Support Ring Grounding Extension for Subsea Pipeline Welding
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Solution Overview
Problem
The subsea pipeline welding process is bottlenecked by the sequential and time-consuming steps of welding, testing, and coating, particularly due to limitations in the number of welding rings that can be used simultaneously, and variations in cut-back zones complicating grounding and coating operations.
Innovation Solution
A support ring system that allows for the mounting of additional welding rings and effective grounding, featuring a tubular body with offset grounding extensions to accommodate multiple welding bugs without enlarging the cut-back zones, ensuring reliable electrical connections and efficient welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple welding rings are used simultaneously to increase welding speed, then productivity improves, but device complexity increases due to the need for additional support structures and grounding systems
Solution Approach 1:
The support ring serves multiple functions simultaneously: it provides structural support for the welding ring, establishes electrical grounding connections, and maintains proper positioning. This multi-functionality allows multiple welding rings to operate concurrently without requiring separate complex systems for each function, thereby increasing productivity while controlling device complexity.
Solution Approach 2:
The support ring system is divided into modular components including the tubular body, grounding extensions, and connection elements. This segmentation allows the system to be scaled by adding or removing modules, enabling multiple welding rings to be supported simultaneously while maintaining manageable complexity through standardized, replaceable parts.
2Ease of operation
If the cut-back zone is enlarged to accommodate grounding extensions, then ease of operation improves for welding setup, but loss of substance increases due to more coating material being removed
Solution Approach 1:
The grounding extensions are positioned radially outward from the tubular body in a direction perpendicular to the pipe axis, utilizing the radial dimension rather than requiring additional axial length. This dimensional arrangement allows grounding connections to be made without enlarging the cut-back zone axially, maintaining ease of operation while minimizing coating material loss.
3Reliability
If sequential welding, testing, and coating operations are performed to ensure quality, then reliability improves, but loss of time increases due to the sequential nature of operations
Solution Approach 1:
Multiple welding rings can operate simultaneously on different pipe sections, creating continuous welding action rather than sequential operations. The support ring system enables this parallel processing while maintaining quality control, thereby reducing total fabrication time without sacrificing weld reliability.
Solution Approach 2:
The support rings and grounding extensions are pre-installed on pipe sections before welding begins. This preliminary preparation ensures that electrical connections and positioning are already in place, allowing welding operations to proceed immediately without setup delays, thus maintaining reliability while reducing overall fabrication time.
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 solution doubles the number of welding rings that can operate simultaneously, significantly increasing welding speed without prolonging the field joint coating process, thus optimizing pipeline fabrication and installation efficiency.
Implementation Method 1
a tubular body with substantially circular curvature around a longitudinal axis to support the welding ring
Implementation Method 2
at least one grounding extension connected to the body; wherein the or each grounding extension is offset longitudinally with respect to the body, and radially outwardly along or with respect to the body and the longitudinal axis
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A support ring (42) supports a welding ring (52) to guide welding bugs around a coated pipe section. The support ring (42) has a tubular body (44) to support the welding ring (52), the body (44) having substantially circular curvature around a longitudinal axis. At least one grounding extension (62) connected to the body (44) is offset longitudinally and radially outwardly with respect to the body (44) and the longitudinal axis. This allows the grounding extension (62) to lie radially outboard of a parent coating (32) of the pipe section while the body (44) encircles a cut-back end zone (40) where the parent coating (32) has been cut back. Pipe sections abutting end-to-end for welding may each be fitted with these support rings (42). This enables welding rings (52) to encircle both of the cut-back end zones (40) and allows effective grounding connections to be made without enlarging the cut-back end zones (40).