Tube forming equipment

Abstract

According to the present invention, there is provided a pipe forming apparatus for forming a pipe at an installation site. The apparatus comprises a former on which material is wound, and a mould for receiving the former carrying the wound material. An applicator is arranged to apply a curable liquid within the mould. Advantageously, the pipe is formed at the site so as to be configured to effectively form a pipe. The transported ISO container providing the material and curable liquid to the site can produce 800 metres of pipe sections, compared to 60 metres of pipe sections in the prior art, representing a significant improvement in efficiency.

Description

Technical Field

[0001] The present invention relates to a pipe forming apparatus for forming a pipe at an installation site.

[0002] The invention has particular, but not exclusive, application to forming continuous tubing. Background Art

[0003] The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

[0004] Industrial oil pipelines and natural gas pipelines are laid in remote areas.

[0005] In practice, the pipes that form the pipeline are manufactured in the factory and then transported to the installation site. Typically, an ISO shipping container can only carry five complete 12-meter pipes at a time to form a 60-meter pipeline section, which greatly affects the efficiency of pipeline construction.

[0006] The preferred embodiments provide for more efficient formation of industrial pipes. Summary of the invention

[0007] According to one aspect of the present invention, there is provided a pipe forming apparatus for forming a pipe at an installation site, the apparatus comprising:

[0008] The former on which the material is wound;

[0009] a mold for receiving the former carrying the wound material; and

[0010] An applicator for applying a curable liquid within the mold.

[0011] Advantageously, the tube is formed on site to be configured to efficiently form a pipe. The transported ISO container providing the material and curable liquid to the site can produce 800m pipe sections, compared to 60m in the prior art, representing a significant efficiency improvement.

[0012] The apparatus may further include a propeller for promoting relative movement between the former and the material during winding. The wound material at one end of the former may be complementary to the other end. The ends may be stepped.

[0013] The former may include a rotating mandrel. The mandrel may use air pressure that can be released through various holes / devices to help release the tube. The cross-sectional area (CSA) of the former decreases when winding the material and increases when applying the curable liquid. The former may include one or more wall segments that move inward when reducing the CSA and move outward when increasing the CSA. Each wall segment may be tapered.

[0014] The apparatus may include a lock for locking the former to a finished tube while enabling the former to rotate when wrapping material around another tube. The apparatus may include a sleeve for surrounding the former. The sleeve may be formed of a non-stick material (e.g., silicone).

[0015] The mould may form a sealed cavity within which the wound material is located. The mould may include end seals for sealing against the sleeve.

[0016] The applicator may include a sprayer.The curable liquid may include a resin.

[0017] The apparatus may include a hot water system for heating the mold. The apparatus further includes a tracked vehicle for propelling the apparatus to produce a continuous pipe. The apparatus may include a holder for holding a roll of the material.

[0018] The material may be a dry material. The material may include composite glass fibers. The material may be a sheet. The sheet may be approximately 12 meters wide. The material may include an adhesive on its bottom surface.

[0019] According to another aspect of the present invention, there is provided a method of forming a pipe at an installation site, the method comprising:

[0020] Winding the material around the former;

[0021] receiving the former carrying the wound material within a mold; and

[0022] A curable liquid is applied inside the mold.

[0023] The method may include promoting relative movement between the former and the material during winding. The method may include reducing the CSA of the former for winding. The method may include increasing the CSA of the former for applying the liquid.

[0024] The method may include applying an adhesive to the material prior to winding.

[0025] The method may include solidifying the liquid to form the tube. The method may include forming another tube adjacent to the formed tube. The method may include assembling the tubes together. The method may include molding the assembled tubes together in the mold.

[0026] Within the scope of the present invention, any feature described herein may be combined with any one or more other features described herein in any combination. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The preferred features, embodiments and variations of the present invention can be discerned from the following "Detailed Description", which provides sufficient information for those skilled in the art to implement the present invention. The detailed description should not be construed as limiting the scope of the foregoing summary of the invention in any way. The detailed description will refer to the following figures:

[0028] Figure 1 is a schematic diagram of a tube forming apparatus according to an embodiment of the present invention, wherein the die is in an open position;

[0029] Figure 2 yes Figure 1 A schematic diagram of the tube forming apparatus shown, wherein the die is in a closed position; and

[0030] Figure 3 yes Figure 1 A schematic diagram of a brake of the tube forming apparatus shown; and

[0031] Figure 4 Shows the use of Figure 1 The sequence of forming a continuous tube by the tube forming apparatus is shown. DETAILED DESCRIPTION

[0032] According to an embodiment of the present invention, there is provided Figure 1 The apparatus 100 of a continuous pipe forming device is shown. The apparatus 100 forms a continuous industrial pipe at the installation site. The apparatus 100 includes a central former 102 in the form of a rotating mandrel, on which a dry sheet 104 is wound. A mold 106 is provided for accommodating the former 102 carrying the wound material 104. The apparatus 100 further includes an injector 108 (i.e., an applicator) for injecting a curable liquid resin into the material 104 in the mold 106.

[0033] Advantageously, the tube is formed at the site where it is installed so as to be configured to efficiently form a pipe. An ISO container providing material 104 and resin to the site can produce 600m pipe sections, compared to 60m in the prior art, representing a significant improvement in efficiency.

[0034] The apparatus 100 includes a holder 109 for holding a roll of material 104. In addition, the apparatus 100 includes a bracket system 110 (i.e., a pusher) for axially advancing the held material 104 along the former 102 during the winding process. In this way, the ends of the wound material 102 are each formed into a step 112, which complementarily fits together for adjacent windings. For each revolution of the former 102, the bracket system 110 moves a set number of degrees. The degree of movement per revolution can be a set number of millimeters. For example, a 10-12 mm movement will create a 100-120 mm tapered connection, and the next wound section replicates this taper in the opposite direction, thereby creating a perfect scarf-like or stepped connection.

[0035] The former 102 includes a pair of tapered wall sections 114a, 114b. The wall sections 114a, 114b move inward to reduce the cross-sectional area (CSA) of the former 102 for winding material 104. Conversely, the wall sections 114a, 114b move outward to increase the CSA of the former 102 for injecting resin.

[0036] The apparatus 100 further comprises a tracked vehicle 116 for propelling the apparatus 100 to produce the coiled tubing.

[0037] Figure 2 The mold 106 is shown closed around the former 102 carrying the wound material 104 and ready for injection of resin. The wall sections 114a, 114b have been moved outward to increase the CSA of the former 102 to the inner diameter of the tube to be formed. The apparatus 100 includes a hot water system 200 for heating the mold 106 by providing hot water at 65°C through the mold 106 to avoid shocking the injected resin. All tube materials and components are kept at a constant temperature to ensure constant quality control and material handling.

[0038] Reference Figure 3 , the apparatus 100 includes a locking brake 300 for locking the former 102 to the finished tube 302 while allowing the former 102 to still rotate when wrapping material 104 for another adjacent tube. The brake 300 expands within the finished tube 302 to lock the former 102 in place and retracts when the former 102 is advanced.

[0039] The former 102 can rotate while remaining within the previously cured pipe section 302. The rear section of the former 102 is separate from the main section carrying the dry material 104. The rear section is mechanically held to the longer main section of the former 102 via a locking brake 300 that locks it to the cured pipe section 302. In turn, the two former sections are connected to a bearing system so that the rear section remains locked and does not rotate as a brake, while the front section rotates to bring the fiberglass material 104 with it.

[0040] The apparatus 100 also includes a sleeve 304 for surrounding the former 102. The sleeve 304 is formed of a non-stick silicone material to resist sticking of the resin. The sleeve 304 may also include an additional release agent. The mold 106 also includes an end seal for sealing against the sleeve 304 to form a sealed cavity in which the wound material 104 is located.

[0041] Material 104 comprises composite glass fibers and is provided in sheets approximately 12 meters wide. Alternatively, the sheet may comprise components of a smaller width of 12 meters. Material 104 comprises an adhesive applied to its bottom surface to facilitate adhesion of the wound material to itself. The adhesive dissolves when the resin is injected.

[0042] Now refer to Figure 4 , a method of using the apparatus 100 to form a continuous tubing at an installation site is described.

[0043] In an initial stage 1, the field device 100 is provided with a rotatable former 102 .

[0044] In stage 2, the sheet 104 is wound at a predetermined wall thickness onto a rotary former 102 having a reduced CSA. Adhesive is applied to the dry material 104 between the storage roll and the former 102. A carriage system 110 advances the material 104 relative to the rotary former 102 to form an end step 112.

[0045] In stage 3, the first winding is complete. Next, the mold 106 receives the former 102 carrying the wound material 104. The CSA of the former 102 is increased to the desired inner diameter of the tube, compressing the layered glass fibers, ensuring the final resin to glass ratio. Resin is then injected into the mold 106 to post-impregnate the material 104, completely wet the glass fibers, and leave a completely void-free structure. The liquid resin then solidifies to form the tube 302.

[0046] The CSA of the former 102 is reduced, and the apparatus 100 including the former 102 is advanced relative to the curing tube 302 using the vehicle 116. The brake locks the former 102 to the curing tube 302.

[0047] In stage 4, as the sheet 104 is wound on the rotary former 102, another tube is formed adjacent to the formed tube 302, as previously described with respect to stage 2 above. As previously described, resin is injected into the mold 106 to post-impregnate the material 104, and the liquid resin cures to form the adjacent tube 302.

[0048] In stage 5, the two tubes 302 are assembled together at their ends. The joint is received in the mold 106 and molded to securely fasten the tubes together. In this manner, the mold 106 has a small annular ring or knurled section to provide a mechanical bond. Alternatively, the tube ends may be glued or welded together.

[0049] In stage 6, the former 102 advances to the next adjacent position to form the next section of the continuous pipe, and so on. In this way, a continuous composite pipe can be formed in sections of any diameter and any specified wall thickness up to 12 meters long, with smooth and undetectable joints that are as structurally good as the main laminate. The finished pipe is capable of carrying any and all materials used in pipes today.

[0050] The machine 100 operates on site using minimal external machinery or support equipment (i.e., cranes, welding, sustained heavy transport). The machine 100 produces pipe for use above ground, below ground, above or below river, estuary, or above or below marine environments. Additionally, the machine 100 is CNC automatically controlled, has GPS guided and robotically controlled handling systems.

[0051] Those skilled in the art will appreciate that many embodiments and variations can be made without departing from the scope of the invention.

[0052] The apparatus 100 can be used with, but is not limited to, all types of polyesters, vinyl esters, epoxies, phenolics, and plastic polymers and variations available on the market today. The apparatus 100 is not limited to the aforementioned resins, and other and new advanced materials can be used as they become available. Additionally, the curable liquid can include catalysts or hardeners added to the resin.

[0053] In one embodiment, a prepreg type material may be used, thereby providing a composite material 104 in which reinforcing fibers are pre-impregnated with a thermoplastic or thermosetting resin matrix in a certain ratio.

[0054] The material 104 may include carbon fiber, aramid, E-glass, S-glass, Combimat, Mouldmat, and / or combinations and variations thereof.

[0055] The above-described tapered connection designs can be modified and adjusted to accommodate variations in the engineer-specified design parameters.

[0056] In one embodiment, the former 102 in the form of a rotating mandrel uses air pressure that can be released through various holes / devices to help release the tube. The air is released through small holes on the mandrel. Small valves such as pistons are flush with the mandrel and when they are activated, they retract, allowing air pressure to help release the tube 302.

[0057] In compliance with the statute, the invention has been described in language more or less specific to structural or methodological features. It is to be understood that the invention is not limited to the specific features shown or described since the method described herein comprises preferred forms of putting the invention into effect.

[0058] Throughout this specification, reference to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the phrases "in one embodiment" or "in an embodiment" appearing at various places throughout this specification do not necessarily refer to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

Claims

1. A pipe forming apparatus for forming a pipe at an installation site, the apparatus comprising: a holder for holding the sheet; a former including a pair of tapered wall sections that move inwardly when reducing a cross-sectional area (CSA) of the former and move outwardly when increasing the CSA of the former; a bracket system for axially advancing the holder relative to the former so that the sheet is wrapped around the former to form a tube having one or more steps at each end of the tube, so that the tube has two stepped ends, wherein the wrapped material at one end of the tube forms a complementary fit with the other end; a mold for receiving the former carrying the wound sheet; and an applicator for applying a curable liquid within the mold; and A lock is used to lock the former to the finished tube while allowing the former to rotate when wrapping material for another adjacent tube.

2. The tube forming apparatus according to claim 1, which is located at the installation site, wherein: The tube is formed on site so as to be configured to effectively form a pipeline on site.

3. The pipe forming apparatus of claim 1 further comprising a transported ISO container, wherein the transported ISO container provides the material and curable liquid to the site, and can typically produce 800 meters of pipe sections, compared to 60 meters of pipe sections in the prior art, representing a significant improvement in efficiency.

4. The tube forming equipment according to claim 1, wherein: The apparatus further comprises a pusher for promoting relative movement between the former and the material during winding.

5. The tube forming apparatus according to claim 1, wherein: The former includes a rotating mandrel.

6. The tube forming apparatus according to claim 1, wherein: The cross-sectional area (CSA) of the former decreases as the material is wound and increases as the curable liquid is applied.

7. The tube forming apparatus of claim 1 wherein the lock expands within the finished tube to lock the former in place and retracts when the former is advanced.

8. The tube forming apparatus of claim 1, comprising a sleeve for surrounding the former, the sleeve being formed of a non-stick or anti-stick material.

9. The tube forming apparatus according to claim 8, wherein: The mold forms a sealed cavity within which the wound material is located, and includes end seals for sealing against the sleeve.

10. The tube forming apparatus according to claim 1, wherein: The applicator includes a sprayer, and the curable liquid includes a resin.

11. The tube forming apparatus of claim 1 including a tracked vehicle for propelling the apparatus to produce continuous tube and / or a holder for holding a roll of the material.

12. The tube forming apparatus according to claim 1, wherein: The material is a dry sheet comprising composite glass fibers, the material comprising an adhesive on its bottom surface.

13. A method of forming a pipe at an installation site, the method comprising: reducing the cross-sectional area of ​​the former by moving a pair of tapered wall sections inwardly; winding the material onto the former having a reduced cross-sectional area; receiving the former carrying the wound material in a mold; increasing the cross-sectional area of ​​the former for applying a curable liquid within the mold by moving the pair of tapered wall sections outward; applying the curable liquid within the mold; and A lock is used to lock the former to the finished tube while allowing the former to rotate while wrapping material for another tube.

14. The method of claim 13, further comprising promoting relative movement between the former and the material during winding.

15. The method of claim 13, further comprising applying an adhesive to the material prior to winding and / or curing the liquid to form the tube.

16. The method of claim 13, further comprising forming another tube adjacent to the formed tube, and fitting the tubes together.

17. The method of claim 16, further comprising molding the assembled tubes together in the mold.

18. The method of claim 13, further comprising applying air pressure to release the tube from the former.

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