track (6). The rotating ring is arranged to comprise means for cutting, machining of grooves, welding and non-destructive testing (NDT). The round up of the pipe is performed via 6 or more clamping shoes independently operated by screw jacks (18), a wedge mechanism (15) or directly acting hydraulic cylinders.

Description: INTEGRATED MODULAR TOOL SYSTEM The invention concerns an integrated modular tool for pipe end preparation and end-to-end welding of pipes. The tool can be used under all conditions where fast repair or joining of pipelines is needed. Especially by working under hyperbaric conditions on the seabed it is essential that the repair can be done in a fast and secure way. To achieve acceptable mechanized welds it is essential to have the pipe ends prepared and aligned within defined toler¬ ances. When two pipe ends are to be butt welded the con¬ fronting ends of the members will be cut and normally also beveled before welding. This involves separate machinery. In welding of large diameter pipe sections to one another it is extremely difficult to position and maintain the pipe sec¬ tions in proper position end-to-end so that they properly may be welded to one another. In such operations it is conventional to encircle one section with a clamp with a plurality of jacks which extend beyond the free end of one pipe section and span the joint between the two pipe sections that are to be welded together. The jacks include jack screws which are adjustable radially of the clamp so as to move into engagement with the second pipe section and support one end of the latter in confronting relation with the free end of the pipe section on which the clamp is mounted. The jack screws may be adjusted to align the second pipe section with the first pipe section and, in most cases, the jack screws may be adjusted so as to reform or reshape the configuration of the second pipe to match that of the first pipe. From GB 2.074.068 there is known an apparatus and method for use in fitting, prior to welding, two pipe sections in end-to-end or telescoping relation. The apparatus includes a fixed support for one of the members to be welded and an annular clamp that is adapted to encircle and clamp such mem¬ ber adjacent that end of the latter to which the second mem¬ ber is to be welded. The apparatus also includes a second annular clamp member adapted to encircle the second member that is to be welded to the first member. The two clamp mem¬ bers are spaced apart a distance sufficient to enable the confronting ends of the members to be welded to lie in an exposed position between the two clamp members. Each of the clamp units is provided with a plurality of pressure devices for exerting force on the pipe as to reform or reshape the pipe ends. The pressure devices has to be operated manually. The welding is normally done by a welding machine on a separate track. An apparatus of this type is as an example described in GB 1.534.773. The apparatus comprises a track capable of being secured to and to encircle one of the pipes to be welded at a predetermined distance from an end of the pipe. A movable member is capable of being rapidly coupled to and uncoupled from the track. This member carries an arc welding head and is capable of movement along the track by means of a drivable pinion which is made to engage teeth on the track. After welding, control of the weld is required. This involves another operation with testing apparatus on a separate track. The process of preparing two pipe ends to be welded, the welding and finally inspection involves many different operations and most of them also include manual work. Due to the many steps of operation and the use of different tools the whole process will in addition be time-consuming. Especially when working under hyperbaric conditions in habitat with maximum working depth 400 msw it is essential that physical work is avoided and that the work can be finished within short time. The main object of the invention is therefore to obtain a tool for faster and easier repair of pipelines. Another object of the invention is to use the same basic tool for all operations involved such as round up, cutting, preparing the pipe end grooves, welding and finally non-destructive testing (NDT). The integrated modular tool system (IMT) is basicly built up by two split rings, one stationary clamp and one rotating flange (tool-carrier) mounted on the clamp face on a track. Alternatively the clamp can have two rotating rings, one at each side of the clamp. A tool with two rotating rings is preferably used in welding pipelines under hyperbaric con¬ ditions in a habitat with use of a pup piece. It is essential that the clamp can be used as a round up tool and is rigid enough to hold the roundness of the pipe after it is formed. The round up function is carried out via six or more inde¬ pendent shoes operated by a screw jack, screw operated wedges or direct acting hydraulic cylinders. The same basic tool can be used for all operations involved such as cutting, preparing the pipe end grooves, welding and finally non-destructive testing (NDT), by fixing the different tools to the tool carrier ring. The scope of the invention and the special features are as defined in the accompanying claims. Other features charac¬ terizing the invention are described in the following and are also shown in the accompanying drawings Fig. 1-7, wherein; Fig. 1 is a side view of the apparatus with one part cut away and shown in section. Fig. 2 is a perspective view of the integrated tool system with one tool carrier ring. Fig. 3 shows the roller-chain system. Fig. 4 is a transverse section along the line A— in figure 3. Fig. 5 shows a view with and without faceplate of a tool with two rotating rings and with screw jacks. Fig. 6 shows a cross section of the tool with screw jacks and two rotating rings. Fig. 7 shows the face plate of the tool carrier ring with different tools fixed to it. Figure 1 shows the integrated modular tool system 1 with one rotating ring closed around a pipeline 2 in a welding habitat 3. The integrated modular tool system is basicly built up by two split rings, one stationary (central clamp) 4 and one rotating ring (tool carrier) 5 mounted outside the clamp on a track 6. The central clamp 1 as shown in figures 1-4 is a ring square—box profile and split along the vertical centerline. On the top the two halves are connected with a hinge 7. The clamp can be positioned around an existing pipe 2 by opening the split. A lifting frame and a hoist is used to position the clamp on the pipe. The opening and closing motion of the split is controlled by an oilhydraulic operated cylinder 8. To ensure that the clamp acts like a ring, the splits are locked with wedges when installed on the pipeline. Two oil¬ hydraulic cylinders on top and two at the bottom are con- trolling the βplit-lock wedges. It is important to have the support clamp as perpendicular to the pipeline as possible. With the closed central clamp around the pipeline the clamp is lowered until upper clamping shoes 9 (fig. 2) touch the pipeline surface. A square is used for checking the position at four points. The square measures the angle between the tool-carrier ring 5 and the pipeline surface 2. Max allowable difference is 1 mm. In figure 1 a machining/sawing tool 10 and a welding/NDT-tool 11 is shown fixed to the tool-carrier ring 5. On one side the clamp is equipped with a rail ring 6 with hexagonal profile which is the track for the tool carrier ring 5. An oilhydraulic operated worm gear motor is installed on the top of the clamp. The system is also extended to carry one rail ring on the other side of the clamp; one clamp and two rotating rings. The central clamp 4 can be used as a round up tool and shall have strength to keep the achieved roundness and exact position during preparing and welding. In order to round up the pipe and keep the clamp in correct position on the pipe eight clamp shoes 9 (fig. 2) inside is activated and con¬ trolled by a chain system 12 and two oilhydraulic operated motors 13 (fig. 3). Figure 2 is a perspective view of the integrated modular tool system and shows the clamp shoes inside the ring. The chain system 12 and clamp shoes 9 are shown more in detail in figure 3 and 4. The roller chain 12 and chain wheels 14 transforms the force from the motors to the shoes 9 simul¬ taneously and make them move in radial direction towards the pipe. Figure 4 is a transverse section along line A-A in figure 4 and shows the mechanism in detail. Each clamp shoe 9 is moved by a wedge-mechanism 15 that is driven by a left-or righthand threaded spindle 16. The method of driving the spindle to operate the shoes is by the chain system shown in figure 3. A chain wheel 17 at the hinge position ties the two drive systems together ensuring that all spindles 16 receive the same amount of rotation. Non-return valves are used on the drive motors to ensure the shoes stay locked on the pipe in the event of a drop in hydraulic oil pressure. Alternatively the round up of the pipe can be done by the use of screw jacks. This system is preferred especially when a clamp with two tool carrier rings is used. This is shown in figures 5 and 6. Figure 5 shows a view with and without the faceplate 5. Screw jacks 18 of conventional type with hydrau¬ lic motors 19 are used. Eight screw jacks 18 with clamping shoes 9 are arranged around the clamp. The tool also is equipped with two brackets 20 for lifting and 21 shows a split hydraulic cylinder. The number 22 refers to a locking hook system. By this design the central clamp 4 no longer has a square-box profile, but plates are screwed to the two sides of the screw jack forming the clamp 4. This is best shown in figure 6. The software system controls opening of servovalves for the hydraulic motors on each jack. The movement is controlled in a closed loop based on feedback from transducers compared with the demanded movement relative to a reference point for each jack. This reference point is programmable in a menu. The round up of the pipe is based on equal movement of all jacks from a precalibrated perfect circle. The jacks are con¬ trolled using the feed back from the transducers and are moved until a preset maximum round up force. The maximum force is restricted by feedback of supply pressure to jack motors. This pressure is limited by a programmable pressure unit in the jack menu thus limiting the maximum force exer¬ ted. After initial round up, measurement of out of center and out of roundness is done. If this measurement is not within the desirable, individual movement of jacks can be done manually or automatically according to an algoritm worked out. All censors for measure- ment are fixed to the rotating tool carrier ring. All measurements are recorded by an inclinometer for positioning and further reference to welding parameters. This method also is used by rounding up by the roller chain system. The round up function can also be carried out using directly acting hydraulic cylinders. The tool carrier ring 5 is shown both in figures 1, 2 and 7. The tool carrier is a split ring with -profile. The face plate of the tool carrier ring can be continuous as shown at the figures or partly continuous. The two halves are kept together with a hinge. The tool carrier is equipped with thirty grooved wheels 23 that retain it to the clamp rail 6 ensuring smooth movement and non-separation from the clamp. The circumference of the tool-carrier is gear toothed to accept the gear drive from the motor mounted on the clamp. When operating the motor the tool-carrier revolves around the pipeline. The tool-carrier has three stations 24 (fig. 2) for installing different tools. The rotating tool carrier ring carries interchangeable hydraulic and/or electric step motors driven tools as follows: 1. Cut off and bevel module. 2. Counter-bore module. 3. Milling module for removing defects or surface machining. 4. Remote operated welding head including weld pool observation system. 5. Remotely operated NDT head. 6. Metrology system. A tool retainer 25 is installed by skids and wedges into clamping shoes 26 (fig. 2) at one of the selected stations on the tool carrier. The tool connection plate on the tool retainer 25 can be moved in two directions, along the pipe and radial to the pipe. The motions are controlled by manu¬ ally rotating of spindles. One saw 10 is installed to the ool connection plate by skids and wedges. The saw is shown in figure 7. An oilhydraulic operated motor is directly coupled to the saw blade and gives a controlled speed of approx. 40 rev./min. The saw operation is manually carried out by forcing the rotating saw blade radially through the pipe wall. Then the worm gear motor is activated and the saw travels around the pipe cutting off the pipe. The cut-off piece is, when small lifted away manually, but otherwise hooked on a crane and gently turned away. After the cut completion the saw is removed. The welding of the pipeline requires two different milling operations, from outside to make a L-shaped groove radially on the pipe end and inside (counter bore) to make a smooth surface and an accurate height of the groove land. The mill is installed after the same procedure. The milling tool is able to perform these operations. The mill is controlled by an oilhydraulic operated motor. The outside and inside milling operation is carried out by manually adjustment of the tool connection plate until cor¬ rect machinery settings is achieved according to a selected groove configuration. The vorm gear motor is activated and travels the mill around the pipe. Both the sawing and milling operations are supplied with cooling and lubricating fluid. The lubricating function (cooling) is particularly important during sawing. All different IMT-operations are controlled from an oil¬ hydraulic operation panel. The panel has one directional valve for each operation. The system also consists of one-way valves, pressure valves, pressure gauges etc. Due to the system design the directional valve on the split locking has no effect before the clamp split is closed and the valve is in closed position. Then the locking wedges can be activated. To keep all cylinders in fixed position they are equipped with pressure controlled one-way valves. The vorm gear motor can be controlled manually from the maneuver panel or automatically from the computer (only when welding). During the automatic control all other functions are dead. The motor is protected by a pressure valve in case of an accident with the tool-carrier motion. The clamping function is controlled by an adjustable pressure valve on the locking. The safety system consists of two hydraulic operated valves placed on each side of the pipe close to the work site. When these handles are activated the complete hydraulic system is dead and all motions will stop immediately. The safety system is overriding the automatic surface control if activated. The welding/non-destructive testing system 11 is shown both in figure 1 and 7. There is used a shielding gas flow system and an observation system based on two video cameras 27 for double side viewing of the weld pool. The welding process can be remotely controlled from the sea surface. Finally the welds shall be examined simultaneously from both sides. In figure 7 28 is brackets for the motor and 29 shows support brackets for a pup-piece. To obtain a round pipe and to get information for setting up correct welding parameters several measurements must be carried out. A linear voltage transducer ( VDT) is used and the following measurements are carried out: 1. Measurement of out of center and out of roundness. 2. Measurement of internal diametre prior to counter bore. 3. Measurement of internal diameter after counter bore. 4. Measurement of land thickness after groove machining. 5. Measurement of high/low after alingment/pup piece installation. 6. Measurement of high/low for weld II af er release of round up forces. All measurements are recorded by an inclinometer for positioning and further reference to welding parameters. Measurement 2 is used to decide maximum allowable counterbore and to decide wished internal diameter to fit internal dia¬ meter of pup piece or internal diameter of opposite pipe end. Measurement 3 is a check of measurement 2. Measurements 4-6 are used to compose a menu of welding para¬ meters based on data and tolerance boxes as function of "idealized" fit up's. When repair of pipelines is done under hyperbaric conditions in habitat a pup-piece is sometimes used to fit between the two pipe ends. The following installation procedure is followed using the integrated modular tool system with two tool carrier rings: For positioning the clamp to the pipe a crane is used. The clamp with tool carrier rings are first positioned on pipe end one, centered, measured and locked into fixed and final position. Screw jacks or roller chains etc. are activated and the pipe is rounded up. Then the cut-off/bevel module is installed to the tool-carrier ring on the pipe end one. Cut-off and end preparation is performed and the cut-off ring is removed from pipe end one via a support clamp. A counter-bore module is installed on the tool carrier ring after removing the bevel module. Then the clamp is moved and positioned at pipe end two. The gap between the two pipe ends is measured. The same procedure with round up, cut, bevel, counter-bore and internal diameter measurement is followed at pipe end two. Then the pup piece is installed by a handling system. Pulling equipment and height extended centering clamps and extended support clamps are used to align and lock the pup piece to the two pipe ends. Then welding is performed between pipe end two and the pup piece and followed by ND -test. The clamp is then moved back to pipe end one. The welding equipment is fixed to the other tool carrier ring. The pipe end one is then again rounded up or adjusted to the pup ovality if necessary, and welding and NDT-testing is performed. Then all equipment is removed. By welding in habitat using pup piece it is especially an advantage to use a clamp with two rotating rings. This makes it possible just to move the clamp between the two pipe ends without having to open the clamp, take it off, turn it and finally lock the clamp to get the tool carrier ring in right position. For welding without pup piece, only one tool carrier ring is necessary. By this system there is obtained a fast and easy repair of specially pipelines. The use of the equipment is not limited to use under seabed hyperbaric conditions. It can also be used whereever a fast, easy and almost automatic process for preparing and welding of pipe ends is wanted. A special advantage with this system is that it has only one reference for the whole pipe end preparing- and welding process.

Claims: Claims 1. Integrated modular tool system for pipe end preparation and end to end welding of pipes (2), c h a r a c t e r i z e d b y a stationary annular clamp (4) for clamping and round up of pipes (2) and with one or two rotating tool carrier rings (5) mounted at one or both sides of the clamp on a track (6), which rings can be provided with means (10, 11) for cutting, machining of grooves, welding and non-destructive testing (NDT). 2. Integrated modular tool system according to claim 1, c h a r a c t e r i z e d i n t h a t the tool carrier ring (5) is equipped with grooved wheels (23) for rotation on a rail (6) of the central clamp (4) and where the ring (5) is gear toothed or has worm gear to accept a gear drive from a motor mounted on the clamp. 3. Integrated modular tool system according to claim 1, c h a r a c t e r i z e d i n t h a t the face plate of the tool carrier ring (5) is con¬ tinuous or partly continuous. 4. Integrated modular tool system according to claim 3, c h a r a c t e r i z e d i n t h a t the face plate of the tool carrier ring (5) has several stations (24) for installation of different tools. 5. Integrated modular tool system according to claim 1, c h a r a c t e r i z e d i n t h a t the clamp (4) is equipped with 6 or more (independent) clamping shoes (9) arranged to be independently operated by screw jacks (18), a wedge mechanism (15) or directly acting hydraulic cylinders. 6. Integrated modular tool system according to claim 5, c h a r a c t e r i z e d b y a chain system (12) arranged for equal movement of the round up wedges (15). 7. Integrated modular tool system for pipe end preparation and end to end welding of pipes, especially for subsea use in habitats (3), c h a r a c t e r i z e d b y a stationary annular clamp (4) with eight independent shoes (9) arranged to be operated by the help of screw jacks (18) for clamping and round up of pipe and with a tool carrier ring (5) mounted at both sides of the clamp arranged to comprise means for cutting, machining of grooves, welding and non-destructive testing (NDT) . 8. Integrated modular tool system according to claim 7, c h a r a c t e r i z e d i n t h a t position sensors are mounted on the screw jacks (18) . 9. Method for pipe end preparation and end to end welding of pipes, c h a r a c t e r i z e d b y the application of a stationary annular clamp (4) for both clamping and round up of pipes and with one or two rotating tool carrier rings mounted at one or two sides of the clamp on a rail (6) and where cutting, machining of grooves, welding and NDT can be per¬ formed by fixing different tools to the tool carrier ring (5) and revolve this ring around the pipe (2) . 10. Method according to claim 9, c h a r a c t e r i z e d i n t h a t the round up of the pipe (2) is performed by 6 or more independent shoes automatically operated by a screw jack (18), a wedge mechanism (15) or direct acting hydraulic cylinders. 11. Method according to claim 10, c h a r a c t e r i z e d b y microprocessor control of the automatic round up function either by precalibration of circularity and control of equal movement of the clamping shoes or by feed back from a sensor rotating on the tool carrier ring (15) sensing the inside of the pipe (2). 12. Method according to claim 9, c h a r a c t e r i z e d i n t h a t there is used inclinometer control of the rotational movement and welding.

Inventors: KNAGENHJELM HANS OLAV, KNAGENHJELM, HANS, OLAV
Applicants: NORSK HYDRO AS, NORSK HYDRO A.S
Application year: 1988
Main classification: B23K33
IPC codes: B23K33, B23K37