Pipeline isolation tool equipped with a large gap sealing member having a mini pressure head and an iris-type structural sealing member

Abstract

A pipeline isolation tool (10) having a circumferential seal (30) having a T-shaped cross section. The seal has a radial lower seal profile (36) and an axial upper seal profile (38). Pressure heads (40, 50) are located on both sides (32, 34) of the lower profile. Overlapping structural members (60, 80) are located on both sides (32, 34) of the upper profile and include a concave area (70, 90) to accommodate a portion of the upper seal profile. The inner face (64, 84) of the structural member contacts the outer surface (42, 52) of the pressure head. An angle plate (100, 110) defines an inner face (102, 112) that contacts the outer face (66, 86) of each structural member. The tool may be configured as a penetration tool or a non-penetration tool.

Description

Technology Field

[0001] The present disclosure relates to a pipeline tool designed to block product flow during pipeline maintenance and repair operations. Specifically, the present disclosure relates to a seal used in a plugging head or module of this type of tool when it is necessary to span a large gap between a seal at an unset position and a seal at a set position. For the purposes of this application, a large gap means a seal gap extrusion where the ratio of the inner diameter of the pipeline to the outer diameter of the tool is greater than about 1.10. Background Technology

[0002] Large gap seals of the prior art can exhibit high strain or strain gradients when activated to a set position and forced radially inward to seal against an unset inner diameter. The absolute strain level in the seal may or may not be significant for elastomer damage. If structural segments are used to reinforce the seal, there is a potential risk that segment flipping or permanent deformation under high isolation pressure may cause segment jamming and prevent the seal from shrinking. Point loads on the structural segments against the inner pipe wall can introduce high stress peaks that can cause pipe damage as well as difficulties when attempting to comply with pipeline standards.

[0003] Creep crack growth can be a major cause of failure when seals are subjected to prolonged loads. The complexity of the seal's lateral profile can be directly related to the risk of crack initiation. Selecting more "exotic" materials unaffected by creep crack growth is costly due to potential requirements for smaller volumes and unconventional manufacturing methods. The complexity of the seal's lateral profile directly impacts manufacturing costs. Additionally, in large-gap seal designs, the required piston stroke is larger, resulting in a longer tool and thus a lower risk of pigging. The length of the tool reduces the benefits of high-extension sealing capability.

[0004] An embodiment of the isolation tool of the present disclosure is for a penetration (hot tap) application and can span a large gap through a "T-bone" or "T-shaped" seal, and pressure heads on each side of the lower profile of the seal act as supports and prevent extrusion of the seal ID. Overlapping structural support elements provide support for the upper profile of the seal. The embodiment may also be provided for a non-penetration application where the tool is pigged to a specific location within a pipeline.

[0005] Because the pressure heads located on each side of the lower profile of the seal have a smaller diameter (radial height) than the seal member when the seal member is in an unset position, the present disclosure sometimes refers to the heads as “mini” pressure heads. The heads are also smaller in size than the angle plate that applies pressure to the seal through the structural member and the mini pressure heads.

[0006] The structural member is an overlapping structural member that functions like an iris. The structural member eliminates the use of gap segments as used in the prior art. For example, refer to US 10,436,372 B2 of Bjorsvik et al., the contents of which are incorporated herein by reference. This arrangement provides more options for sealing around primary seals, such as seals on a pressure head or on the side of a bowl, for example.

[0007] For the purposes of this disclosure, a large gap means a seal gap extrusion in which the ratio of the pipeline inner diameter to the tool outer diameter is greater than about 1.10 (e.g., 10% radial expansion).

[0008] The advantages of the embodiments of the present disclosure include the following:

[0009] a) Elimination or reduction of the risk of elastomer tearing;

[0010] b) Controllability of the amount of compression of the seal and the resulting contact pressure of the seal;

[0011] c) Removal of tilting of support segments;

[0012] d) Simplification of the lateral profile of the seal compared to the large gap seal design of the prior art;

[0013] e) Elimination of the need for "exotic" materials for the seal and reduction of manufacturing costs;

[0014] f) Size scalable;

[0015] g) Low pressure and high pressure isolation possible;

[0016] h) (Compared to the design of the prior art) a reduction in the amount of piston stroke required and, consequently, a shorter overall length of the tool;

[0017] i) Elimination of the need for a secondary sealing head; the primary (high-pressure side) sealing head is sufficient;

[0018] j) Capable of sealing large gaps, including gaps exceeding 20% ​​radial expansion.

[0019] Embodiments of the present disclosure may be used in pipeline isolation tools as disclosed in U.S. Patent No. 10,989,347 of McKone et al. (“McKone”), the contents of which are incorporated herein by reference. For example, the tool may comprise a pair of plugging heads, one of which is on the higher pressure side of the tool and acts as a primary seal, and the other is on the lower pressure side of the seal and acts as a secondary seal. Thus, the tool defines two independent sealing systems and two independent locking systems. In some embodiments of the tool, a single plugging head is used.

[0020] Regardless of whether a single plugging head is used or a pair of plugging heads is used, in some embodiments, the hydraulically actuated piston is surrounded by a hydraulic cylinder formed at least partially by each of the two pressure heads. The cylinder head may be formed by the opposing pressure head of which forms the cylinder body.

[0021] The pipeline isolation tool of the present disclosure comprises a sealing member having an expanding, reusable seal, and a single seal can be used for a wide range of pipe wall thicknesses of the same nominal size. The seal can be self-energized, and its actuation force is in the same direction as the force from the isolation pressure.

[0022] The structural segments of the present disclosure enable a wider range of extrusion with a higher pressure holding capability. The plugging head may use a hydraulically actuated piston and cylinder array to compress the seal axially, which consequently expands the seal radially for sealing against the pipe wall. The structural segments slide radially together with the seal, maintain a degree of overlap with one another, and support the extruded rubber against the differential pressure.

[0023] The tool may include some machining and assembly methods for delivering hydraulic fluid from an external excavation location to a jackscrew, connecting through a number of components, and ultimately controlling a double-acting piston at a plug head. In some embodiments, the tool includes a control bar comprising a hydraulic delivery sleeve and a manifold. The manifold is arranged to be connected to an external fluid line, and the sleeve provides fluid inside the tool. A delivery pin may be used to deliver fluid between components. In an embodiment, the end of the piston may include a trapezoidal thread that accommodates a variable gap between components and requires less precision in placement during assembly. The gap between components can still be accommodated even if it falls up to one full turn.

[0024] Some embodiments of the tool include the tool of the present disclosure comprising an arched bumper that contacts the ID of the pipe to redistribute the force the tool experiences when sealing against the pipe back to the pipe. For example, the bumper may be cam-actuated and connected to an arm that moves in contact with the ID of the pipe when the tool enters the pipe and can move to a position ready to seal against the ID. In other embodiments, the cam-actuated arm array may be replaced with a bumper connected to a hydraulically actuated arm or body.

[0025] In some embodiments, an additional feature is a urethane disc mounted on the front of the tool that pushes the chip away from the sealing surface. This "chip sweep" makes seal formation easier. The sweep can be replaced or supplemented by a nozzle that injects fluid ahead of the tool.

[0026] The tool may be provided as a penetration tool. It may also be provided as a non-penetration tool comprising a gripping means and a hydraulic operating cylinder communicating with the sealing and gripping means. Brief explanation of the drawing

[0027] FIG. 1 is a schematic cross-section of a large gap seal of the present disclosure. Figure 2 is a schematic cross-section of a seal showing the main dimensions. FIG. 3a illustrates the equivalent strain upon activation. This linear FEA is sufficient for the qualitative evaluation of the embodiments of the present disclosure. The strain field is uniform across the entire cross-section and reaches up to 50% (the hoop component of the strain is dominant). The reported maximum strain is located at the boundary between the structural (interlocking) segments, but due to the non-optimized geometry, this value may be negligible in other embodiments. Multiple O-rings provide a seal between the axial surface of the pressure head and the guide. Fig. 3b is a cutaway perspective view of the seal of Fig. 3a. FIG. 4a illustrates an embodiment of the present disclosure using a mini pressure head to completely prevent extrusion of the seal ID. The seal is shown in an unset position. A pair of O-rings provides a seal between the axial surface of the pressure head and the guide. FIG. 4b is an example of FIG. 4a when switching to the set position. Figure 5 is a screenshot from an FEA animation showing a structural member when the seal is in an unset position. Figure 6 is a screenshot from an FEA animation showing a structural member when the seal is in a set position. FIG. 7 is an isometric view of the large gap seal of the present disclosure when it is in a test fixture. Figure 8 is a cross-sectional view of the sealing portion of Figure 7. FIG. 9 is a front elevation view of one embodiment of a structural member of the present disclosure. FIG. 10 is a plan view of the member of FIG. 9. FIG. 11 is a bottom view of the member of FIG. 9. FIG. 12 is a rear elevation view of the member of FIG. 9. FIG. 13 is a left elevation view of the member of FIG. 9. FIG. 14 is a right elevation view of the member of FIG. 9. FIG. 15 is an isometric view of one embodiment of a T-shaped seal portion of the present disclosure. Fig. 16 is a cross-sectional view of the sealing portion of Fig. 15. FIG. 17 is a front elevation view of one embodiment of an angle plate of the present disclosure. In some embodiments, the plate comprises an angled surface in the range of 10° to 20°, and there are sub-ranges and discrete values ​​within this wider range. FIG. 18 is a right elevation view of the plate of FIG. 17. FIG. 19 is an isometric view of one embodiment of a mini pressure head of the present disclosure. Figure 20 is a cross-sectional view of the mini pressure head of Figure 19. FIG. 21 is an isometric view of one embodiment of a mini pressure head of the present disclosure that is more suitable for higher pressures than the head of FIG. 19. Figure 22 is a cross-sectional view of the mini pressure head of Figure 21. FIG. 23 is an isometric exploded view of an isolation tool of the present disclosure. The tool may include a pair of bumpers on a primary plugging head, and the bumpers come into contact with a pipe wall (lateral access) cutout when the tool is inserted into a main pipeline and retracted. FIG. 24a is an embodiment of a sealing tool of the present disclosure comprising an arm having an arched bumper that contacts the ID of a pipe to redistribute the force experienced by the tool when sealing against a pipe back to the pipe. For the purpose of illustration, only one plugging head is shown. With the sealing member in an unset position, the arm is shown in a set or fully extended position. The arm is connected to a control bar and can be moved to a position where the tool enters the pipeline or can be hydraulically actuated. When in the set position, the sealing member can be extended. Fig. 24b is a plan view of the isolation tool of Fig. 24a. FIG. 25a is a side view of FIG. 24a when the arm is in an unset position. FIG. 25b is a side view of the arm of FIG. 24a when it is in a set or fully extended position. FIG. 25c is a plan view of the arm of FIG. 24a (unset position). FIG. 25d is a plan view of the arm of FIG. 24a (set position). FIG. 26a is an isometric view of one embodiment of a transfer pin of the present disclosure. The transfer pin helps to sustain a fluid circuit between adjacent components, such as a control bar and a yoke, or a yoke and a plugging head. FIG. 26b is a cross-sectional view of the transfer pin of FIG. 26a. The transfer pin has threads along the length opposite the O-ring groove. FIG. 27a is a cross-sectional view showing a transfer pin located along a hydraulic fluid passage between two adjacent components of an isolation tool. FIG. 27b is a drawing of an anti-rotation pin and a transmission pin on the lower pressure side of the tool between the secondary hinge and the secondary piston. FIG. 28a is a cross-sectional view of one embodiment of a spring-loaded anti-rotation pin of the present disclosure in which the stem is located on the higher pressure side in the contracted (minimum stroke) position. The spring may be a wave spring. FIG. 28b is a cross-sectional view of the spring-loaded anti-rotation pin of FIG. 28a with the stem in the extended (maximum stroke) position. FIG. 29 is an example of an actuator bar for use with an isolation tool of the present disclosure. The actuator includes a hydraulic transfer sleeve (Fig. 32) comprising a manifold (Fig. 33) that transfers hydraulic fluid from outside the pipe to the isolation tool. FIG. 30 is a cross-sectional view of the top of the actuator bar indicated by section 30 of FIG. 29. FIG. 31 is a cross-sectional view of a portion of the top of an actuator bar indicated as section 31 of FIG. 30. FIG. 32 is an example of the hydraulic transmission sleeve of FIG. 30 and FIG. 31. FIG. 33 is an example of the manifold block of FIG. 30 and FIG. 31. FIG. 34 is an embodiment of a plugging head of the present disclosure having a hydraulic cylinder formed at least partially by each of two pressure heads. The cylinder head may be formed by an opposing pressure head of which forms the cylinder body. Providing the hydraulic cylinder in this way results in a shorter overall tool length. FIG. 35 is an example of the hydraulic cylinder of FIG. 34 integrated into a high-pressure plugging head. The use of the hydraulic cylinder is not limited to the T-shaped seal of the present disclosure and can be used with other circumferential seal designs. FIG. 36 is an example of a non-penetrating array of a pipeline isolation tool. The tool includes a gripping means. Sealing cups or discs of a type known in the art may be arranged around the tool body to help position the tool at the center of the pipe and propel the tool forward under differential pressure. Means known in the art may also be used to arrange the tool as part of a plugging train. FIG. 37 is an embodiment of a piston and pressure head assembly of the present disclosure. The piston includes a trapezoidal thread at each end. The thread accommodates a variable gap between the piston and the component to which the piston is connected, so that the gap can be one full thread rotation. Specific details for implementing the invention

[0028] Now, referring to the drawings, an embodiment of a pipeline isolation tool (10) is illustrated and described. The pipeline isolation tool (10) is housed in a pipe (20). The pipe (20) defines the pipe wall (22). The pipeline isolation tool (10) includes a circumferential seal (30). The circumferential seal (30) has a first side (32) and a second side (34). The seal (30) is extendable between an unset position and a set position. The seal (30) is configured to engage sealably with the pipe wall (22) at the set position. When in the set and unset positions, the seal (30) defines a T-shaped cross section defining a lower seal profile (36) in the radial v direction and an upper seal profile (38) in the horizontal direction. In some embodiments, the cross section of the lower seal profile (36) in the radial v direction is smaller than that of the upper seal profile (38) in the axial direction.

[0029] For the purposes of the present disclosure, the radial and axial directions are relative to the seal (30). For example, if the tool (10) is set on a horizontal pipe, the radial direction is vertical (z-axis) and the axial direction is horizontal (y-axis). If the tool (10) is set on a vertical pipe, the radial direction is horizontal (y-axis) and the axial direction is vertical (z-axis).

[0030] Circumferential pressure heads (40, 50) are located on each side (32, 34) of the sealing portion (30). The first circumferential pressure head (40) is located adjacent to the first side (32) of the radial lower sealing portion profile (36). The first circumferential pressure head (40) defines the outer surface (42). The second circumferential pressure head (50) is located adjacent to the second side (34) of the radial lower sealing portion profile (36). The second circumferential pressure head (50) defines the outer surface (52).

[0031] A plurality of first structural members (60) are positioned adjacent to the first side (32) of the sealing portion (30). Each of the plurality of first structural members (60) has an upper surface (62), an inner face (64), and an outer face (66). Each of the plurality of first structural members (60) defines an overlapping portion (68) (e.g., see FIG. 5) with at least a portion of the adjacent first structural member (60). Each of the plurality of first structural members (60) defines a concave area (70) adjacent to the upper surface (62) to accommodate a portion of the axial upper sealing portion profile (38) of the sealing portion (30). The inner face (64) of the plurality of first structural members (60) contacts the outer surface (42) of the first circumferential pressure head (40).

[0032] As the sealing portion (30) moves from an unset position (e.g., see FIG. 1, FIG. 2, FIG. 4) to a set position (e.g., see FIG. 3a), the amount of overlap (68) of adjacent first structural members among the plurality of first structural members (60) decreases. As the sealing portion (30) moves from a set position (minimum or less overlap) to an unset position (maximum or larger overlap), the amount of overlap (68) of adjacent first structural members among the plurality of first structural members (60) increases. Therefore, the plurality of first structural members (60) define a first outer diameter (74) at the unset position (see FIG. 5) and define a second outer diameter (72) at the set position (see FIG. 5). The second outer diameter (72) is larger than the first outer diameter (74).

[0033] A plurality of second structural (interlocking) members (80) are located on the second side (34) of the sealing portion (30). Each of the plurality of second structural members (80) has an upper portion (82), an inner face (84), and an outer face (86). Each of the plurality of second structural members (80) defines an overlapping portion (88) (e.g., see FIG. 5, FIG. 6, and FIG. 13) with at least a portion of an adjacent second structural member (80). Each of the plurality of second structural members (80) defines a concave area (90) adjacent to the upper portion (82) to accommodate a portion of the axial upper sealing portion profile (38) of the sealing portion (30). The inner face (84) of the plurality of second structural members (80) contacts the outer surface (52) of the second circumferential pressure head (50).

[0034] As the sealing portion (30) moves from an unset position to a set position, the amount of overlap (88) of adjacent second structural members among the plurality of second structural members (80) decreases. As the sealing portion (30) moves from a set position (minimum or less overlap) to an unset position (maximum or larger overlap), the amount of overlap (88) of adjacent second structural members among the plurality of second structural members (80) increases. Therefore, the plurality of second structural members (80) define a first outer diameter (92) at the set position (e.g., see FIG. 3a, FIG. 6) and define a second outer diameter (94) at the unset position (e.g., see FIG. 1, FIG. 2, FIG. 4, FIG. 5). The second outer diameter (94) is larger than the first outer diameter (92).

[0035] The first and second structural members (60, 80) engage with each circumferential angle plate (100, 110). The first circumferential angle plate (100) defines an inner angle surface (102). The inner angle surface (102) contacts the outer face (66) of each of the plurality of first structural members (60). The second circumferential angle plate (110) defines an inner angle surface (112). The inner angle surface (112) contacts the outer face (86) of each of the plurality of second structural members (80). The angle plates (100, 110) function as pressure heads to apply pressure to the structural members as well as to the mini pressure heads (40, 50).

[0036] The plate (100, 110) may extend over a radial distance from the bottom (45, 55) of the pressure head (40, 50) to the top (62, 82) of the structural member (60, 80) (accordingly, it is a pressure head larger in size than the pressure head (40, 50)). In an embodiment, the plate (100, 110) is not a mirror image of the other, nor is the pressure head (40, 50).

[0037] Embodiments of the present disclosure further include a sealing member (30) having a cross section that is "T-shaped" or "T-shaped" (see FIG. 1, FIG. 3, FIG. 4a, and FIG. 15, FIG. 16), and the sealing member (30) has an upper profile (38) and a lower profile (36). The two profiles (36, 38) may have different shapes from each other. In some embodiments, the lower profile (36) has a narrower cross section than the upper profile (38). Circumferential pressure heads (40, 50) are positioned on each side of the lower profile (36) of the sealing member (30) and contact it. A plurality of structural members (60, 80) are arranged around the pressure heads (40, 50), and each structural member (60, 80) overlaps with at least a portion of an adjacent structural member (60, 80).

[0038] In an embodiment, a pair of circumferential angle plates (100, 110) and a pair of circumferential pressure heads (40, 50) may be arranged so that the pair of circumferential angle plates (100, 110) apply pressure to a plurality of structural members (60, 80) before the pair of circumferential pressure heads (40, 50) apply pressure to the radial lower profile (36) as the circumferential seal (30) moves from an unset position to a set position.

[0039] The structural member (60, 80) includes a recess (70, 90) at the top (62, 82) where a portion of the upper profile (38) of the sealing member (30) exists, and an inner face surface (64, 84) that contacts the outer surface (42, 52) of the pressure head (40, 50). The amount of overlap (68, 88) between adjacent structural members (60, 80) decreases as the sealing member (30) moves from an unset position to a set position, and the amount of overlap (68, 88) increases as the sealing member (30) moves from a set position to an unset position. Because the amount of overlap (68, 88) increases and decreases, the structural member (60, 80) expands between a first size and a second size. The cylindrical angle plate (100, 110) includes an inner angle surface (102, 112) that contacts the outer face surface (66, 86) of the structural member (60, 80).

[0040] The radial lower seal profile (36) may have a smaller cross-section than the axial upper profile (38) of the seal (30). However, the smaller cross-section is not important for the seal (30) to function as intended. Mini pressure heads (40, 50) on each side (32, 34) of the lower seal profile (36) (see FIGS. 19 to 22) act as support structures and prevent extrusion of the seal ID.

[0041] In the unset position, the lower profile (36) is located between the mini pressure heads (40, 50), and the upper profile (38) is located entirely on the top (44, 54) of the heads (40, 50). The seal (30) extends toward the pipe (20) with an almost pure "natural" hoop elongation to achieve a uniform strain distribution along the entire cross-section of the seal.

[0042] Note that in some embodiments, the bottom (37) of the seal (30) does not come into contact with the opposing axial surface (56) of the pressure head (50), and as the seal (30) moves between an unset position and a set position (compare FIG. 4a (unset position) with FIG. 3a (set position) and FIG. 4b (moving to the set position), the radial distance between the two increases. The bottom (37) is spaced apart from the axial surface (56) by a first radial distance when the circumferential seal (30) is in the unset position, and is spaced apart by a second radial distance greater than the first radial distance when the seal (30) is in the set position, and the first radial distance is greater than zero (0). Due to this arrangement, and as a non-limiting example, the seal (30) can be extended to about 60% to 70% of the available radial area.

[0043] As contact with pipe ID (22) occurs, the mini pressure head (40, 50) is compressed toward the seal (30) and acts across a large cross-section to distribute the load from the isolation pressure. Refer to FIGS. 4a and 4b. Unlike the outer surface (42, 52) of the pressure head (40, 50) which has a constant slope, the inner surface (41, 51) of the pressure head (40, 50) does not. In some embodiments, the inner surface (41, 51) may include a plurality of surfaces (43A-C, 53A-C) oriented at different angles to form a recess area (47) (thereby providing a greater axial distance between the head (40, 50) at the top (44, 54) than at the bottom (45, 55)). For example, the surface (43A, 53A) may be vertical, the surface (43B, 53B) may be inclined toward the outer surface (42, 52), and the surface (43C, 53C) may be vertical or slightly deviated from vertical and inclined toward the outer surface (42, 52).

[0044] When switching to the set position, and when in the set position, a portion of the lower profile (38) may exist within the recess (47), that is, in contact with the surfaces (43B-C, 53B-C) but not with 43A, 53A, and another portion of the lower profile exists entirely on the top (44, 54) of the pressure head (40, 50). A pair of O-rings (59) positioned between the lower face surface (58) of the pressure head (50) and the opposing face surface (114) of the angle plate (110) provide a seal between the pressure head (50) and the angle plate (110). The O-rings (59) do not extend.

[0045] Referring to FIG. 2, the main dimensions "A" and "B" of the T-shaped seal (30), along with the distance "D" between the structural segments (60, 80), indicate when contact is established between the elastomer and the steel component. In the embodiment, the mini pressure head (40, 50) does not begin to compress the seal (30) immediately but compresses it later in the activation cycle to build a uniform strain field within the seal (30). The dimensions "A", "B" and "C" are predetermined with the design expansion gap in mind and can be optimized to accommodate one or more pipe IDs. Note that if two or more pipe IDs are designed, the seal (30) will have multiple set positions, i.e., one for each pipe ID. For example, the circumferential seal (30) may have a first set position and a second set position, the first set position for a first pipe diameter and the second set position for a second pipe diameter larger than the first pipe diameter. Thickness "C" should be sized to (generally) combine as many segments (60, 80) as possible and prevent the rubber seal (30) from being extruded inward into the cavity between the mini pressure heads (40, 50). Thickness "C" may be smaller than "B". In some embodiments, the total height of the seal (30) (radially when not set) is smaller than the radial distance "G" (see, for example, FIG. 3 to 4b). The distance "E" also helps prevent extrusion, so that the seal (30) provides sufficient support for the segments (60, 80), thereby reducing the risk of the seal (30) being extruded radially inward. The pressure heads (40, 50) include a radius "F" at the top where the seal (30) transitions between the lower and upper profiles (36, 38).

[0046] Extrusion of the ID of the seal (30) at high pressure can be dangerous. FIG. 3 illustrates an embodiment in which the extrusion of the ID of the seal (30) is limited but possible. This design is considered for low-pressure applications and can be optimized as previously described by manipulating the dimensions "C", "D", and "E" as well as "G". FIG. 4a and FIG. 4b illustrate an embodiment in which the extrusion of the ID of the seal (30) is completely prevented. Refer also to FIG. 21 and FIG. 22. The lower profile (36) of the seal (30) does not come into contact with the upper axial surface (51) of the pressure head (50). The bottom (37) of the profile (36) may have a narrower cross-section than the middle and top of the profile (36). In some embodiments, the cross-section toward the bottom (37) is a semi-hexagonal shape. When the seal (30) is activated, the mini pressure head (40, 50) compresses and also contacts the ID extension of the seal (30). This introduces an adjustable reinforcement effect that can be adapted to high-pressure isolation.

[0047] Additionally, to achieve a tight seal that prevents radial extrusion, high Shore rubber may be molded into the ID of the seal (30) (lower Shore rubber is in the OD of the seal). The contact between the mini pressure head (40, 50) and the seal (30) may also be designed as a high-friction contact to help minimize these effects. In some embodiments, higher Shore rubber is used at the upper corner of the seal (30) than at other areas of the seal (30).

[0048] Increased stress and jamming of the movable mini pressure head (40, 50) are other risks that may be resolved by design features such as increased material thickness, low friction surface and ensuring proper gap tolerance between the mini pressure head (40, 50), and angle feature angle plate (100, 110).

[0049] The large gap seal (30) of the present disclosure expands radially with a small force and does not deform relative to the axial direction during setting, and introduces a reinforcing effect to the supporting segment that prevents the segment from tilting in the large expansion gap. An embodiment of the present disclosure expands radially by more than 20% to engage with the pipe wall (22) due to the reinforcing effect of the segments (60, 80), and there is no need to extrude the seal (30) radially inward. The seal (30) is also independent of the isolation pressure size without the ID of the seal (30) extrusion. The seal (30) can also be highly customized in that it can be optimized for various expansion gaps and isolation pressures by manipulating the angle, thickness, and height of the segments (60, 80) and the T-shaped seal (30).

[0050] Now, referring to FIGS. 23 and 35, an embodiment of the isolation tool (10) of the present disclosure may include first and second plugging heads (210, 220) that are pivotal with respect to each other. When inserted into a pipe (20) in the same direction as the pipeline product flow, the plugging head (210) acts as a primary plugging head (where there is a pressure difference across the head (210) on the higher pressure side of the tool (10)) and the plugging head (220) acts as a secondary plugging head (where there is a pressure difference across the head (220) on the lower pressure side of the tool). Each plugging head (210, 220) includes a seal (30), a pressure head (40, 50), and a segment (60, 80) as described above. Any pipeline product leaking through the first head (210) is prevented from passing through the second head (220). Therefore, the tool (10) defines a double barrier or double block because it has two independent sealing systems and two independent locking systems. When in the sealing position, extraction or ventilation of the pipeline product between the heads (210, 220) may be provided.

[0051] When provided as a penetration tool, the plugging head (210) is pivotally connected to the carrier (212) by a yoke (214). The yoke (214) rotates around a yoke pin (216) contained within a yoke mount (218) connected to the carrier (212). A plugging head (220), which may be a secondary plugging head (on the low-pressure side of the tool (10)), is connected to the plugging head (210) by a yoke (238) that rotates around a yoke pin (240). The yoke (238) may include a pair of bumpers (242) that help prevent the yoke (214) and the plugging head (210) from getting stuck in the access connection to the pipe (20) while they are being installed in and removed from the pipe (20).

[0052] In an embodiment, the tool (10) moves downward through a lateral access connection and moves into the pipe (20) in a manner similar to that described in US 7,841,364 B2 of Yeazel et al. (“Yeazel”), the contents of which are incorporated herein by reference. Ventilation between the heads (210, 220) may occur through a vent port. For example, refer to Yeazel. The tool (10) may also be configured as a non-penetrating tool as shown in FIG. 36 and includes a gripping means (320). Sealing cups or discs of a type known in the art may be arranged around the tool body to help position the tool (10) at the center of the pipe (20) and propel the tool (10) forward under differential pressure. Means known in the art may also be used to arrange the tool (10) as part of a plugging train. Each plugging head (210, 220) may be a separate module of the plugging train.

[0053] Referring to FIGS. 29 through 33, when configured or provided as a penetration tool, the carrier (212) is connected to the control bar (230) at the top (222). The control bar (230) is used to radially insert, rotate, and position the tool (10) in conjunction with the control bar head (212) and the yoke (214, 238) to the final sealing position within the pipe (20). The control bar (230) also supplies hydraulic fluid to each plugging head (210, 220). In some embodiments, the control bar head (212) may be the same or similar as disclosed in U.S. Patent No. 10,989,347 by McKone et al.

[0054] Some embodiments of the tool (10) may include a control bar (230) including a hydraulic transfer sleeve (232) (Fig. 32) which includes a manifold (236) (Fig. 33) that transfers hydraulic fluid from outside the pipe (20) to the isolation tool (10). The hydraulic transfer sleeve (232) includes a set of ports (234) that communicate with a complementary set of ports (238) of the manifold (236). Then, the ports (238) communicate with an external fluid line.

[0055] In an embodiment, the leading plugging head (210 or 220) may include a chip sweep (250) during insertion into the pipe (20). The chips swept downstream of the tool (10) by the sweep (250) are typically the result of a hot tap operation. The chips may also include other pipeline debris that may interfere with the seal (30) when engaged with the pipe wall (22). In some embodiments, the sweep (250) may be a urethane disc. In other embodiments, the sweep (250) may be supplemented (or replaced) by a nozzle arranged to inject an inert gas or pipeline product, such as nitrogen or liquid, ahead of the sweep (250) or the tool (10). The nozzle may include a port arranged to draw the gas or liquid into the nozzle by the Venturi effect as the tool (10) is inserted into the pipe (20).

[0056] Now, referring to FIGS. 24a through 25d, in some embodiments, the tool (10) may include an arcuate-shaped bumper (262) that engages with the pipe wall (22) and distributes the force experienced by the tool (10) to the pipe (20). The bumper (262) may be deployed via mechanical means such as an arm (260) or extended and retracted by a hydraulic cylinder. The arcuate-shaped bumper (262) is movable between a first position and a second position. When in the first position, the arcuate-shaped bumper (262) is inside the sealing diameter of the circumferential seal (30). When in the second position, the arcuate-shaped bumper (262) extends to the sealing diameter of the circumferential seal (30).

[0057] In one embodiment, the arm (260) is fixed at the bottom (231) of the control bar (230). The arm (260) is arranged to move between a first (unextended) position and a second (fully extended) position as the tool (10) is positioned within the pipe (20). The arm (260) is curved between its two ends (264, 268) and includes an arched bumper (262) at its top (distal end) (264). The bumper (262) is formed in a shape complementary to the ID of the pipe (20). A linkage (266) is connected to the bottom (proximal end) (268) of the arm (260) at one end (270) and fixed to the yoke (214) or control bar (230) at the other end (272). The lower end (268) of the arm (260) includes a cam surface (276), and the end (272) of the linkage (266) includes a cam (278).

[0058] As the yoke (214) moves into the pipeline (20), the yoke (214) pushes the cam (278) and the arm (260) moves between the first position and the second position, and when in the second position, the bumper (262) contacts the inner diameter of the pipeline (20). The force experienced by the tool (10) is distributed to the pipe (20). When in the second position, the arm (260) may overlap with part of the plugging head (210) but is located behind the seal (30).

[0059] The arm (260) can be formed and arranged in such a size that contact with the ID of the pipe (20) occurs within the length of the pipe (20) surrounded by a fitting located on the outside of the pipe (20). The fitting is a saddle branch fitting of a type known in the art for lateral access connections typically used in hot tapping operations.

[0060] Now, referring to FIGS. 26a through 27b, a transfer pin (290) including a hydraulic passage (292) can be used between adjacent components of a tool (10) to transfer hydraulic fluid to each plugging head (210, 220) while avoiding an external hydraulic line. For example, the transfer pin (290) can be positioned between a yoke and a piston. The transfer pin (290) includes an O-ring groove (298) at one end and a thread length (294) at the other end. The thread length (294) may be a standard metric thread. In an embodiment, the transfer pin (290) may include a hex-shaped head (296) to accommodate the assembly of the tool (10).

[0061] Referring to FIGS. 27b through 28b, an embodiment of the tool (10) may include a spring-loaded anti-rotation pin (300). The anti-rotation pin (300) prevents relative rotation between the nose of the plugging head (210 or 220) and the hydraulically actuated piston (306). The spring may be a wave spring (302).

[0062] During the assembly of the tool (10), using the spring (302) associated with the stem (304), the assembler can grasp the anti-rotation pin (300) and lock it in the unlocked position. Since there is a thread at the end of the stem (304), the assembler can secure a nut to the end of the stem (304) to keep the spring (302) in a compressed state.

[0063] In an embodiment, the piston (306) has unclocked threads (314) at each end (see FIG. 37), and accordingly, the gap between the piston (306) and the hinge (yoke) (214) can be as large as one full thread pitch (e.g., a 6 mm thread allows for a gap of 0-6 mm). Threads, which may be trapezoidal threads, allow for a variable gap between any components forming threads on the piston. In this way, a gap of 0 to 1 full turn can be accommodated to ensure that the components and the piston (306) are properly clocked relative to each other.

[0064] In some embodiments of the plugging head (210 or 220) of the present disclosure, the piston or hydraulic cylinder (308) is formed at least partially by each of the two angle plates (100, 110). Refer to FIG. 34 and FIG. 35. The cylinder (308) may be provided such that the inactive volume (310) is larger than the working volume (312). Compared to embodiments using the piston (306), the hydraulic cylinder (308) provides a shorter overall tool length. The cylinder head may be formed by the opposing angle plates (100, 110) of which form the cylinder body (308). The use of the cylinder (308) is not limited to the T-shaped seal (30) and may be used with other sealing members. For example, the cylinder (308) may be used with sealing members identical or similar to those disclosed by McKone et al.

[0065] Although embodiments have been described, the isolation tool of the present disclosure may be modified by those skilled in the art without departing from the scope of the following claims, and the elements cited in the claims are entitled to the entire scope of equivalents. Explanation of the symbols

[0066] 10: Pipeline Isolation Tool 102: Inner Surface 20: Pipe 110: Angle plate 22: Pipe wall 112: Inner face 30: Sealing part 114: Face surface 32: 1st side 210: 1st plugging head 34: Second Side 212: Carrier 36: Lower seal profile 214: Yoke 37: Bottom 216: Yoke pin 38: Upper seal profile 218: Nose 40: Pressure head 220: Second plugging head 41: Inner 222: Top 42: External 230: Control bar 43: Angled surface 231: Bottom 44: Top 232: Transfer Sleeve 45: Bottom 234: Port 47: Recess 236: Manifold 50: Pressure head 238: Yoke 51: Inner self 240: York pin 52: Exterior 242: Bumper 53: Angled surface 250: Sweep 54: Top 260: Arm 55: Bottom 262: Bumper 56: Axial surface 264: Distal end 57: Recess 266: Linkage 58: Lower face surface 268: Proximal end 59: O-ring 270: End 60: Structural member 272: End 62: Top 276: Cam surface 64: Internal Face 278: Cam 66: External face 290: Transmission pin 68: Overlapping section 292: Passage 70: Concave area 294: Thread length 72: Second outer diameter 296: Hexagonal head 74: 1st outer diameter 298: O-ring groove / O-ring 80: Structural member 300: Anti-rotation pin 82: Top 302: Spring 84: Inner face 304: Stem 86: Outer face 306: Piston 88: Overlap section 308: Hydraulic cylinder 90: Concave area 310: Disabled volume 92: 1st outer diameter 312: Activation volume 94: Second outer diameter 314: Trapezoidal thread 100: Angle plate 320: Gripping means

Claims

Claim 1 A pipeline isolation tool (10) applied for insertion via a hot tap, wherein the pipeline isolation tool comprises at least one plugging head (210), wherein the at least one plugging head (210) has a first diameter at an unset position and a second diameter larger than the first diameter at a set position, and has a circumferential seal (30) having upper and lower seal profiles in cross-section; a pair of circumferential pressure heads (40, 50), wherein one of the circumferential pressure heads is located on each side (32, 34) of at least the lower seal profile (36); A pipeline isolation tool (10) comprising a pair of circumferential angle plates (100, 110), wherein each circumferential angle plate is positioned outwardly to a corresponding one of the circumferential pressure heads (40, 50), each circumferential angle plate (100, 110) defines an inner angle surface (102, 112), and one of the circumferential pressure heads (40, 50) includes an axial surface provided adjacently on the opposite side of the bottom end of the lower seal profile (36). Claim 2 A pipeline isolation tool according to claim 1, wherein the circumferential seal (30) has a symmetric T-shaped cross-section, the lower seal profile (36) is oriented in the radial direction, and the upper seal profile (38) is oriented in the axial direction. Claim 3 In claim 1, each circumferential pressure head (40, 50) defining an outer surface (42, 52); and further comprising a plurality of structural members (60, 80) on each side (32, 34) of the upper sealing profile (38), wherein each of the plurality of structural members defines an overlapping portion (68, 88) with at least a part of an adjacent structural member among the plurality of structural members, and each of the plurality of structural members comprises a concave area (90) for accommodating a corresponding portion of the upper sealing profile (38); and an inner face (64, 84) in contact with the outer surface of a corresponding circumferential pressure head among the pair of circumferential pressure heads (40, 50). A pipeline isolation tool comprising an outer face (66, 86), wherein the plurality of structural members (60, 80) on each side determine a first outer diameter when the circumferential seal is in the unset position and determine a second outer diameter larger than the first outer diameter when the circumferential seal (30) is in the set position. Claim 4 A pipeline isolation tool according to claim 1, wherein the axial surface (56) is provided on the opposite side of the bottom end of the lower sealing profile (36), and the bottom end is spaced apart from the axial surface by a first radial distance when the circumferential sealing part (30) is in the unset position, and is spaced apart by a second radial distance greater than the first radial distance when the circumferential sealing part (30) is in the set position, and the first and second radial distances are greater than zero (0). Claim 5 A pipeline isolation tool according to paragraph 3, characterized in that the amount of the overlap portion of adjacent structural members among the plurality of structural members decreases as the circumferential seal moves from the unset position to the set position and increases as the circumferential seal moves from the set position to the unset position. Claim 6 A pipeline isolation tool according to claim 3, further comprising the inner angle surface of each circumferential angle plate that contacts the corresponding outer face among the outer faces of each of the plurality of structural members (60, 80). Claim 7 A pipeline isolation tool according to claim 1, further comprising: a hydraulic cylinder (308) formed at least partially by the pair of circumferential angle plates (100, 110); and a hydraulic actuating piston (306) arranged to move the circumferential seal (30) between the unset position and the set position, wherein the hydraulic actuating piston (306) is enclosed within the hydraulic cylinder (308). Claim 8 A pipeline isolation tool according to claim 3, wherein the pair of circumferential angle plates (100, 110) and the pair of circumferential pressure heads (40, 50) are arranged such that the pair of circumferential angle plates (100, 110) apply pressure to the plurality of structural members (60, 80) before the pair of circumferential pressure heads (40, 50) apply pressure to the lower profile of the circumferential seal (30) as the circumferential seal (30) moves from the unset position to the set position. Claim 9 A pipeline isolation tool according to claim 1, further comprising a second plugging head (220) pivotally connected to at least one plugging head (210). Claim 10 A pipeline isolation tool applied to insertion via a hot tap, comprising: a control bar head (212); at least one plugging head (210) including a circumferential seal (30); a yoke (214) pivotally connected to the control bar head and the at least one plugging head; and an arched bumper (262) communicating with the yoke and movable between a first position and a second position, wherein when in the first position, the arched bumper is provided inside the sealing diameter of the circumferential seal, and when in the second position, the arched bumper is provided up to the sealing diameter of the circumferential seal. Claim 11 A pipeline isolation tool according to claim 10, further comprising an arched bumper including an arm (260) having a proximal end (268) and a distal end (264), wherein the arched bumper is connected to the distal end of the arm. Claim 12 A pipeline isolation tool according to claim 11, wherein the arm further comprises a linkage (266) including a cam surface (276) at a proximal end and a cam (278) in contact with the cam surface, and wherein, as the cam moves along the cam surface, the arm moves between the first position and the second position. Claim 13 delete Claim 14 A pipeline isolation tool applied for insertion via a hot tap, comprising: at least one plugging head (210) including a hydraulically actuated piston (306); a yoke (238) connected to the at least one plugging head (210) and including a hydraulic fluid passage (292); and at least one hydraulic fluid delivery pin (290); wherein the at least one hydraulic fluid delivery pin (290) includes at least one O-ring groove (298) at one end and a thread length (294) at the other end, extending between the at least one plugging head (210) and the yoke (238), and connecting the hydraulic fluid passage (292) of the yoke (238) to the hydraulically actuated piston (306). Claim 15 A pipeline isolation tool according to claim 14, wherein the hydraulic operating piston comprises at least one end having a trapezoidal thread (314). Claim 16 A control bar (230) applied for use with a pipeline isolation tool (10) applied for insertion through a hot tap, wherein the pipeline isolation tool (10) comprises at least one plugging head (210), the control bar (230) is connectable to the at least one plugging head (210), the control bar (230) comprises a hydraulic fluid transfer sleeve (232) comprising a manifold (236), and the manifold comprises a plurality of ports (234) arranged to connect to a hydraulic fluid line located outside the control bar. Claim 17 A pipeline isolation tool (10) applied to insertion through a hot tap, further comprising at least one plugging head (210) including a nose (218), a hydraulically actuated piston (306), and a spring-loaded anti-rotation pin (300), wherein the spring-loaded anti-rotation pin (300) is provided to prevent relative rotation between the nose and the hydraulically actuated piston. Claim 18 A pipeline isolation tool according to claim 17, wherein the spring-loaded anti-rotation pin comprises a wave spring (302). Claim 19 A pipeline isolation tool according to claim 17, wherein the at least one plugging head (210) includes a chip sweep (250) downstream of the circumferential seal (30). Claim 20 A pipeline isolation tool according to claim 17, further comprising a gripping means (320) positioned around the pipeline isolation tool (10). Claim 21 A pipeline isolation tool according to claim 17, wherein the hydraulic operating piston (306) comprises at least one end having a trapezoidal thread (314). Claim 22 A pipeline isolation tool (10) applied to insertion via a hot tap, comprising at least one plugging head (210, 220), wherein the pipeline isolation tool (10) further comprises a bumper (262) that distributes the force experienced by the pipeline isolation tool (10) to the pipe (20) as the at least one plugging head (210) moves to a sealing position within the pipe (20). Claim 23 A pipeline isolation tool according to claim 22, wherein the bumper (262) comprises an arm (260) having a proximal end (268) and a distal end (264), and the bumper (262) is connected to the distal end (264) of the arm (260). Claim 24 A pipeline isolation tool according to claim 23, wherein the arm (260) is curved between the proximal end (268) and the distal end (264). Claim 25 A pipeline isolation tool according to claim 23, wherein the arm (260) further comprises a linkage (266) including a cam surface (276) at the proximal end (268) and a cam (278) in contact with the cam surface (276). Claim 26 In paragraph 22, the above bumper (262) is a pipeline isolation tool characterized by being hydraulically operated. Claim 27 A pipeline isolation tool according to claim 22, further comprising at least one plugging head (210) communicating with a hydraulic fluid circuit, wherein the hydraulic fluid circuit comprises one or more transfer pins (290), and wherein the one or more transfer pins (290) comprise a hydraulic fluid passage (292), at least one O-ring groove (298) at one end and a thread length (294) at the other end. Claim 28 A pipeline isolation tool according to claim 27, wherein one of the one or more transfer pins (290) extends between the at least one plugging head (210) and the yoke (214) to which the at least one plugging head (210) is connected. Claim 29 A pipeline isolation tool according to claim 27, further comprising at least one plugging head (210) including a hydraulically actuated piston (306), wherein the hydraulically actuated piston (306) includes at least one end having a trapezoidal thread (314). Claim 30 A pipeline isolation tool according to claim 29, further comprising a spring-loaded anti-rotation pin (300) provided to prevent relative rotation between the nose (218) of the pipeline isolation tool (10) and the hydraulic operating piston (306). Claim 31 In claim 22, the invention further comprises at least one plugging head (210), wherein the at least one plugging head (210) comprises: a circumferential seal (30) having an upper seal profile (38) and a lower seal profile (36) in cross-section; and a pair of circumferential pressure heads (40, 50), wherein one of the circumferential pressure heads is located on each side of at least the lower seal profile (36) of the circumferential seal (30). A pipeline isolation tool comprising a pair of circumferential angle plates (100, 110), wherein each circumferential angle plate is positioned outwardly to a corresponding one of the circumferential pressure heads (40, 50), and each circumferential angle plate (100, 110) has a height greater than that of a corresponding one of the pair of circumferential pressure heads (40, 50), and wherein one of the circumferential pressure heads (40, 50) includes an axial surface provided adjacently on the opposite side of the bottom end of the lower seal profile (36). Claim 32 A pipeline isolation tool according to claim 31, characterized in that the axial surface is provided adjacently below the bottom of the other one of the circumferential pressure heads (40, 50). Claim 33 A pipeline isolation tool characterized in that, in claim 31, the upper sealing profile (38) is oriented in the axial direction. Claim 34 A pipeline isolation tool (10) applied to insertion through a hot tap, comprising at least one plugging head (210) communicating with a hydraulic fluid circuit, wherein the hydraulic fluid circuit comprises one or more transfer pins (290), wherein the one or more transfer pins (290) comprise a hydraulic fluid passage (292), at least one O-ring groove (298) at one end, and a thread length (294) at the other end. Claim 35 A pipeline isolation tool according to claim 34, wherein one of the one or more transfer pins (290) extends between the at least one plugging head (210) and the yoke (238) to which the at least one plugging head (210) is connected. Claim 36 A pipeline isolation tool according to claim 34, further comprising at least one plugging head (210) including a hydraulically actuated piston (306), wherein the hydraulically actuated piston (306) includes at least one end having a trapezoidal thread (314). Claim 37 A pipeline isolation tool according to claim 36, further comprising a spring-loaded anti-rotation pin (300) provided to prevent relative rotation between the nose (218) of the pipeline isolation tool (10) and the hydraulic operating piston (306). Claim 38 A pipeline isolation tool according to claim 34, further comprising a bumper (262) that distributes the force experienced by the pipeline isolation tool (10) to the pipe (20) as the at least one plugging head (210) moves to a sealing position within the pipe (20). Claim 39 In claim 34, further comprising at least one plugging head (210), said at least one plugging head (210) comprises a circumferential seal (30) having an upper seal profile (38) and a lower seal profile (36) in cross-section; a pair of circumferential pressure heads (40, 50), wherein one of the circumferential pressure heads is located on each side of at least the lower seal profile (36) of said circumferential seal (30); A pipeline isolation tool comprising a pair of circumferential angle plates (100, 110), wherein each circumferential angle plate is positioned outwardly to a corresponding one of the circumferential pressure heads (40, 50), and each circumferential angle plate (110, 110) has a height greater than that of a corresponding one of the pair of circumferential pressure heads (40, 50), and wherein one of the circumferential pressure heads (40, 50) includes an axial surface provided adjacently on the opposite side of the bottom end of the lower seal profile (36). Claim 40 A pipeline isolation tool according to claim 39, characterized in that the axial surface is provided adjacently below the bottom of the other one of the circumferential pressure heads (40, 50). Claim 41 A pipeline isolation tool characterized in that, in claim 39, the upper sealing profile (38) is oriented in the axial direction.

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