Patent Publication Number: US-10759008-B1

Title: Pipe alignment system

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 15/812,488, filed Nov. 14, 2017, which claims priority to U.S. Provisional Patent Application No. 62/422,240, filed Nov. 15, 2016, and which is herein incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention is directed to a pipe alignment apparatus and system in order to align a pair of adjacent pipe ends together. In particular, the present invention is directed to a pipe alignment system and apparatus to position and align a pair of adjacent pipe ends together in advance of and during welding of the pipe ends. 
     2. Description of the Related Art 
     Pipelines and other liquid and gas transmission systems are often assembled from lengths or sections of pipes or tubes. The pipes or tubes are joined together by welding in the field. The ends of adjacent pipe sections may be brought together in various ways for performing welding operations. The pipes should be aligned so that the axis of each pipe is concentric with the other. Additionally, a consistent gap width, meeting the appropriate welding parameters, must be set and kept throughout the entire welding process. 
     Furthermore, on some occasions, it is necessary to reform or slightly reshape a pipe that is not cylindrical but is slightly out of round. 
     Accordingly, it would be desirable to provide a pipe alignment system that will align ends of adjacent pipes both in advance of and during welding operations. 
     It would also be desirable to provide a pipe alignment system capable of adjusting positioning of adjacent pipes in all three dimensions or directions. 
     It would also be desirable to provide a pipe alignment system that is capable of reforming one or both of the pipes prior to welding operations. 
     It would also be desirable to provide a pipe alignment system that can remain in place during welding operations. 
     It would be further desirable to provide a pipe alignment system wherein the apparatus may be quickly and easily attached before welding and then quickly and easily detached from the pipe ends after welding. 
     It would be further desirable to provide a pipe alignment system that may be utilized with a variety of pipe diameter sizes so that a single pipe alignment system may be utilized with different pipe diameters. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a pipe alignment apparatus and system to align a pair of adjacent pipe ends together. 
     In one preferred embodiment, a first pair of arcuate frames surrounds a first pipe wherein the first pair of frames are joined together and move between an open and a closed position. A second pair of arcuate frames surrounds a second pipe. The second pair of frames are joined together to move between an open and a closed position. 
     An inner diameter of each of the pairs of frames is greater than an outer diameter of the respective pipes. 
     A plurality of jackscrews on the first pair of arcuate frames is arranged radially with respect to the pipe ends. A plurality of jackscrews on the second pair of arcuate frames is arranged radially with respect to the pipe ends. Each of the jackscrews is threadably engaged with one of the pair of arcuate frames. 
     A plurality of adjustable turnbuckles extends between the first pair of frames and the second pair of frames. 
     The system is capable of adjusting the pipe ends in three directions or dimensions in order to align the first pipe with the second pipe for welding. 
     In an alternate preferred embodiment, a first chain circumnavigates a first pipe adjacent an end of the first pipe. A first mechanical tensioning mechanism tightens the first chain around the first pipe. A second chain circumnavigates a second pipe adjacent to an end of the second pipe. A second mechanical tensioning mechanism tightens the second chain around the second pipe. A plurality of universal jackbars are attached to the first chain or to the second chain. 
     A plurality of adjustable turnbuckles extends between the first chain and the second chain. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a perspective view of a first preferred embodiment of a pipe alignment system constructed in accordance with the present invention; 
         FIG. 2  illustrates a front view of the pipe alignment system shown in  FIG. 1 ; 
         FIG. 3  illustrates a side view of the pipe alignment system shown in  FIG. 1 ; 
         FIG. 4  illustrates a perspective view of a second preferred embodiment of a pipe alignment system constructed in accordance with the present invention; 
         FIG. 5  illustrates a front view of the pipe alignment system shown in  FIG. 4 ; 
         FIG. 6  illustrates a side view of the pipe alignment system shown in  FIG. 4 ; 
         FIG. 7  illustrates a perspective view of a third preferred embodiment of a pipe alignment system constructed in accordance with the present invention; 
         FIG. 8  illustrates an enlarged view of a portion of the pipe alignment system shown in  FIG. 7 ; 
         FIG. 9  illustrates a sectional view of a portion of the pipe alignment system shown in  FIG. 7 ; and 
         FIG. 10  illustrates a side view of the pipe alignment system shown in  FIG. 7 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The embodiments discussed herein are merely illustrative of specific manners in which to make and use the invention and are not to be interpreted as limiting the scope. 
     While the invention has been described with a certain degree of particularity, it is to be noted that many modifications may be made in the details of the invention&#39;s construction and the arrangement of its components without departing from the scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification. 
     The present invention is utilized to align the ends of adjacent pipes in advance of and during welding operations. The present invention may be utilized in a shop, in a plant, or even in the field. 
     Referring to the drawings in detail,  FIG. 1  illustrates a perspective view,  FIG. 2  illustrates a front view, and  FIG. 3  illustrates a sectional view of a first preferred embodiment of a pipe alignment system  10  constructed in accordance with the present invention. 
     A first tube or pipe  12  having a pipe end is moved adjacent a second tube or pipe  14  having a pipe end. In one preferred arrangement, the pipe ends should be within 1 to 2 inches from each other, but not touching. 
     A first pair of arcuate frames  16  surrounds the first pipe  12 . Each of the frames is in the form of a half cylinder. The first pair of frames  16  is joined together around the first pipe  12  when in the closed position surrounding the pipe. The first pair of frames  16  is installed near but not at the end of the first pipe  12 . In one configuration, a hinge  18  (visible in  FIG. 3 ) on one side of the frames permits rotational movement of the first pair of frames  16  between an open position in order to install and remove the frames and a closed position as shown in  FIGS. 1, 2 and 3 . The frames  16  may be held together when in the closed position by a quick release pin or pins  20 . 
     The inner diameter of the frames  16  is larger than the outer diameter of the pipes so that the system  10  may be used with a variety of pipe diameter sizes. 
     Once the first pair of frames  16  is installed around the outside of the first pipe  12 , a plurality of jackscrews  22  are adjusted to initially center each frame half on the first pipe  12  while allowing for positional adjustability. 
     The jackscrews  22  are positioned around the circumference of the first pipe  12  and are arranged radially with respect to the pipe. The threaded jackscrews  22  each pass through threaded openings in the first frame  16  and are threadably engaged therewith. Rotation of each jackscrew moves the jackscrew radially with respect to the first pipe  12 . 
     Likewise, a second pair of arcuate frames  26  surround the second pipe  14  and are joined together when in the closed position. Each of the frames  26  is in the form of a half cylinder. The second pair of frames  26  is joined together around the second pipe when in the closed position. The second pair of frames  26  is installed near but not at the end of the second pipe. One side of the frames  26  may be held together by a hinge  28  which permits rotational movement between an open and closed position. The opposed sides of the frames  26  may be held together when in the closed position by a quick release pin or pins  32 . 
     The inner diameter of the frames  26  is larger than the outer diameter of the pipe  14  so that the system  10  may be used with a variety of pipe diameter sizes. 
     Once the second pair of frames  26  is installed around the second pipe  14 , a plurality of jackscrews  34  are adjusted, which are arranged around the circumference of the second pipe  14 . The threaded jackscrews  34  each pass through threaded openings in the frames  26  and engage the exterior surface of the second pipe  14 . Rotation of each jackscrew moves the jackscrew radially with respect to the first pipe  12 . 
     A plurality of turnbuckles  36  extends between the first pair of frames  16  and the second pair of frames  26 . The location of each of the frames  16  and  26  is adjusted along the axis of the pipe so that the turnbuckles  36  can connect the frames  16  and  26  using quick release pins and are centered over the gap between the pipes. The frames are then rotated so that they are aligned with the turnbuckle mating features. 
     Each of the turnbuckles  36  is connected on one side to the first pair of frames  16  and connected on the other opposed side to the second pair of frames  26 . The turnbuckles  36  are connected to the frames by a detachable connection, such as a quick release pin  38 . Accordingly, the first pair of frames  16  is joined to the second pair of frames  26 . 
       FIG. 3  illustrates a side view of the system  10 , which is capable of adjustment in three dimensions. Arrows  24  and  30  in  FIG. 3  illustrate x and y dimension positioning, respectively. The jackscrews  22  and  34  are used to adjust the x/y positions of the pipes  12  and  14  until the first pipe  12  is axially aligned with the second pipe  14 . Once pipe alignment is optimized in the x/y positions, any loose jackscrews  22  and  34  are then threaded or screwed tight against the pipes to provide clamping force necessary for the turnbuckle alignment. 
     The turnbuckles  36  each include a body having opposed threaded openings to receive opposed threaded shafts. The body of each turnbuckle  36  may then be rotated to adjust the z position shown by arrow  35  seen in  FIG. 2  until a gap of a desired value is achieved. 
     After the x/y position has been optimized, if reforming of either pipe is required to improve pipe alignment, the respective jackscrews are tightened additionally to apply the force necessary for the desired reforming of one or both pipes. Accordingly, the system is capable of adjusting positioning of each of the adjacent pipes in all three dimensions or directions. 
     The pipe alignment system  10  maintains a consistent space between the ends of the pipes  12  and  14  and holds the pipes in place during welding operations. 
       FIG. 4  illustrates a perspective view,  FIG. 5  illustrates a front view and  FIG. 6  illustrates a sectional view of a second preferred embodiment of a pipe alignment system  40 . 
     A first tube or pipe  42  having a pipe end is moved adjacent a second tube or pipe  44  having a pipe end. In one preferred configuration, the pipe ends should be within 1 to 2 inches from each other, but not touching. 
     A first pair of arcuate frames  46  surrounds the first pipe  42 . Each of the frames is in the form of a half cylinder. The first pair of frames is drawn together around the first pipe  42  when in the closed position surrounding the pipe. The first pair of frames  46  is installed near but not at the end of the first pipe  42 . In one configuration, a hinge  48  permits rotational movement of the first pair of frames  46  between an open position in order to install and remove the frames and a closed position as shown in  FIGS. 4, 5 and 6 . The frames  46  may be held together when in the closed position by a quick release pin or pins  50  through aligned openings. 
     The inner diameter of the frames  46  is larger than the outer diameter of the pipe  42  so that the system  40  may be used with a variety of pipe diameter sizes. 
     Once the first pair of frames  46  is installed around the outside of the first pipe  42 , a plurality of jackscrews  52  are adjusted to initially center each frame half on the first pipe while allowing for positional adjustability. 
     The jackscrews  52  are positioned around the circumference of the first pipe  42  and are each arranged radially with respect to the pipe. The threaded jackscrews each pass through threaded openings in the first pair of frames  46  and are threadably engaged therewith. Rotation of each jackscrew moves the jackscrew radially with respect to the first pipe  42 . 
     Likewise, a second pair of arcuate frames  56  surround the second pipe  44  and are joined together when in the closed position. Each of the frames  56  is in the form of a half cylinder. The second pair of frames  56  is joined together around the second pipe when in the closed position. The second pair of frames  56  is installed near but not at the end of the second pipe. One side of the frames  56  may be held together by a hinge  58  which permits rotational movement between an open and closed position. The opposed sides of the frames may be held together when in the closed position by a quick release pin or pins  62 . 
     The inner diameter of the frames  56  is larger than the outer diameter of the second pipe  44  so that the system may be used with a variety of pipe diameter sizes. 
     Once the second pair of frames  56  is installed around the second pipe  44 , a plurality of jackscrews  54  are arranged around the circumference of the second pipe  44 . The threaded jackscrews  54  pass through threaded openings in the second pair of frames  56  and engage the exterior surface of the second pipe  44 . Rotation of each jackscrew moves the jackscrew radially with respect to the first pipe  42 . 
     A plurality of turnbuckles  66  extends between the first pair of frames  46  and the second pair of frames  56 . The location of each of the frames  46  and  56  is adjusted along the axis of the respective pipe so that the turnbuckles  66  can connect the frames using a quick release pin and are centered over the gap between the pipes. 
     Each of the turnbuckles  66  is connected on one side to the first pair of frames  46  and connected on the other opposed side to the second pair of frames  56 . The turnbuckles  66  are connected to the frames by a detachable connection, such as a quick release pin  68 . 
       FIG. 6  illustrates a sectional view of the system  40 , which is capable of adjustment in three dimensions. Arrows  100  and  102  illustrate x and y dimension positioning, respectively. The jackscrews  64  are used to adjust x/y positions of the pipes until the first pipe is axially aligned with the second pipe  44 . Any loose jackscrews  52  and  54  are then threaded or screwed tight against the pipes to provide clamping force necessary for turnbuckle alignment. 
     The turnbuckles  66  each include a body having opposed threaded openings to receive threaded shafts. The body of each turnbuckle  66  may then be rotated to adjust the z position shown by arrow  104  seen in  FIG. 5  until a gap of a desired value is achieved. 
     After the x/y position has been optimized, if reforming of either pipe is required to improve pipe alignment, the respective jackscrews  52  and  54  are tightened additionally to apply the force necessary for the desired reforming of the pipes. 
     Jackbars  60  and jackscrews  64  are used for adjustment of the x/y position. The plurality of jackbars  60  pass through and are laterally adjustable in at least one of the frames  46  or  56 . Each jackbar  60  has a jackscrew  64  engaging the first pipe  42  and a jackscrew  64  engaging the second pipe  44 . 
     The pipe alignment system  40  brings the pipe ends into alignment, performs any reforming, maintains a consistent space between the ends of the pipes, and holds the pipes  42  and  44  in place during welding operations. 
       FIG. 7  illustrates a perspective view,  FIG. 8  illustrates an enlarged view of a portion,  FIG. 9  illustrates a partial cut-away view, and  FIG. 10  illustrates a sectional view of a third preferred embodiment of a pipe alignment system  70 . 
     A first pipe or tube  72  having a pipe end is moved adjacent a second pipe or tube  74  having a pipe end. In one preferred configuration, the pipe ends should be within 1 to 2 inches from each other, but not touching. 
     With reference to  FIG. 9  and continuing reference to  FIG. 7 , a first chain  76  is brought around the outside or circumference of the first pipe  72 . One end of the first chain  76  is attached to a tensioning mechanism  98  on a main block  78 . The other end of the chain is threaded through the main block  78  and held in place by a chain dog  96  or similar fastener. 
     Likewise, a second chain  80  surrounds the outside or circumference of the second pipe  74 . One end of the second chain  80  is attached to a tensioning mechanism  98  on a main block  82 . The other end of the chain is threaded through the block  82  and held in place by a chain dog  96  or similar fastener. 
     A plurality of turnbuckles  84  extend between the first chain  76  and the second chain  80 . Each turnbuckle includes a body having opposed threaded openings to receive threaded shafts. A number of pusher-puller blocks  86  are attached to each of the chains  76  and  80 . The pusher-puller blocks  86  may be attached to the chains by clamping or other action. A turnbuckle  84  extends between pairs of pusher-puller blocks  86 . The turnbuckle  84  may be secured to the pusher-puller blocks by a quick release pin or pins  88 . 
     A plurality of universal jackbars  90  are attached to one of the chains  76  or  80 . The jackbars  90  are adjustable laterally, movable parallel to the axis of the pipe. Jackscrews  92  pass through threaded openings in the jackbars  90  and engage the pipes  72  and  74 . 
     In order to install each chain in clamping position, the chain is fed through a number of universal jackbars  90  and a number of pusher-puller blocks  86 . The free end of the chain is fed through a main block of a tensioning mechanism and held in place by a chain dog, leaving enough slack to wrap the chain loosely around the pipe. The chain is then wrapped around the pipe when the tensioning mechanism  98  is placed onto the receiving end and held in place by a chain lock. The majority of the chain slack is then removed by pulling the excess chain through the chain dog. Once securely on the pipe, the respective chains are adjusted along the axis of the pipe so that the turnbuckle assemblies  84  are attached to the puller blocks using the quick release pin  88 . Thereafter, a rotating gear on a threaded ratchet device rotated by a handle on the tensioning mechanism  98  on each chain can be engaged until each chain has been pulled tight against the respective pipe. 
     Using the jackscrews  92  on the universal jackbars  90 , the x/y position of each pipe can be adjusted, as shown by the arrows  106  and  108 , respectively, in  FIG. 10 . 
     Thereafter, a body of each turnbuckle  84  is rotated, which adjusts the z position of the pipes  72  and  74 , as seen by the arrow  110  in  FIG. 8 . 
     The pipe alignment system brings the pipe ends into alignment, maintains a consistent space between the pipe ends, and holds the pipes in place both before and during welding operations. 
     Whereas, the invention has been described in relation to the drawings attached hereto, it should be understood that other and further modifications, apart from those shown or suggested herein, may be made within the scope of this invention.