Pipeline Pipe Welding Alignment and Internal Cooling in Remote Fields
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Solution Overview
Problem
Conventional pipeline welding systems face challenges in accurately aligning pipe segments, inspecting weld quality, and efficiently cooling pipes, particularly in remote locations with harsh environments, leading to inefficiencies and potential errors in welding processes.
Innovation Solution
A field system that includes internal and external welding mechanisms with laser-based alignment, a weld torch, and a cooling system for precise alignment and inspection, as well as a method for internal cooling of pipes to facilitate faster temperature regulation and improve welding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional internal welders with internal alignment mechanisms are used, then alignment of pipe segments can be achieved, but internal clutter is created that prevents sufficient space for a rotating or articulating torch
Solution Approach 1:
The patent inverts the conventional approach by using external alignment mechanisms instead of internal ones. The alignment system is positioned outside the pipe, eliminating internal clutter while maintaining alignment accuracy through external manipulation of pipe segments.
Solution Approach 2:
The patent introduces an intermediary alignment mechanism that operates externally to the pipe. This intermediary system facilitates alignment without requiring internal components, thus resolving the conflict between alignment precision and internal space availability for the torch.
2Productivity
If conventional welding systems are used in remote locations, then welding operations can be performed, but accuracy and efficiency are reduced due to harsh environments
Solution Approach 1:
The patent replaces conventional mechanical alignment and welding systems with laser-based alignment technology and automated welding mechanisms. This substitution improves accuracy and efficiency by reducing human error and environmental sensitivity, enabling reliable operation in harsh remote locations.
Solution Approach 2:
The welding system incorporates automated alignment and positioning capabilities that self-correct for environmental variations. The system performs self-adjustment to maintain welding accuracy without requiring constant manual intervention, thereby improving productivity and reliability in challenging conditions.
3Productivity
If rapid cooling of pipes is required after welding, then welding efficiency can be improved, but conventional cooling methods are too slow
Solution Approach 1:
The patent employs a hydraulic or pneumatic cooling system that circulates coolant through the pipe walls to achieve rapid heat removal. This fluid-based cooling method significantly accelerates the cooling process compared to conventional air cooling, reducing temperature regulation time and improving overall welding productivity.
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
The system enables accurate alignment and inspection of welds, reduces errors, and accelerates the cooling process, enhancing welding efficiency and quality while addressing the limitations of existing technologies in remote and harsh environments.
Implementation Method 1
internal and external welding mechanisms with laser-based alignment
Implementation Method 2
a cooling system for precise alignment and inspection, as well as a method for internal cooling of pipes to facilitate faster temperature regulation
Data Source
AI summary
The present application relates to a field system and methods that can be deployed in the application of pipe welding. The field system provides many embodiments relating to pipe welding systems and methods, that can be used in combination with one another, or individually. Such welding systems and methods, include, for example, internal welding systems and methods, tie-in welding system and methods, pipe inspection systems and methods, pipe handling systems and methods, internal pipe cooling systems and methods, non-destructive testing systems and methods, as well as remote interface and database systems and methods (uLog), to name a few. The application further relates to welded pipes that result from some or all of such processes.