Pipe End Alignment Using Bevel Scans and Circumferential Codes
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Solution Overview
Problem
Current pipe welding methods in offshore pipeline laying, particularly during S-lay operations, face challenges in achieving high-quality welds due to manual alignment processes, which are time-consuming and prone to errors, leading to poor alignment and increased costs.
Innovation Solution
A method using machine-readable codes on the pipes to scan and align the bevelled ends, allowing for precise calculation and automatic adjustment of pipe positions to achieve optimal alignment, reducing the need for manual intervention and improving alignment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment processes are used for pipe welding, then operators can visually check and adjust pipe positions, but the alignment time is excessive and error-prone
Solution Approach 1:
The patent replaces manual visual inspection and mechanical adjustment with an automated optical measurement system. Laser scanners or cameras capture pipe end geometries, and a control system automatically calculates and executes alignment corrections, eliminating the need for manual visual checking and physical repositioning by operators.
Solution Approach 2:
The system enables self-alignment by having the pipe handling equipment automatically adjust pipe positions based on measured geometry data. The control unit computes the required movements and directs the handling equipment to execute corrections without human intervention, making the alignment process self-service.
2Ease of operation
If manual alignment processes are used, then operators can adjust pipe positions, but the weld quality is compromised due to poor alignment
Solution Approach 1:
The patent replaces manual adjustment operations with automated positioning controlled by a computer system. The control unit calculates precise alignment corrections based on measured pipe end geometries and directs the handling equipment to execute movements, ensuring consistent and reliable alignment that improves weld quality.
Solution Approach 2:
The system implements feedback by measuring the actual pipe end geometries with laser scanners or cameras, comparing them against target specifications, and automatically calculating correction movements. This closed-loop feedback ensures that alignment adjustments are based on actual measured conditions, improving weld reliability.
3Adaptability or versatility
If visual measurement by operators is used, then alignment can be checked, but the process is time-consuming and requires skilled personnel
Solution Approach 1:
The patent replaces manual visual inspection with automated optical measurement systems such as laser scanners or cameras. These systems rapidly capture pipe end geometries and transmit data to the control unit for processing, eliminating the time required for manual visual checking and increasing pipeline laying productivity.
Solution Approach 2:
The system performs self-inspection by automatically measuring pipe end geometries and calculating alignment corrections without requiring skilled operators. The control unit processes the measured data and directs adjustments, making the inspection and alignment process self-service and significantly faster.
4Manufacturing precision
If automated alignment with machine-readable codes is implemented, then alignment speed and precision are improved, but the device complexity increases
Solution Approach 1:
The patent introduces machine-readable codes as an intermediary element attached to or marked on the pipes. These codes provide reference information that simplifies the automated measurement and alignment process, enabling the control system to quickly identify and locate pipe features without complex image processing, thus improving precision while managing system complexity.
Data Source
AI summary
A method of aligning first and second pipes end-to-end in a position ready for welding. Each pipe has an end bevelled with a shape scanned and stored in memory of a control unit. At least one of the pipes has machine readable codes distributed around their circumference of the pipe. The method includes effecting relative movement of the ends of the first and second pipes towards each other, reading at least one of the codes with a reader, and ascertaining the relative movement required to align the pipes in accordance with a target orientation. The relative movement is ascertained with information provided by the read code and the shapes of the bevelled ends stored in the control unit memory. In other aspects, a closed loop control method and machine-learning may be used to align the pipes. A pipe-laying vessel including pipe handling equipment and the control unit is also provided.