FIELD OF THE INVENTION

The present invention relates to a cooling apparatus, and in particular, but not exclusively, to a cooling apparatus for cooling a weld region between two components.

BACKGROUND TO THE INVENTION

Welding is used in many applications, usually to join two or more metal components together, and is typically initiated by heating the components, or a filler material, to relatively high temperatures, for example by electrical heating, friction heating, heating via a heat source, such as a flame, or the like. In many cases the weld region must be cooled in a controlled manner following the welding process in order to achieve a desired microstructure at the weld region, for example to obtain required material properties, such as mechanical properties, corrosion properties or the like.

It is known in the art to cool a weld region by use of a cooling fluid, such as quenching using water or oil or the like. This may be satisfactory where the welded components can be easily manipulated to be immersed within a cooling fluid, or where the working environment can accommodate dousing or soaking of the components and weld region with cooling fluid. However, in many cases the size of the components prohibits immersion in a cooling fluid, and the working environment may need to be kept free of any contaminants such that dousing the welded components and surrounding region is not desired.

For example, the present applicant has proposed a system for welding tubulars together, specifically casing tubulars for use in a drilled wellbore. The typical size of wellbore tubulars eliminates the possibility of immersion within a cooling fluid. Additionally, the applicant's proposed welding system includes a weld chamber within which the tubulars are welded together. The weld chamber is configured to permit a controlled, clean and dry environment to be established for each welding process such that the use of a cooling fluid, such as water or oil, within the chamber is not desirable. Furthermore, the welding system is typically used in environments which must adhere to strict health and safety regulations, such as offshore platforms, and as such the risk of explosion or fire must be minimised. This further makes the use of certain cooling fluids, such as oil, undesirable.

Controlled cooling of materials, such as metals, is also known for use in heat treating a material which has not necessarily been subject to welding. For example, it is known in the art to establish particular material properties by heating the material to a desired temperature and then cooling at a desired rate. For example, a quenching process may be desired in which metal is heated and rapidly cooled to provide a required hardness. Additionally, an annealing process may be required in which metal is heated and then slowly cooled to increase softness, toughness and ductility while removing internal stresses. In a similar manner as discussed above in relation to cooling of welded regions, there may be occasions in heat treatment of materials where use of conventional cooling techniques using cooling fluids is not desirable or possible. SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a cooling apparatus for cooling a heated region of an object, said apparatus comprising at least one heat sink member configured to selectively engage a heated region of an object to effect cooling thereof.

In use, the at least one heat sink member may be selectively engaged with the heated region to conduct heat therefrom to thus effect a reduction in temperature, while avoiding problems associated with, for example, direct cooling using a cooling fluid. The at least one heat sink member may be selectively engaged with an object to be cooled by relative movement of said at least one heat sink member and object.

The at least one heat sink member may be moveable to effect selective engagement with the object. Alternatively, or additionally, the object may be moved towards the at least one heat sink member to effect engagement therewith.

The apparatus may be configured for use with objects of any configuration or shape. In one arrangement the apparatus may be configured for use with cylindrical objects, such as tubular objects. In this arrangement at least one heat sink member may be configured to engage the outer surface of a tubular object. Alternatively, or additionally, at least one heat sink member may be configured to engage an inner surface of a tubular object.

At least one heat sink member may comprise a solid material. The solid material may be selected to have a high thermal conductivity, and may comprise a metal or metal alloy, such as copper, aluminium, brass or the like.

At least one heat sink member may be inflatable. In this arrangement the at least one heat sink member may comprise a solid member, which may be flexible, articulated, elastic or the like, configured to define a cavity arranged to be filled with an inflating medium. The inflating medium may comprise a solid, such as solid particles, a liquid and/or a gas. The inflating medium may be selected to contribute to absorbing heat from a heated region of an object. For example, the inflating medium may be selected to have a high thermal conductivity. Selective inflation/deflation of the at least one heat sink member may permit selective engagement of the heated region of the object to be cooled.

The apparatus may comprise a single heat sink member.

Alternatively, the apparatus may comprise a plurality of heat sink members.

The plurality of heat sink members may be adapted to engage or accommodate a required object surface area and/or surface configuration or shape. The plurality of heat sink members may be arranged in a configuration to correspond to a peripheral shape of an object to be cooled. In one arrangement the plurality of heat sink members may be arranged in a generally annular configuration. This may permit the apparatus to be used with cylindrical objects, such as tubular objects.

The apparatus may be configured such that the collective orientation of the plurality of heat sink members is adjustable to accommodate different objects with different geometries. For example, the plurality of heat sink members may be arranged to accommodate a cylindrical object, and then altered to accommodate a square, rectangular, plate object or the like.

A clearance gap may be defined between at least two adjacent heat sink members. The clearance gap may be selected in accordance with the required cooling properties of the apparatus. The clearance gap may be adjustable.

Adjustment of the clearance gap may permit the cooling properties of the apparatus to be modified.

At least two adjacent heat sink members may be in intimate engagement, such that no clearance gap exists.

The plurality of heat sink members may be configured to be independently selectively engaged with an object to be cooled. This arrangement may permit control of the cooling properties of the apparatus to be achieved.

The apparatus may comprise a support arrangement configured to support the at least one heat sink member. The support arrangement may comprise a frame.

The support arrangement may be configured or configurable to orientate the at least one heat sink member to accommodate the geometry of an object to be cooled. The support arrangement may comprise a generally annular frame. The support arrangement may be provided as a complete component. The support arrangement may comprise separable portions. This may permit portions of the support arrangement to be separated to accommodate an object to be cooled, for example to allow the support arrangement to be positioned as required relative to the object. The support arrangement may be configured to accommodate movement of the at least one heat sink member. The support arrangement may be configured to accommodate movement of the at least one heat sink member in a predefined direction, for example in a direction to permit the at least one heat sink member to engage/disengage an object to be cooled. The support arrangement may comprise one or more slots, channels, rails, detents, tracks or the like configured to permit selective or predefined movement of the at least one heat sink member.

The at least one heat sink member may be adapted to be moved between an extended configuration for engagement with an object to be cooled, and a retracted configuration to disengage the object. The at least one heat sink member may be biased towards the retracted configuration and moved against this bias towards the extended configuration.

The apparatus may comprise an actuation arrangement configured to permit selective engagement of the at least one heat sink member with an object to be cooled. The actuation arrangement may be configured to move the at least one heat sink member into engagement with an object to be cooled. Alternatively, or additionally, the actuation arrangement may be configured to move the at least one heat sink member out of engagement with an object to be cooled. The actuation arrangement may be utilised to selectively engage one or more heat sink members with an object to be cooled in a desired manner to achieve a required cooling profile.

The actuation arrangement may be configured to be operated hydraulically, pneumatically, mechanically or the like, or any suitable combination thereof.

The actuation arrangement may comprise at least one actuation assembly. A single actuation assembly may be associated with a single heat sink member. Alternatively, a single actuation assembly may be associated with a plurality of heat sink members.

At least one actuation assembly may comprise a piston assembly, gear, chain or belt drive assembly, solenoid assembly, cam assembly or the like. In one embodiment at least one actuation assembly may comprise an inflatable structure configured to be inflated to displace at least one heat sink member. The inflatable structure may be configured to be inflated with a gas, such as air, nitrogen or the like. The inflatable structure may be inflated with a liquid, such as oil, water or the like. The inflatable structure may comprise a flexible material, elastic material or the like.

The inflatable structure may comprise an elastomer, such as natural rubber, synthetic rubber or the like.

The actuation assembly may be configured to be located between at least one heat sink member and a support arrangement for said member.

The apparatus may comprise a cooling arrangement configured to cool at least one heat sink member. The cooling arrangement may comprise a fluid cooling arrangement, wherein at least one heat sink member is configured to be exposed to a fluid coolant. The fluid coolant may comprise a gas, such as air or the like. The fluid coolant may comprise a liquid, such as water, oil or the like.

The cooling arrangement may comprise a conduit associated with at least one heat sink member, wherein the conduit is configured to receive a fluid coolant therein. The conduit may be provided internally of the at least one heat sink member. A plurality of conduits may be provided to increase heat transfer between the fluid coolant and the heat sink member. Alternatively, a single conduit may be provided. The conduit may define a circuitous or winding path, such as a serpentine path, to increase the heat transfer between the fluid coolant and the heat sink member. The conduit may comprise one or more turbulence inducing elements configured to establish turbulence within the cooling fluid to increase the rate of heat transfer. The turbulence inducing elements may comprise ribs, fins or the like.

The cooling arrangement may be configured to circulate a fluid coolant through the conduit, for example via a pump.

The cooling arrangement may comprise a cooling circuit, wherein the conduit associated with the at least one heat sink member forms part of said cooling circuit. The cooling circuit may comprise a plurality of conduits associated with respective heat sink members. In this arrangement the plurality of conduits may be arranged in series or parallel, or a combination of both. The cooling circuit may comprise a heat exchanger configured to cool the fluid coolant.

The cooling arrangement may comprise an air cooling arrangement, such as a fan cooling arrangement.

The at least one heat sink member may comprise a contact surface configured to contact an object to be cooled. The texture of the contact surface may be selected in accordance with the required cooling properties of the at least one heat sink member. The contact surface may comprise a smooth surface. The contact surface may comprise a rough surface, such as a textured surface. The textured surface may be defined by a surface pattern.

The contact surface may be formed to correspond to a surface region of an object to be cooled. For example, in an exemplary use of the apparatus with a cylindrical member, the contact surface may be generally arcuate or curved.

The apparatus may be configured for use in heat treating an object. For example, the apparatus may be configured for cooling a heated region of an object in a desired manner to achieve particular material properties within the object.

The apparatus may be configured for use in cooling a weld region of an object. For example, the apparatus may be configured for cooling a weld region of an object following a welding process, such as a forge welding process or the like. In this arrangement the object to be cooled may comprise first and second components defining a weld region therebetween.

The apparatus may be configured for use with wellbore tubulars, such as casing tubulars, liner tubulars or the like.

The apparatus may be provided in combination with a welding apparatus, such as a forge welding apparatus. According to a second aspect of the present invention there is provided a method of cooling a heated region of an object, comprising selectively engaging at least one heat sink member with the heated region of the object to effect cooling thereof.

The method may comprise the use of the apparatus according to the first aspect.

The method may comprise selectively engaging a plurality of heat sink members with the object.

The method may comprise arranging a plurality of heat sink members around the periphery of an object to be cooled, and then engaging one or more of the arranged heat sink members with the object.

The method may comprise operating an actuation arrangement to selectively engage the at least on heat sink member with the object to be cooled. The actuation arrangement may comprise an inflatable structure, wherein the method comprises selectively inflating/deflating the inflatable structure to move the at least one heat sink member.

The method may comprise cooling the at least one heat sink member.

Cooling may be achieved by a fluid cooling arrangement, wherein at least one heat sink member is configured to be exposed to a fluid coolant. The fluid coolant may comprise a gas, such as air or the like. The fluid coolant may comprise a liquid, such as water, oil or the like.

The cooling arrangement may comprise a conduit associated with at least one heat sink member, wherein the conduit is configured to receive a fluid coolant therein. The conduit may be provided internally of the at least one heat sink member.

The method may comprise circulating fluid coolant through the at least one heat sink member. The method may be configured for use in heat treating an object. For example, the method may be configured for cooling a heated region of an object in a desired manner to achieve particular material properties within the object.

The method may be configured for use in cooling a weld region of an object. For example, the method may be configured for cooling a weld region of an object following a welding process, such as a forge welding process or the like. In this arrangement the object to be cooled may comprise first and second components defining a weld region therebetween.

The method may be performed as part of a welding process.

According to a third aspect of the present invention there is provided a welding apparatus comprising:

a welding assembly configured to weld a first component to a second component to form a welded object; and

a cooling assembly comprising at least one heat sink member configured to selectively engage a weld region of the welded object to effect cooling thereof.

The cooling assembly may be configured in accordance with the apparatus according to the first aspect.

The welding assembly may comprise a heating arrangement configured to heat the first and second components for welding. The heating arrangement may comprise a heat source, such as a chemical heat source, flame heat source, electrical heat source or the like. The heating arrangement may comprise an electrical heating arrangement.

The welding assembly may comprise a weld chamber configured to accommodate welding therein. The cooling assembly may be located with the weld chamber.

The weld chamber may be configured to define a dry environment.

The weld chamber may be configured to provide a sealed environment around the region of the weld between the first and second components. According to a fourth aspect of the present invention there is provided a method of welding a first component to a second component, comprising:

heating at least one of the first and second components;

welding said first and second components together to define a welded object; and

selectively engaging at least one heat sink member with a welded region of the object to effect cooling thereof.

The method may comprise the use of the apparatus according to the first aspect.

According to a fifth aspect of the present invention there is provided a heat treatment apparatus comprising:

a heating assembly configured to heat an object; and

a cooling assembly comprising at least one heat sink member configured to selectively engage a heated region of the object to effect cooling thereof.

The cooling assembly may be configured in accordance with the apparatus according to the first aspect.

According to a sixth aspect of the present invention there is provided a method of heat treating an object, comprising.

heating an object; and

selectively engaging at least one heat sink member with a heated region of the object to effect cooling thereof.

The method may comprise the use of the apparatus according to the first aspect. BRIEF DESCRIPTION OF THE DRAWINGS

These and other aspects of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a diagrammatic representation of an assembly for welding together first and second casing tubulars, wherein the assembly incorporates a cooling apparatus in accordance with an embodiment of the present invention; and

Figure 2 is an enlarged diagrammatic view of the cooling apparatus of Figure 1.

DETAILED DESCRIPTION OF THE DRAWINGS

A welding apparatus, generally identified by reference numeral 10, is diagrammatically shown in Figure 1. The welding apparatus 10 is provided as an exemplary embodiment of at least one aspect of the present invention. The welding apparatus 10 is configured for forge welding together first and second casing tubulars 12, 14 to form a single object having a weld region 16. The tubulars 12, 14 are shown in Figure 1 welded together.

The welding apparatus 10 includes an enclosure 18 which establishes a sealed cavity or chamber 20 around the weld region 16 via seals 22. The sealed cavity may permit a particular environment to be established during the weld process, such as a vacuum. The welding apparatus 10 further comprises an electrical heating arrangement 24 which in use drives an electrical current through the end regions of the tubulars 12, 14 in order to generate heat for welding, following which the tubulars 12, 14 are axially driven together to forge the ends together. The heating arrangement 24 is shown in a retracted configuration within the weld chamber 20.

The welding apparatus 10 further includes a cooling apparatus 26, in accordance with an exemplary embodiment of the present invention, which is shown in Figure 1 engaged with the weld region 16 of the tubulars 16 to effect cooling thereof following the forge welding process. An enlarged diagrammatic view of the cooling apparatus 26 is shown in Figure 2, reference to which is now made.

The cooling apparatus 26 comprises a plurality of metal heat sink members 28 (only 2 shown) mounted within an annular support frame 30 to be peripherally arranged and distributed around the weld region 16 of the tubulars 12, 14. As will be described in further detail below, each heat sink members 28 is adapted to be radially moved between a retracted position, as shown in Figure 2, and an extended position to engage the weld region 16 to conduct heat therefrom. The heat sink members 28 are conveniently formed of a metal or metal alloy such as copper, aluminium, brass or the like, or other material which exhibits a relatively high thermal conductivity.

Each heat sink member 28 comprises a pair of mounting pins 32 located in respective elongate slots 34 which are aligned in a radial direction such that displacement of the pins 32 within the slots 34 permits the heat sink members to be moved between retracted and extended positions. In the embodiment shown the cooling apparatus 10 is arranged to bias the heat sink member 28 towards their retracted positions by use of springs 36.

The cooling apparatus 26 further comprises an actuation arrangement 38 configured to displace the heat sink members 28 towards their extended positions against the bias of the springs 36. In the embodiment shown the actuation arrangement 38 comprises an actuation assembly in the form of an inflatable annular tube 40 positioned between the support frame 30 and each heat sink member 28, such that inflation of the tube 40 displaces the members 28 into engagement with the weld region 16. Release of pressure within the tube 40 will permit the heat sink members 28 to return to their retracted positions by action of the springs 36.

Each heat sink member 28 defines an internal conduit 42 configured to accommodate flow of a cooling medium, such as oil or water therethrough in the direction of arrows 44. This will assist in increasing and providing more accurate control of the cooling effect of the cooling apparatus 26.

A brief description of an exemplary welding and cooling process will now be described with reference to both Figures 1 and 2. The first and second tubular members 12, 14 may be initially axially aligned and the enclosure 18 closed to enclose the weld region 16 within the weld chamber 20, as shown in Figure 1. A preferred environment may be established within the weld chamber 20, such as a vacuum. The weld region 16 may then be heated, using the electrical heating arrangement 24, to a desired weld temperature, following which the tubulars 12, 14 may be forged together. The heating arrangement 24 may then be retracted and the cooling apparatus 26 peripherally aligned with the weld region 16. Inflation of the tube 40 will displace the heat sink members 28 to engage the weld region to conduct heat therefrom and thus effect cooling. Cooling may be assisted, or controlled by circulating cooling fluid through the conduits 42. Once sufficient cooling has been achieved the cooling apparatus 26 may be retracted and the enclosure opened to accommodate a further welding process. The further welding process may comprise welding a further tubular to the first and second tubulars 12 to establish a tubing string.

The cooling effect of the cooling apparatus 26 may be controlled, altered, determined or affected in a number of ways. For example, the contact pressure of the heat sink members may be altered by controlling inflation of the tube 40. Also, the distance between each heat sink member 28 may be selected or modified in accordance with a desired cooling effect. Further, the size of the heat sink members 28 may be selected according to the required cooling effect. Additionally, the flow rate and/or inlet temperature of the cooling fluid through the conduits 42 may be selected or modified to provide a desired cooling effect. Also, the contact surface properties, such as surface pattern, roughness or the like may be selected or modified to provide required cooling properties.

It should be understood that the embodiments described herein are merely exemplary and that various modifications may be made thereto without departing from the scope of the invention. For example, the heat sink members may be arranged or orientated in any desired manner to accommodate the shape of the object to be cooled. Additionally, each heat sink member may be mounted within the frame in any desired manner, and is not limited to a pin and slot arrangement. For example, one or more of the heat sink members may be mounted such that movement may be permitted in alternative directions, in addition to, or alternatively of a radial direction. Furthermore, the cooling apparatus used within the weld chamber may also be used for general heat treatment of objects that have not necessarily been subject to welding. For example, the cooling apparatus may be used in a quenching process, annealing process or the like.