METHOD AND APPARATUS FOR LINING A BURIED PIPE WITH A POLYMER LINER

Abstract: A liner (30) of polyethylene housing an SDR of (33) or less is pulled through a die (36) and through the pipe (10) and allowed to revert to the internal diameter of the pipe (10). The force of pulling is half the yield strength of the liner (30) or less. The die (36) has an entry (54); a throat (58) and an exit (59), the entry (54) decreasing in diameter towards the throat (58) and the exit (59) increasing in diameter away from the throat (58). The liner (30) has a maximum diameter before the die (36), a minimum diameter in the die (36) and intermediate diameter after the die (36). The liner (30) bending inwards before first contacting the die (36) at the entry (54), then continuously bending through its minimum diameter as it passes the throat (58) and then undergoing die (36) swell resulting in said intermediate diameter. The throat (58) is defined by the merger in a continuous curve of a radius joining the entry (54) and a radius joining the exit (59).

Description: The invention relates to a method of and apparatus for lining a buried pipe with a polymer liner. The method is applicable, for example, to lining a buried gas, water or sewage pipe. Such pipes are made of cast iron or steel or particularly, in the case of water, of asbestos cement or concrete for example, and particularly cast iron pipes may be lined with bitumen or concrete. In British Gas patent application GB-A-2186340 there is described a method applicable to buried gas, water or sewage pipes in which a length of synthetic resin liner is heated, pulled through a die and through the pipe to be lined and pressurised to cause it to expand into engagement with the internal wall of the pipe. In United States patent No. 3 462 825 (Pope et al) there is described a method applicable to the lining of flexible or rigid pipes in the factory by pulling a liner through a die and through the pipe and then releasing the liner pipe, whereupon the liner pipe expands into tight engagement with the internal wall of the pipe. The pipe was of relatively small diameter, having an inside diameter of 2.06 inches (51.5 millimeters) and the liner pipe had an outside diameter of 2.3 inches (57.5 mm). The liner pipe was relatively thin, having a wall thickness of 0.07 inch (1.75 mm) giving a Standard Dimension Ratio (SDR) of 33. The liner pipe was of fluorocarbon. In general, the outside diameter of the liner pipe was 10 to 15% greater than the inside diameter of the pipe to be lined. In British patent specification No. 807 413 (Tubovit Societa per Azioni) there is described a method applicable to the lining of metal pipes in the factory by pulling a heated liner pipe through a die and through a pipe to be lined, releasing the liner pipe, and heating the liner pipe. The die diameter is the same as the pipe to be lined or very slightly less. The liner is of polyvinyl chloride very slightly larger than the pipe to be lined and is 3mm thick or less. The liner is heated before or during the die reduction to a temperature at which it is relatively soft and the force used to pull it through the pipe is only relatively low. In GB 2186340 such die swell as does occur after the main die is eliminated by the effect of the second die which makes the diameter of the throat, in each case, the diameter which goes into the pipe. In US 3 462 825 and GB 807 413, no die swell is shown and the diameter which goes into the pipe is the diameter of the throat. Die swell is the increase in diameter which the liner undergoes, according to the present invention, after passing through the die. A method of lining a buried pipe with a polymer liner, according to the invention, comprises pulling a length of liner through a die to reduce its diameter and through the pipe and on revival of the pulling load allowing the liner to revert to at least the minimum internal diameter of the pipe, the liner having a maximum diameter before the die and a minimum diameter in the die, and the die having a central, longitudinal die axis and comprising an entry and a throat which are symmetrical about said axis, the entry decreasing in diameter towards said throat characterised in that the die also comprises an exit which increases in diameter away from said throat and the liner having an intermediate diameter after the die before the liner enters the pipe, the force of pulling being such as partially to restrain die swell of the liner after its emergence from the throat, and the liner bending inwards before first contacting the die at the entry, then leaving the entry before continuously bending through its minimum diameter as it passes the throat, and then undergoing die swell resulting in said intermediate diameter, which enters the pipe. The throat may be defined by the merger, in a continuous curve, of a radius joining the entry and a radius joining the exit. Alternatively, the throat may comprise a short cylindrical section not more than one centimetre in length which is joined by a radius to the entry and joined by a radius to the exit. Preferably, the entry makes an angle of 12.5 degrees with the die axis. Apparatus, according to the invention, for lining a pipe with a polymer liner comprises a die having a central longitudinal die axis and comprising an entry and a throat which are symmetrical about said axis, the entry decreasing in diameter towards said throat, the apparatus including anchoring means for anchoring the die to the ground or anchoring means for anchoring the die in front of the pipe, pulling means and means engageable with the end of the pipe or engageable with the ground for anchoring the pulling means after the pipe, the method of using the apparatus comprising pulling the liner through the die to reduce its diameter and through the pipe and on removal of the pulling load allowing the liner to revert to at least the minimum internal diameter of the pipe, the liner having a maximum diameter before the die and a minimum diameter in the die characterised in that the die has an exit which is also symmetrical about said axis and which increases in diameter away from said throat, the liner in use of the method having an intermediate diameter after the die before the liner enters the pipe. The throat may be defined by the merger, in a continuous curve, of a radius joining the entry and a radius joining the exit. Alternatively, the throat may comprise a short, hollow cylindrical section parallel to the die axis of not more than one centimetre in length which is joined by a radius to the entry and joined by a radius to the exit. One method of lining a buried pipe will now be described by way of example with reference to the accompanying drawings, in which :- Figure 1 is a vertical section through the ground showing the pipe to be lined and showing a liner pipe in the course of being pulled through the pipe to be lined; Figure 2 is an enlarged vertical part-section through a die; Figure 3 is an enlarged vertical part-section through a modified die; Figure 4 is an enlarged vertical part-section through the die and through the liner pipe as it is passing through the die; Figure 5 is a graph showing diameter plotted against time for the liner pipe as it passes through the die; Figure 6 is an isometric view of a pushing device in position for use adjacent the die; and Figure 7 is a vertical section through the die shown supported by the entry end of the pipe to be lined together with pushing means. From now on, the liner pipe will be referred to as "the liner" and the pipe to be lined will be referred to as "the pipe". Figure 1 shows a buried pipe 10, which in this case may be for example a cast-iron gas main, with its ends 12,14 exposed at two excavations 16,18. The pipe continues at 20,22 and pieces have been removed at the excavations 16,18. Eventually, the whole pipe will be lined and the liner joined up to make a continuous main. The liner 30 is made of polyethylene and is pulled by a winch 32 and cable 34 through a swaging die 36 and through the pipe 10. The liner 30 after emerging from the die 36 is guided by a roller 38 to facilitate entry into the end 12 of the pipe 10. The die 36 is secured by members (not shown) driven into the ground. In another alternative position, the die 40 is supported by direct engagement with the end 12 of the pipe 10, or with members engaging the end 12. The winch 32 also has to be secured by members (not shown) driven into the ground, or from the end of the pipe 14. Prior to the operations shown in Figure 1, the pipe was cleaned and checked for internal size by suitable pigs passed through the pipe. At the same time, any protrusions were removed from within the pipe. The liner was made up of lengths of liner above ground. The lengths of liner were joined end to end by butt fusion and the external bead at each fusion joint was removed or directly inserted from a coil of liner (this being the case in sizes up to 180 mm, for example). A pulling cone was attached to the leading end of the liner. The cable 34 was attached to the end of a stiff rod and the rod was pushed through the pipe 10 from the end 14 to the end 12 until the cable end (at the trailing end of the rod) emerged at the end 12. The cable 34 was disconnected and fed through the die 36 and attached to the cone on the liner. The winch 32 was then operated to draw the liner through the die 36, with the longitudinal extension of the liner being less than 10%, preferably 8%. The operator of the winch keeps the winch turning at a constant rate, or nearly so. The rate of advance of the liner 30 may for example be 3 metres per minute. When pulling is completed, the liner is allowed to revert at least to the minimum internal diameter of the pipe. The liner is cut leaving sufficient pipe to enable a suitable connection to be effected. Where the die position 40 is used, a split die is essential. The winch cable 34 is removed from the liner 30 which is then cut to allow sufficient length to accomodate contraction as the liner reverts. It is a particular advantage of using the present method that the length of pipe 10 can be lined even where the pulling has to be interrupted for any reason. For example, the winch may fail and require attention. This means that the pulling tension in the cable 34 is removed, with the liner 30 at rest part-way through the pipe, while a repair is effected for example. Then, the pulling tension is again applied and the liner 30 again advances through the pipe 10. The period required for such an emergency can vary but for the lining of buried gas pipes it is considered that a period of 30 minutes should be provided, for example. During such a break in pulling, the liner pipe increases in diameter. If the diameter of the liner increases so that it approaches the internal pipe wall then frictional forces on restarting the operation of pulling are so high as to prevent the pipe moving without yielding. Figure 2 shows the die 36 in greater detail. It has a central die axis 50 passing through the mid-point of the die and normal to the plane of the die. The die is usually of steel but may be of cast iron or sintered polyterafluoroethylene and has a circular opening 52 forming an entry 54, a throat 58 and an exit 59, all of which are symmetrical with respect to the central longitudinal die axis 50. The entry 54 preferably makes an angle between 10 degrees and 15 degrees with the axis 50: in this example it is 12.5 degrees to the axis 50, the angle being shown at 66. The throat 58 is defined by the merger, in a continuous curve, of a radius 56 joining the entry 54 and by a radius 60 joining the exit 59. The entry 54 is joined by a radius 62 to merge with the vertical, planar face 64 of the die 36. For the present example, the liner 30 is polyethylene of the grade known as PE-A supplied by DuPont (UK) Ltd., and made from DuPont Company Ltd. material sold under the Registered Trade Mark "Aldyl A". The liner 30 has an external diameter of nominally 215 millimetres and a Standard Dimension Ratio of 26. The liner is used to line a spun cast grey iron main having a nominal bore of 8 inches (203.2 mm). Owing to variations in the wall thickness of the cast iron, the bore may vary between 209.8 mm and 218.4 mm. Accordingly, the die 36 has a diameter of 188.7 mm at its throat 58. The diameter of the liner at exit from the die is 197.5 mm. On release of the load the pipe diameter increases to 209.4 mm after 1 hour and 210.9 mm after 24 hours. The throat diameter of an unlubricated die is preferably between 8-12% less than the original liner diameter 30, to keep the pulling load below half yield. However, the throat may be relatively smaller, for example 18% less when lining a 4-inch (10,16 cm) pit cast iron main with 110 mm liner of polyethylene. The pipe 10 may be of 4 inches (101.6 mm) up to 12 inches (304.8 mm) or more in internal diameter. For gas pipe, the typical sizes are 6 inch (152.4 mm); 8 inch (203.2 mm); 10 inch (254 mm); and 12 inch. As stated above, the minimum internal diameter of such cast iron pipes varies greatly. In order to reduce the problem it is convenient to have available a range of dies to suit both the size and the type of pipe being lined. In a modification shown in Figure 3, the die 36 has a short cylindrical section forming the throat 58. Typically, for example, the cylindrical section is 8 mm long and is joined by a radius at 56 to the entry 54 and by a radius at 62 to the exit 59 of the die 36. The throat 58 has a diameter of 188.7 mm. The exit 59 in both cases, is such as to minimise the area of the die 36 engaged by the liner 30 as it leaves the die 36. The exit 59 has a radius such that the throat 58 is the last point at which the die 36 contacts the liner 30. Figure 4 shows the behaviour of the liner 30 as it passes through the swaging die 40. For simplicity it is assumed the die 40 is at the alternative position shown in Figure 1. The die 40 can be located relative to the end 12 of the pipe 10 by locating members, one of which is shown at 70. However, the behaviour would be exactly the same if the die were at the position 36 shown in Figure 1. As is shown in Figure 4, the liner 30 engages the die 40 at its entry 54 at the area 72, the liner wall 74 having bent inwardly to do so. Continuing to bend inwardly, the wall 74 leaves the entry 54 in the zone 76. Then, the wall bends continuously through its minimum diameter as it passes the throat 58. The liner then undergoes "die swell" until it reaches its greatest intermediate diameter at 80. After the point 80 the wall 74 bends inwards very slightly to the diameter shown at 82. Figure 4 also shows the end 12 of the pipe 10 into which the liner 30 is pulled by the tension in the cable 34. The increase in diameter which the liner 30 undergoes after passing through the die 40 is known as "die swell". The exact amount of die swell is the difference between the diameter at 80 and the minimum or throat diameter at 58 of the die 40. It is more practical to measure the liner diameter at a greater distance from the die 40 i.e. to measure the diameter 82 and call die swell the difference between the diameter at 82 and the minimum or throat diameter at 58 of the die 40. The die swell has to be taken account of in choosing the parameters of the present invention. Thus, in this invention, it is the diameter of the liner, including die swell, which is chosen to be less than the minimum bore diameter of the pipe 10. The pulling force is kept preferably at about half the yield strength of the liner, and the die 36 or 40 is dimensioned to ensure that the die swell is just at the correct value. Preferably, the choice is made to allow the liner 30 to be pulled into the pipe 10 with a "window" to allow the pull to be stopped for say, for example, 30 minutes if necessary. The die acts as means of reducing the liner diameter through its profile and frictional resistance. Work on the liner is primarily bending. The liner first makes contact with the die entry, the liner must then break away from this surface to enable further bending to take place as it passes through the die throat. The liner finally bends to its final diameter on the exit side of the die as it comes under the influence of the applied load. The complex bending stresses experienced by the liner are felt to be the main feature contributing to the performance of the invention. Throughout its passage through the die the liner remains circular on any plane, and no plastic flow occurs. Figure 5 shows the time after the release of load plotted along the axis of abscissas and the diameter of the liner 30 plotted along the axis of ordinates. The liner 30 has a diameter represented as A. As the liner 30 passes through the entry 54 of the die 36 or 40, the diameter decreases to the value B, which corresponds to the throat 58. Beyond the throat 58 the diameter increases to the value C, which corresponds to the diameter 80 in Figure 4. The slight decrease in diameter to 82 is not shown in Figure 5. At time equal to "t", the load is removed. The diameter increases very rapidly to the diameter D and then much more slowly, over a period of some 24 hours, to the value E. The diameter at E represents the minimum internal diameter of the pipe 10. Diameter 82 (in Figure 4) is dependent upon the die throat diameter B and the load in pulling the liner through the die. If the load was very small then the diameter 82 would be very similar to the diameter D. The ideal situation is one which produces a maximum clearance between liner and pipe internal wall under a load which is below half yield in the material of the liner. On releasing this load a controlled recovery takes place allowing the liner gradually to come into contact with the pipe internal wall. If the liner is preheated before pulling into the pipe, the resultant liner is tapered with a minimum diameter at the winch end and a maximum diameter at the die end. Longitudinal strains along the liner also vary. The resultant liner following pulling into the pipe without the application of heat is of a fairly uniform diameter along its length and is of uniform longitudinal strain. The difference in performance between the two methods can be explained by creep of the liner whilst under load at the higher temperature. If the pull has to be stopped and the load removed for any reason, e.g. winch or cable failure, the liner recovery should not be so great to cause the liner to expand against the pipe internal wall. In practise it has been found that the majority of faults can be rectified within 30 minutes. It is preferred therefore that the die design and the loads required will produce a window of 30 minutes before the liner engages the pipe internal wall around its full circumference. On restarting the pulling operation, the leading end will not reduce to its original diameter C. The reduction obtained is only due to the Poisson's ratio of the material. This is shown in Figure 5. The broken line between X and Y shows the characteristic. The continued broken line Y to Z shows the characteristic for the reversion of the liner following a halt to pulling after a repair. Clearly, the point X is the latest possible to resume pulling. The clearance shown at G was the smallest permissible to avoid high friction with the pipe internal wall. The material passing through the die on re-starting the pull is at diameter C. On completion of the operation the pipe recovers to the same dimension, i.e. the pipe internal wall, throughout its whole length. The liner is normally passed through the die without preheating. When the weather is cold, it may be necessary to pre-warm the liner to bring its temperature up to for example 30 o C. In that case, the equipment that would be used, for example, is the heater shown in our GB patent application publication No. 2186340 A. The method enables over 90% of the gas carrying capacity of the pipe to be retained when the pipe is lined as explained herein. For example, using liner of SDR = 26 for lining gas pipe, tests have shown that up to 93.5% of the gas carrying capacity of the gas pipe can be used for pipe up to 315mm. The overall towing force can be reduced by the use of a liner pushing device positioned preferably after the die, especially where the liner is 268mm or 315 mm and above. Figure 6 shows an example of such a device. It consists of a support frame 100 secured to the die or the die support frame. The frame 100 supports a carriage 102 running on rollers 104 and movable backwards and forwards by hydraulic cylinder 106. The carriage 102 supports a fixed lower jaw 108 and two movable jaws 110. The jaws 110 are carried by arms 112 pivoted on pins 114 and movable by a hydraulic cylinder 116. The carriage 102 is shown in the position in which, in use, the jaws 108, 110 are released from the liner 30. The cylinders 106 next retract, the jaws 108, 110 are closed by the cylinder 116 and the cylinder 106 extend again to push the liner 30 towards the pipe 10 in the direction of the arrow shown. An alternative position for the pushing device is as shown in Figure 7 downstream of the die 36 or 40. In Figure 7 the die is at position 40. It is supported on the end of the existing cast iron or other pipe 10 by struts 150. Pushing hydraulic cylinders are shown at 152. The gripping jaws are shown at 154. The hydraulic cylinder for actuating the jaws is not shown, for simplicity. The die 40 is split, for example into two halves, and can be removed from the liner 30 when pulling through the pipe 10 is completed. Whether the pushing device is used or not, an approved lubricant can be used to reduce friction between the liner and the pipe. The lubricant can be water or a water-based lubricant, for example. It may be preferable to use lubricant at the die to reduce friction. The lubricant may be water or a water-based lubricant. Alternatively, a non-aqueous lubricant, such as CASTROL D416 (CASTROL is a Registered Trade Mark) or monoethylene glycol, for example. The lubricant is applied to the die inner surface where it is wiped by the liner 30. Alternatively, it is applied to the surface of the liner 30. For example, the lubricant may be projected from an annulus surrounding the liner 30. For example, jets or sprays of liquid lubricant may impinge on the liner 30. Alternatively, the ring may have an inwardly projecting brush or swab which bears on the liner 30. Depending upon the load derived by pulling the liner through the die it may be preferable to lubricate the liner as it enters the pipe and not on the entry to the die. Three examples below of lining gas pipes with a polyethylene liner are given below. In the first two examples, the expected bore was less than the liner diameter after 30 minutes. Therefore, less than 30 minutes would have been available for any repair involving a halt in pulling and removal of load. Of course, had the expected bore been properly anticipated in use, a suitably larger die would have been used. In practise, now, a range of dies has been made and with proper gauge-pigging before lining commences, the true expected bore can be anticipated and a die chosen to give a 30 minute window as explained. In the third example the pipe was 10-inch. The liner diameter after 30 minute (262 mm) was found to be less than the expected bore (266 mm) of the pipe. A 30 minute window would have been a feasible option. The purpose of giving these examples is to show that the invention provides for controlled reversion to the internal wall of the pipe. There is no need for heating or pressurisation to achieve a liner tight against the internal wall. With care, the true anticipated expected bore can be known beforehand and a die chosen to give the 30 minute window to allow repairs involving stoppage of pulling.

Claims: A method of lining a buried pipe(10) with a polymer liner(30) comprising pulling of the liner(30) through a die(36;40) to reduce its diameter and through the pipe and on removal of the pulling load allowing the liner(30) to revert to at least the minimum internal diameter of the pipe(10), the liner(30) having a maximum diameter(A) before the die(36;40) and a minimum diameter(B) in the die(36;40) and the die(40) having a central, longitudinal die axis(50) and comprising an entry(54) and a throat(58) which are symmetrical about said axis(50), the entry(54) decreasing in diameter towards said throat(58) characterised in that the die(36;40) also comprises an exit(59) which increases in diameter away from said throat(58) and the liner(30) having an intermediate diameter(C) after the die(36;40) before the liner enters the pipe, the force of pulling being such as partially to restrain die swell of the liner(30) after its emergence from the throat(58), and the liner(30) bending inwards before first contacting the die(36;40) at the entry(54), then leaving the entry(54) before continuously bending through its minimum diameter(B) as it passes the throat(58), and then undergoing die swell resulting in said intermediate diameter(C), which enters the pipe(10). A method according to claim 1, in which the throat is defined by the merger, in a continuous curve, of a radius (56) joining the entry (54) and a radius (60) joining the exit (59). A method according to claim 1, in which the throat (58) comprises a short cylindrical section of not more than one centimetre in length which is joined by a radius (56) to the entry (54) and joined by a radius (62) to the exit (59). A method according to any preceding claim, the entry (54) making an angle of 12.5° with the die axis (50). A method according to any preceding claim, no heat being applied to or generated within the liner (30) save for heat as may be generated by friction between the liner (30) and the die (36;40). A method according to any preceding claim, the liner (30) being pushed into the pipe (10) by pushing means which grip the liner (30). A method according to claim 6, said liner (30) being pushed by pushing means positioned after the die (36;40). Apparatus for lining a pipe(10) with a polymer liner(30) comprising a die (36;40) having a central longitudinal die axis(50) and comprising an entry(54) and a throat(58) which are symmetrical about said axis(50), the entry(54) decreasing in diameter towards said throat(58), the apparatus including anchoring means(100) for anchoring the die(36) to the ground or anchoring means (70;150) for anchoring the die(40) in front of the pipe(10), pulling means(32) and means engageable with the end of the pipe(10) or engageable with the ground for anchoring the pulling means(32) after the pipe(10), the method of using the apparatus comprising pulling the liner(30) through the die to reduce its diameter and through the pipe and on removal of the pulling load allowing the liner to revert to at least the minimum internal diameter of the pipe, the liner having a maximum diameter(A) before the die and a minimum diameter(B) in the die characterised in that the die (36;40) has an exit(59) which is also symmetrical about said axis(50) and which increases in diameter away from the said throat(58), and the liner, in use of the method(30) having an intermediate diameter(C) after the die(36;40) before the liner enters the pipe. Apparatus according to claim 8, the throat(58) being defined by the merger, in a continuous curve, of a radius(56) joining the entry(54) and a radius(60) joining the exit(59). Apparatus according to claim 8, the throat(58) comprising a short, hollow, cylindrical section parallel to the die axis(50) of not more than one centimetre in length which is joined by a radius(56) to the entry (54) and joined by a radius (62) to the exit (59). Apparatus according to any claim of claims 8 to 10 the entry making an angle of 12.5° with the die axis. Apparatus according to any claim of clains 8 to 11 pushing means being provided for pushing the liner (30) into the pipe (10). Apparatus according to claim 12, the pushing means comprising jaws (108,110;54) reciprocable by powered means (106;152) parallel to the die axis (50), and further powered means (116) operable to effect jaw movement towards and away from the liner (30).

Inventors: MCGUIRE BRIAN EDWARD, MCGUIRE, BRIAN EDWARD
Applicants: BRITISH GAS PLC
Application year: 1989
Main classification: F16L55
IPC codes: B29C63, F16L55