FIELD OF THE INVENTION

This invention relates to an alignment device. In particular, the invention relates to an alignment device for aligning the end walls of adjacent flexible pipes.

BACKGROUND OF THE INVENTION

The energy requirements of the world are increasing rapidly. Accordingly the consumption of natural resources is also increasing. As the majority of the population is located in cities and many natural resource deposits are located some distance from the cities, transportation of natural resources is often an issue. This is certainly the case with the oil and gas industry.

A popular way of transporting both oil and gas is through pipelines. Traditionally metal pipes have been used to produce oil and gas pipelines. However, the construction material of pipelines has changed in recent times to flexible pipelines made from plastic such as polyethylene. Flexible pipes have a lifespan which is comparable to metal pipping and is substantially quicker and easier to lay within the ground. This is due to both the machinery that is available to lay the flexible pipe and lengths of pipe that can be laid continuously.

One issue with flexible pipes is joining to the ends together of separate lengths of pipe. A conventional approach is to weld the ends together. This works very effectively when the end walls are aligned. Unfortunately, aligning the end walls is often difficult. The lengths of flexible pipe are often transported substantial distances on vehicles, they are left in storage yards in the weather and are generally are handled roughly. Subsequently, the end walls of the piping are often not circular. Therefore, when two end walls are placed together for welding, there is often misalignment between the two end walls. Accordingly, the surface area that is available for welding is reduced considerably. Misalignment of pipes often causes the welds joining the two lengths of flexible pipe to be inadequate and the welds must be redone at considerable labour cost. In a worst case scenario, the welds will fail during use causing a leak. A leak can result in both an environmental and economic disaster.

The reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

OBJECT OF THE INVENTION

It is the object of the invention to overcome or to alleviate one or more of the above disadvantages and/or provide the consumer with a useful or commercial choice.

SUMMARY OF THE INVENTION

In one form, although not necessarily the only or broadest form, the invention recites in an alignment device suitable for use with flexible piping, the alignment device comprising:

a ring;

a series of alignment members spaced around the ring;

wherein the alignment members are moveable with respect to the ring.

The ring may be formed from a ring body. The ring body may include one or more ring members. Normally there are two ring members. Preferably, the ring body is substantially hollow.

The ring body may include a series of alignment apertures. The number of alignment apertures may be equal to the number of alignment members. The alignment apertures may extend radially through the ring body. The alignment apertures may be threaded.

The ring body may be a complete ring or a partial ring. Normally the ring body includes a number of hinges to allow the ring body to be placed around a flexible pipe. Preferably there is a single hinge dividing the ring body into two halves.

A closure may be used to close and hold the ring body around the flexible pipe. The closure may be of any suitable form including a clamp, pin, clasp, latch or the like closure.

The alignment members may be moved mechanically or manually. One or more movement devices may be used to move the alignment members mechanically. For example, the alignment members may be moved mechanically using hydraulics or pneumatics or motors.

The alignment members are normally moved in a radial direction with respect to the ring. The alignment members may be moved with respect to the ring by rotation of an alignment member. Accordingly, each alignment member may include a threaded shaft. More preferably, the alignment member may be in the form of a bolt.

Each alignment member may include an attachment portion to assist in rotation of the bolt. The attachment portion may be in the form of a shaped head for engagement with a socket or spanner. Alternatively, the attachment portion may be in the form of an aperture which can be engaged by an Allen key or screw driver.

Alternatively, the alignment members may be rotated using one or more motors. The motor is normally an electric motor. However, the motor may also be a pneumatic or hydraulic motor. The motor may be attached to a one or more gears or cogs which engage with one or more alignment members. Normally there is a single motor for each alignment member.

Alternatively, the alignment members may be moved through the use of a fluid. The fluid may be a liquid or a gas. Normally, the alignment member is attached to or forms part of a ram. Suitably, the alignment member includes a piston of the ram. Accordingly, the ram is normally a hydraulic ram. Each alignment member may include a protective tip. The protective may be used to protect a pipe from damage when the alignment member engages with the pipe. The protective tip may be removable and replaceable.

Each alignment member may initially stop when each of the alignment members engage with a pipe. That is, the alignment members may initially stop when a predetermine force is applied to the alignment member. This force may be measured using a force determiner. The force determiner may be formed using a pressure sensor, strain gauge, pressure gauge or the like device. Each alignment member may have an associated force determiner.

The distance each alignment member is displaced from the ring may be measured. A displacement determiner may be used for this purpose. It should be appreciated that the displacement determiner may take many forms which would readily be appreciated by a person skilled in the art. For example, if the alignment member forms part of a hydraulic ram, the amount of fluid that is placed within or taken out of a cylinder of the ram may be used to calculate displacement of the alignment member. Similarly, if the alignment member is moved using a motor with an associated gear, the number of revolutions of the gear may be used to determine displacement. Alternatively, an optical sensor or ultrasonic sensor mounted to the ring may be used to determine displacement by measuring the distance between the ring and the pipe regardless of how the alignment member is moved.. Other methods of determining displacement would be appreciated by a person skilled in the art. Each alignment member may have an associated displacement determiner.

Each alignment member may be connected to a controller. The controller may control the operation of alignment members. Accordingly, the controller may both receive inputs and transmit outputs. The controller typically includes a processor to process the inputs and provide outputs. The controller may control the operation of the alignment members based on feedback provided by the displacement from the displacement determiner and/or the force from the force determiner. That is, the controller may be connected to both the displacement determiner and the force determiner.

The series of alignment members may be spaced equally around the ring.

In another form,. the invention resides in an alignment system suitable for use with flexible piping; the alignment system including:

two or more alignment devices, each alignment device including a ring and a series of alignment members spaced around the ring; the alignment members being moveable with respect to the ring; and

a controller connect to each of the alignment devices;

wherein the movement of each alignment device of the two or more alignment device is being controlled by the controller.

In another form, the invention resides in a method of aligning two end walls of adjacent flexible pipes, the method including the steps of:

moving alignment members located around on one or more of the pipes until the end walls of the adjacent pipes are in alignment.

The method may include one or more of the following steps: determining the displacement of one or more alignment members;

comparing the displacement of two or more alignment members on different alignment devices

moving one alignment member to match the displacement of another alignment member on a different alignment device.

Preferably, the alignment members are located around a respective ring.

The alignment members may be rotated to cause the alignment members to engage the pipe to move the end wall of a pipe. BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described with reference to the accompanying drawings:

FIG 1 is a side view of an alignment device according to a first embodiment of the embodiment of the invention.

FIG 2 is a perspective view of the alignment device of FIG 1 located around a pipe.

FIG. 3A is a front view of an alignment device according to a second embodiment of the invention;

FIG. 3B is a detailed view of an alignment member connected to a motor;

FIG. 4 is a perspective view of an alignment system that utilises two alignment devices shown in FIG 3A;

FIG. 5A to 5C is a side sectional view of the alignment device of FIG 3 in use;

FIG. 6 is a front view of an alignment device according to a third embodiment of the invention; and

FIG. 7 is a perspective view of an alignment system that utilises two alignment devices shown in FIG 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS 1 and 2 show an alignment device 10 that is used to align the end walls of two adjacent pipes 1 so that they can be effectively welded together. The alignment device 10 is formed from a ring 20 and a series of alignment members 30. It should be appreciated that the size of the ring 20 and the number of alignment members 30 may be varied according to the design.

The ring 20 is formed from a ring body 21. The ring body 21 is formed from two ring members 22 which are substantially acuate in shape. The two ring members 22 are interconnected by a series of jointer nuts 22. The jointer nuts 23 are connected to the ring members 22 by spot welds. Each of the joint nuts 23 includes an alignment aperture 24 that is threaded. The joiner nuts 23 are substantially equally spaced around the ring body 21.

A hinge 25 is used to divide the ring body 21 into two halves

21A and 21B. Accordingly, one half 21 A of the ring body 21 is able to pivot with respect to the other half 21 B of the ring body 21. A closure 26 is used to lock the two halves 21 A and 21 B of the ring body 21 together. The closure 26 is located opposite the hinge 25. The closure 26 is in the form of a pin 27 with a corresponding circiip 28. The pin 27 extends through pin hole 29 located within the ring members 22.

Each alignment member 30 is formed from a hex bolt 31 and a cap nut 32. The bolt 31 is a standard bolt having a threaded shaft 33 and a hexagonally shaped head 34. The hexagonally shaped head 34 forms an attachment portion of the alignment member 30 to aid in rotation of the bolt with a spanner. The cap nut 32 is located on the end of the threaded shaft 33 and provides a protective tip.

An alignment member 30 is attached to the ring body 21 by screwing the thread shaft 33 of the bolt 31 through the alignment aperture 24 in the jointer nut 22 of the ring body 21. The cap nut 32 is then located on the end of the threaded shaft 33 of the bolt 31. Accordingly, the alignment members 30 are equally spaced around the ring body 21

In use, two pipes (not shown) that are to be fused together are located in standard aligning clamps within a fusion machine. A minimum distance of 60-100 mm is allowed between the end of each of the pipes and the locking clamps. Both pipe ends are then faced. The pipes are brought together in the fusion machine to check for misalignment.

If misalignment is evident when the pipe ends are touching, the affected areas are marked. The pipe ends are then moved apart. The circiip 28 is then removed from the pin 27 and the pin 27 removed from the ring body 21 of the alignment device 10. The alignment device 10 is then located over one of the pipe ends by pivoting the two halves 11 A and 11 B of the ring body 21. The ring body 21 is then is closed by reinserting the pin 27 through the pin holes in the ring members 22 and reinserting the circlip 28 through the pin 27. It should be appreciated that a further alignment device 10 can be placed over the second pipe if this pipe also requires alignment.

All of the alignment members 30 are rotated by hand until they are finger tight against an exterior of the respective pipe. The pipe pieces are then brought back together. The alignment members 30 are rotated using a spanner until the misalignment of each pipe has been removed. Once the pipes are in alignment the pipe ends must again be refaced prior to calculating weld and drag pressures and ultimately performing the fusion weld.

FIG 3A and 3B shows a second embodiment of an alignment device. Two alignment devices are connected to form an alignment system shown in FIG 4. Like numerals have been used to describe like components.

Each alignment device 10 that forms part of the alignment system 100 is similar to the alignment device 10 described in FIG 1 and 2 except that the alignment members 30 are moved using electric motors 40. Each alignment member 40 of each alignment device is driven by an associated electric motor 40. Each electric motor 40 is mounted to the ring body 10 and drives threaded cogs 41 which engage with the thread shaft 33 of the alignment member 30 which passes through a threaded mount 42. Accordingly, rotation of the threaded cogs 41 causes subsequent rotation of associated shaft 33 causing the alignment device 30 to move inwardly or outwardly with respect to the ring body 21.

Each alignment member 30 of each alignment device 10 has an associated force determiner 70 in the form of a strain gauge which is measures the force that is applied to the alignment member 30. Each alignment member 30 of each alignment device 10 also includes a displacement determiner 80 in the form of rotary transducer that is used to determine the displacement of the alignment member 30 with respect to the ring body 21.

A controller 50 is connected to the alignment members 30 of each alignment device 10. The controller includes a processor 51 and memory 52. The controller controls 50 the operation of the alignment members 30 from both alignment devices. Specifically the controller is provided feedback from the force determiner and the displacement determiner to control movement of the alignment members 30.

In order to use the alignment system 100, the ring body 21 of each of the alignment device 10 is located adjacent respective pipe ends that are to be welded together, as described previously. The alignment devices 10 are positioned around their respective pipes so that the alignment members 30 are in the same angular position as shown in FIG 5A.

The controller provides an output to each of the motors 40 commence operation that rotates their respective threaded cogs 41 to move the alignment members toward the pipe 1 until the alignment members 30 contact the pipe 1 as shown in FIG 5B. When the alignment members contact the pipe 1 , the strain gauge will sense a substantial increase in strain. The increase in strain is fed back to the controller 50. The controller 50 then stops rotation of the electric motors and accordingly stops movement of the alignment members 30. The displacement of the alignment members with respect to the ring body 21 is determined by the controller 50.

The controller 50 then compares the displacement of a pair of alignment members (i.e. an alignment member 30 from each alignment device 10) that are at the same angular position around the pipe 1. If the displacement of each of the alignment members 30 is the same, then the pipes 1 are in alignment at that angular position. That is, the displacement of the alignment members 30 determines the alignment members 30 relative position and hence the position of the pipe 1. If the pair of alignment members are not are the same displacement, then the pipes are misaligned at that angular position as shown in FIG 5B. Accordingly, the controller rotates the alignment member 30 within the smallest relative displacement by activating the motors 40 until the displacement (and therefore position) is the same for both alignment members 30 as shown in FIG 5C. When the displacement for both of the alignment members 30 is the same, then the pipes 1 are in alignment. Once the pipes 1 are in alignment the pipe ends must again be refaced prior to calculating weld and drag pressures and ultimately performing the fusion weld.

It should be appreciated that the force determiner may be avoided by supplying a low power to the motors 40 so that when the alignment members 30 contact the pipe 1 , there is not sufficient force to continue to drive the alignment member 30. Increased power may be supplied to the alignment member 30 when the shafts need to be moved to the same position.

FIG. 6 and 7 show a third embodiment of an alignment device 10. Two alignment devices 10 are connected to form an alignment system 100. Again, like numerals are used to describe like components.

There In this embodiment the alignment members 30 on both alignment devices 10 are in the form of a piston. Each alignment member 30 is located within a cylinder 61 which forms part of a hydraulic ram 60. Each alignment member of each alignment device is driven by hydraulic fluid that is provided by a hydraulic pump/motor (not shown) via associated hydraulic valves (not shown). Movement of fluid into and out of the cylinder causes reciprocation of the alignment member 30.

Each alignment member 30 of each alignment device 10 has an associated force determiner 80 in the form of a pressure sensor which measures the pressure that is applied to the alignment member 30. Each alignment member of each alignment device also includes a displacement determiner 70 in the form of linear transducer that is used to determine the displacement of the alignment member with respect to the cylinder 61 and accordingly the ring body 21.

A controller 50 is connected to the alignment members 30 of each alignment device 10. The controller 50 includes a processor 51 and a memory 52. The controller 50 controls the operation of the alignment members 10 from both alignment devices 10. Specifically the controller is provided feedback from the force determiner and the displacement determiner to control movement of the alignment members 30.

In order to use the alignment system 100, the ring body 21 of each of the alignment device is located adjacent respective pipe ends that are to be welded together, as previously described. The alignment devices 10 are positioned around their respective pipes so that the alignment members 30 are in the same angular position.

The controller 50 provides an output to the hydraulic valves to permit the transfer of hydraulic fluid into respective cylinders 61 to drive the alignment members 30 forward to meet contact the pipe 1. When the alignment members 30 contact the pipe 1 , the pressure sensor will sense a substantial increase in pressure. The increase in pressure is fed back to the controller 50. The controller 50 then stops fluid being feed into the cylinders 61 via the valves and accordingly stops movement of the alignment members 30. The displacement of the alignment members 30 with respect to the cylinder is measured by linear transducer and fed back to the controller 50.

The controller 50 then compares the displacement of a pair of alignment members 30 (i.e. an alignment member from each alignment device) that are at the same angular position around the pipe. If the displacement of each of the alignment members 30 is the same, then the pipes are in alignment at that angular position. That is, the displacement of the alignment members determines the alignment members 30 relative position and hence the position of the pipe 1. If the pair of alignment members 30 are not are the same displacement, then the pipes 1 are misaligned at that angular position. Accordingly, the controller 50 extends the alignment member within the smallest relative displacement by moving respective values to supply fluid to the cylinder 61 until the displacement (and therefore position) is the same for both alignment members 30. When the displacement for both of the alignment members is the same, then the pipes 1 are in alignment. Once the pipes 1 are in alignment the pipe ends must again be refaced prior to calculating weld and drag pressures and ultimately performing the fusion weld.

It should be appreciated that a person skilled would readily be able to design a hydraulic circuit to perform individual movement of the alignment members as described. It would also be appreciated that individual pumps/motors may be associated with each hydraulic ram if desired.

It should be appreciated that the force determiner may be avoided by supplying a low pressure hydraulic fluid so that when the alignment member contacts the pipe, there is not sufficient force to continue to extend the alignment. Increased pressure may be supplied to the hydraulic fluid when the alignment members need to be moved to the same position.

It should be appreciated that the control of the alignment system and a processing unit of a fast fusion welding machine may the same controller. Therefore, the fast fusion welding machine could also automatically align the pipes as well as welding the pipes.

It should be appreciated that various other changes and modifications may be made to the embodiments described without departing form the scope of the invention.

In the present specification and claims (if any), the word "comprising'' and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers unless the context of use indicates otherwise.