Pipe Alignment System Using Optical Measurement for J-Lay
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for aligning pipes during pipeline laying at sea are inefficient and prone to errors, particularly in deep water J-Lay processes, where manual alignment by skilled operators is time-consuming and susceptible to inaccuracies, leading to potential weld rejection and increased operational costs.
Innovation Solution
A method and system for aligning pipes using external measurements to ascertain and improve alignment before welding, utilizing a pipe handling system with movable clamps and optical or laser measurement systems to ensure precise alignment without the need for heavy-duty clamps, allowing for accurate alignment verification immediately before welding and reducing the likelihood of weld rejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment by skilled operators is used in deep water J-Lay processes, then alignment can be achieved, but the process is time-consuming and susceptible to inaccuracies
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical measurement and control system. Laser scanners and cameras capture pipe positions, and a control system automatically calculates and executes alignment corrections, eliminating reliance on manual operator skills and significantly reducing alignment time while improving precision.
Solution Approach 2:
The alignment system is self-regulating through automated feedback control. The measurement system continuously monitors pipe positions, the control system automatically calculates required corrections, and the pipe handling system executes adjustments without human intervention, creating a self-service alignment process that is both fast and highly accurate.
2Strength
If heavy-duty clamps are used for holding pipe sections, then pipe sections can be securely held, but the device complexity and operational difficulty increase
Solution Approach 1:
The patent replaces heavy-duty mechanical clamps with a magnetic holding system. Magnets mounted on the pipe handling structure securely hold the pipe sections through magnetic attraction, eliminating the need for complex mechanical clamp mechanisms while maintaining secure holding capability and simplifying the overall system.
3Reliability
If alignment measurements are not performed immediately before welding, then the process is faster, but weld quality may be compromised due to alignment changes
Solution Approach 1:
The patent implements continuous alignment monitoring and verification immediately preceding welding operations. The optical measurement system continuously tracks pipe positions, and the control system maintains real-time alignment corrections, ensuring that alignment is verified at the critical moment before welding without significant time loss, thereby guaranteeing weld quality.
Solution Approach 2:
The system employs real-time feedback control where alignment measurements taken immediately before welding are fed back to the control system, which automatically makes final adjustments if needed. This closed-loop feedback ensures that alignment is optimized at the precise moment before welding, maximizing weld quality while minimizing time expenditure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time and cost associated with pipe alignment, enhances the accuracy of welds, and ensures higher quality welds by allowing precise alignment verification immediately before welding, thereby improving the efficiency and reliability of pipeline laying operations.
Implementation Method 1
a measurement system (213) located in the region in which the pipe section and the pipeline meet
Implementation Method 2
optical or laser measurement systems
Implementation Method 3
laser measurement systems to ensure precise alignment
Data Source
Figure 1a~1b
Figure 2~3a
Figure 3b~3c
AI summary
A method of joining a first pipe section (109) to a second pipe section (111), for example during J-lay of an undersea pipeline, is described. The method includes positioning the two pipe sections (109, 111) in an end-to-end configuration to define therebetween a joint to be welded (115), measuring the degree of alignment of the pipe sections (109, 111) when they are in the end-to-end configuration in a position ready for welding, ascertaining the relative movement required of the pipe sections (109, 111) in order to improve their alignment, effecting the relative movement so ascertained, and welding together the two pipe sections (109, 111). The method may include the use of geometric data of the end of the pipes in order to ascertain the relative movement required of the pipe sections. A control unit may be used to calculate, using such data, a target orientation that lines up the pipe sections. The measuring step may be performed using, for example, a laser (123) or a camera (223) and backlight (225).