Technical Field

[0001 ] The present invention generally relates to crossing an obstruction whilst laying composite pipe.

Background Art

[0002] When laying pipes in the ground, there can be a need to cross other pipe networks, roadways and other obstructions is common. When crossing other pipe networks the convention is that a new pipe must lie below the existing pipes. When crossing ground level obstructions, such as roadways, the new pipe is also generally laid below the road.

[0003] Where conventional sectional pipes are used, angled sections can be included to bring the relevant portions of the sectional pipe below the existing pipes. This requires additional angled sections and a plurality of joins between angled sections pipe sections leading up to and away from the obstruction and the length of pipe that extends below the obstruction. This adds additional sections of pipe and requires additional labour to join the different pipe sections together.

[0004] A recent development in pipe production in relation to the formation and laying of a uniform composite pipe is disclosed in WO 12/054992 {Graham) and is known as "Long Pipes", the contents of which are incorporated herein by way of reference. Graham describes the construction and laying of a composite pipe in a continuous process so that the pipe can be formed and laid in position in one continuous process.

[0005] A shortcoming of the laying of long pipes according to Graham is that when an obstruction is encountered in the proposed path of the long pipe, the long pipe cannot be continuously laid. Laying of the long pipe must be stopped, the obstruction traversed and then the laying of the long pipe is resumed.

[0006] The preceding discussion of the background art is intended to facilitate an understanding of the present invention only. The discussion is not an acknowledgement or admission that any of the material referred to is or was part of the common general knowledge as at the priority date of the application. Summary of Invention

[0007] It is an object of this invention to ameliorate, mitigate or overcome, at least one disadvantage of the prior art, or which will at least provide the public with a practical choice.

[0008] The present invention provides a system for directing composite pipe around an obstruction during formation of the pipe, wherein:

a passageway is formed to one side of and beyond the obstruction, the composite pipe is sealed part way along its length with a first sealing means prior to reaching the obstruction so as to leave a sealed section of pipe prior to the obstruction and a length of flexible sock with an end; and

wherein the length of flexible sock is adapted to pass under and beyond the obstruction; and

wherein a pulling means is connected to the end of the flexible sock and passed along the passageway beyond the obstruction; and

wherein the pulling means pulls the flexible sock along the passageway beyond the obstruction so that further formation of the pipe may be continued from the end.

[0009] This allows the composite pipe to be laid up to an obstruction. The first sealing means allows the section of the pipe beyond the first sealing means to be flexible and easily manipulated so that it can be directed along the preformed passageway beyond the obstruction and then is continued to be formed further.

[0010] Preferably the passageway is formed under the obstruction.

[001 1 ] Preferably the composite pipe is inflated prior to the first sealing means.

[0012] Preferably the composite pipe becomes rigid after it is inflated.

[0013] This allows the composite pipe to be left in a condition to become rigid in the position prior to the first sealing means.

[0014] Preferably the sealing means is a clamp.

[0015] Preferably a second length of flexible sock is joined to the end to allow the further formation of the pipe.

[0016] Preferably the second length of sock is located in a container. [0017] Preferable the second length of flexible sock is spliced to the end.

[0018] Preferable the second length of flexible sock is welded to the end.

[0019] Preferably, the second length of flexible sock is spliced to the flexible sock proximate the end.

[0020] Preferably, the second length of flexible sock is welded to the flexible sock proximate the end.

[0021 ] Preferably, the flexible sock is uninflated. [0022] Preferably, the flexible sock is partially inflated.

[0023] Preferably, the length of flexible sock is adapted to extend 8 metres beyond the obstruction.

[0024] Preferably, when the flexible sock is extended by 8 metres it is clamped and partially inflated to ensure that resin within the flexible sock is fully wetted out.

[0025] Preferably, only the end of the flexible sock is partially inflated.

[0026] This provides ample length of flexible sock to pass beyond the obstruction, be lifted above ground and to be joined/spliced to the second pipe section to continue the continuous formation and laying of the pipe. The second pipe section can be located in a container.

[0027] Preferably, the length of flexible sock is adapted to extend less than 5 metres beyond the obstruction.

[0028] Preferably, the length of flexible sock is adapted to extend more than 5 metres beyond the obstruction.

[0029] Preferably, the composite pipe is laid below ground.

[0030] Preferably, a second sealing means is placed on the flexible sock in the portion of the flexible past the first sealing means towards the end, wherein resin is placed in the sock between the first sealing means and the second sealing means. [0031 ] This allows the region between the two sealing means to maintain flexibility but to be primed with resin ready to be placed into a pipe profile and set.

[0032] Preferably the second sealing means is a clamp.

[0033] Preferably the second sealing means is located along the flexible sock so that it extends beyond the obstruction.

[0034] Preferably, the first sealing means is removed when the sock has been pulled beyond the obstruction, a second sock section is spliced/joined to the end of the first sock section to become part of the first sock section and continues the formation of the pipe extend the composite pipe.

[0035] Preferably, once the second sealing means has been removed, resin is fed into the region beyond the second sealing means.

[0036] This primes the section of the sock that did not include resin ready to be expanded and set into a pipe structure.

[0037] Preferably, once the second sealing means has been removed the sock is inflated so that the resin fills the sock.

[0038] Preferably the resin is inserted into the sock at a compression device.

[0039] Preferably, once the sock inflates the resin sets so that the sock becomes part of the rigid composite pipe.

[0040] This continues the formation of the pipe beyond the obstruction.

[0041 ] Preferably the passageway is a trench.

[0042] Preferably the obstruction is a conduit.

[0043] Preferably the conduit runs across the composite pipe.

[0044] Preferably the obstruction is a road.

[0045] Preferably the road runs across the composite pipe.

[0046] In a further embodiment of the present invention, there is provided a method of directing a composite pipe around an obstruction during formation of the pipe, wherein: a passageway is formed under and beyond the obstruction, the composite pipe is sealed part way along its length with a first sealing means prior to reaching the obstruction so as to leave a sealed section of pipe prior to the obstruction and a length of flexible sock with an end; and

wherein a pulling means is fitted to the end of the flexible sock once the passageway is formed and the pulling means is passed along the passageway to a point beyond the obstruction; and

wherein the pulling means is used to pull the flexible sock along the passageway beyond the obstruction once it is fitted to the end of the flexible sock so that further formation of the pipe may be continued from the end.

[0047] In yet a further embodiment of the present invention, there is provided a composite pipe formed according to the method.

[0048] In yet a further embodiment of the present invention, there is provided a composite pipe formed according to the system.

Brief Description of the Drawings

[0049] Further features of the present invention are more fully described in the following description of several non-limiting embodiments thereof. This description is included solely for the purposes of exemplifying the present invention. It should not be understood as a restriction on the broad summary, disclosure or description of the invention as set out above. The description will be made with reference to the accompanying drawings in which:

Figure 1 is a plan view of the equipment used in a method of directing a composite pipe according to the present invention;

Figure 2 is a perspective view of a composite pipe lying under an existing pipe crossing laid according to a first method of the present invention;

Figure 2a is a top down view of the composite pipe of Figure 2;

Figure 2b is a side on view of the composite pipe of Figure 2;

Figure 3 is a plan view of a composite pipe being laid in accordance with an embodiment of the present invention; Figure 4 is a side view of a composite pipe used in a method of the present invention compressed and unfilled with resin;

Figure 4a is a side view of a composite pipe used in a method of the present invention curved and unfilled with resin

Figure 5 is a side vies of a composite pipe used in a method of the present invention compressed and filled with resin;

Figure 6 is a side view of a clamp used in a method of laying a composite pipe according to the present invention;

Figure 7 is a side view of a composite pipe used in a method of the present invention filled with resin and expanded;

Figure 8 is a plan view of a composite pipe being laid using the method by which the composite pipe of Figure 2 was laid;

Figure 9 is a plan view of a composite pipe being laid using the method by which the composite pipe of Figure 2 was laid;

Figure 10 is a plan view of a sealing means for sealing the composite pipe used in a method of the present invention;

Figure 1 1 is a plan view of a composite pipe being laid using the method by which the composite pipe of Figure 2 was laid;

Figure 12 is a plan view of a composite pipe being laid using the method by which the composite pipe of Figure 2 was laid;

Figure 13 is a plan view of a composite pipe being laid using the method by which the composite pipe of Figure 2 was laid;

Figure 14 is a plan view of a composite pipe laid according to a second embodiment of the present invention;

Figure 15 is a plan view of a composite pipe being laid according to the method by which the composite pipe of Figure 14 was laid; and Figure 16 a plan view of a composite pipe being laid according to the method by which the composite pipe of Figure 14 was laid.

[0050] In the drawings like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.

Description of Embodiments

[0051 ] Referring to Figures 1 to 15, the invention is in the form of a system/method for crossing an obstruction when laying composite pipe 1 1 that forms a unitary pipe, where the composite pipe 1 1 is formed during laying of the pipe.

[0052] The composite pipe 1 1 is formed leading up to an obstruction in the form of a cross-lying pipe 21 by using the method of WO 12/054992. The formation of the composite pipe 1 1 in a continuous manner is achieved through the filling of uninflated composite pipe 1 1 with resin, inflating the uninflated sock section and letting it set. Sections of the uninflated sock are spliced together as the pipe is being formed so that the composite pipe 1 1 is continuously formed.

[0053] In one embodiment, the uninflated composite pipe 1 1 is injected with resin at the location of compression apparatus 31 .

[0054] In an alternative embodiment the uninflated socks are joined together through a method other than splicing, such as welding or otherwise as understood by the skilled addressee.

[0055] As the composite pipe 1 1 is formed in this manner it can be laid into a trench leading up to an obstruction, such as a cross-lying pipe 21 or road 47. The trench extends as a passageway 23 under the obstruction and continues away from the obstruction as a trench. The composite pipe is sealed off with a sealing means leading up to the cross obstruction to leave an uninflated sock section 13 that is capable of extending beyond the obstruction by a sufficient length so that it can be spliced to a second sock section 17 beyond the obstruction, and the composite pipe 1 1 can be continued to be formed in accordance with Graham's Long Pipes pipe formation.

[0056] When the sealing means has been placed on the composite pipe 1 1 , the uninflated sock section 13 has a cap 25 fitted to its end 14. With the cap 25 in place a pulling means is threaded through the passageway 23, along the trench and connected to the cap 25. When connected to the cap 25, the pulling means then pulls the uninflated sock section 13 along the trench, through the passageway 23 and beyond the obstruction.

[0057] When the uninflated sock section 13 is beyond the obstruction, it is partially filled with resin and spliced to the second sock section 17. The remainder of the uninflated sock section 13 and the second sock section 17 are drawn through the compression apparatus 31 and filled with resin as they pass through the compression apparatus and they are progressively inflated and set so that the composite pipe 1 1 can continue to be formed and laid in accordance with Graham's Long Pipes.

[0058] In one embodiment the resin is injected into the uninflated sock section 13 approximately 1 m before it enters the compression apparatus 31 .

[0059] Following are specific embodiments of the system/method of this invention with reference to the accompanying drawings.

[0060] Referring to Figure 1 , as the composite pipe 1 1 is formed and laid out of container 20 approaching an obstruction, a first sealing means in the form of a clamp 12 is placed at the end of inflated section 15 so that air cannot escape into uninflated sock section 13 of the composite pipe 1 1 . When inflated, resin within the inflated section 15 fills out within the wall of the inflated pipe 15 and the inflated section 15 cures and becomes rigid.

[0061 ] Sock section 13 has no resin within its wall, has not become rigid, and is flexible and able to be directed into desired positions. As noted above, resin is injected when the sock 13 passes through the compression apparatus 31 . The sock section 13 is measured out to pass beyond the obstruction and terminate at end 14.

[0062] Typically, the sock section 13 is measured to extend 8 metres beyond the obstruction.

[0063] In a separate embodiment of the invention the sock section 13 is measured to extend less than 8 metres beyond the obstruction. In yet a further embodiment, the sock section 13 is measured to extend more than 8 metres beyond the obstruction. [0064] In these embodiments, the sock section 13 when measured out beyond the obstruction is dry. Once measured out the dry sock section 13 is pulled back through the compression apparatus 31 and injected with resin with the end left dry to enable splicing to the next section of pipe 1 1 . The resin injected sock section 13 is then drawn beyond the obstruction, inflated and set.

[0065] In an alternative embodiment, the sock section 13 measured to extend beyond the obstruction is injected with resin before it is measured out to extend beyond the obstruction and fully inflated to ensure that the sock section 13 is fully wetted out with resin. Once fully wetted out, the sock section 13 is partially deflated to enable it to be manipulated into position. The end 14 of the sock section 13 that passes beyond the obstruction is left dry to enable it to be spliced to the end of the next section of pipe 1 1 .

[0066] A second sock section 17 has a second sock end 16 that is joinable to the dry end 14 of sock section 13 beyond the obstruction to become part of sock section 13 and pipe 1 1 . The manner in which the second sock end 16 is joined to end 14 is discussed below.

[0067] Referring to Figures 2, 2a and 2b, when an obstruction in the form of a cross-lying pipe 21 is encountered in the path of the proposed laying of the pipe 1 1 , passageway 23 in which the pipe 1 1 is being laid is extended underneath the cross-lying pipe 21 . The dry end 14 of sock section 13 that is directed through the passageway 23, is spliced to sock section 17 end 16 to become part of pipe 1 1 as is discussed in further detail below.

[0068] Either side of the cross-lying pipe 21 , the passageway 23 is in the form of a trench.

[0069] Referring to Figure 3, between the clamp 12 and the end 14 a second sealing means in the form of a clamp 22 is placed on the pipe 1 1 along the sock section 13. The portion of the sock section 13 between the clamps 22 and 12 forms a resin-filled sock section 18. The resin-filled sock section 18 is a flexible sock section that has not been cured and made rigid. The resin-filled section 18 is filled with resin 19 as it passes through the compression apparatus 31 prior to the clamp 22 being placed on the pipe 1 1 . When a sufficient portion of the sock section 13 is filled with resin to pass beyond the cross-lying pipe 21 , the clamp 22 is placed on the sock section 13 to form resin-filled sock section 18. The resin-filled sock section 18 and sock section are passed along the passageway 23 underneath the cross-lying pipe 21 . The placement of the clamp 22 must be far away enough from the cross-lying pipe to enable the clamp 22 to pass outside the passageway 23 above ground.

[0070] As noted above, in an alternative embodiment, the sock section 18 of sock 13 can be partially inflated before the sock section 1 8 is passed along the passageway 23.

[0071 ] In this embodiment, clamps 12 and 22 are the same type of clamp, a screw clamp. Clamps 12, 22 are profiled so as to be able to pass along the passageway 23.

[0072] In a separate embodiment, the clamps 12 and 22 can be different types of clamps suitable for sealing the pipe 1 1 to the passage of gas. In yet a separate embodiment, the clamps 12 and 22 can be alternative types of sealing means, such as a membrane, clip, press fit seal or otherwise as understood by the skilled addressee.

[0073] Figures 4 and 4a illustrates sock section 13 of the pipe 1 1 in its collapsed flexible state. Figure 5 illustrates the resin-filled sock section 18 of the pipe 1 1 filled with resin 19. Figure 6 illustrates a clamp 12, 22 as a screw clamp. Figure 7 illustrates the inflated sock 15 as cured.

[0074] Referring to Figure 8, in order to allow the resin-filled sock section 18 and sock section 13 to be passed along passageway 23, a cap 25 is connected to the dry end 14 of sock section 13. The cap 25 tightly grips the dry end 14. A ring 27 is located on the cap 25. A pulling means in the form of a funicular element 29 connects to the ring 27 with funicular ring 31 . With the funicular ring 31 and ring 27 connected, the funicular element 29 is passed along the passageway under the cross-lying pipe 21 and is used to pull the sock section 13 and resin-filled sock section along the passageway 23.

[0075] Alternatively the funicular element 29 can be passed under the cross-lying pipe 21 from beyond the cross-lying pipe 21 and then connected to the cap 25.

[0076] Alternative connection means can be used to the funicular ring 31 and ring 27. For example screw locks, carabiners, clips or alternative locking devices can be used as would be understood by the skilled addressee.

[0077] Figure 9 illustrates the pipe 1 1 during being passed under the cross-lying pipe 21 . The inflated section 15 is clamped at clamp 12 and lifted into the passageway 23. Resin has been injected into section 18 at the compression apparatus 31 and clamped off at clamp 22 to leave sock section 13 extending beyond clamp 22. Cap 25 is connected to the end dry end 14 of sock section 13, to be passed through passageway 23. Ring 27 is connected to the cap 25 and funicular ring 31 is connected to the ring 27. Funicular element 29 is connected to the funicular ring and the funicular element is passed through the passageway 23 then pulls the cap 25 and connected sock section 13 underneath the cross laying pipe 21 .

[0078] Alternatively the funicular element is passed from beyond the cross-lying pipe 21 , connected to the cap 25 and then pulls the cap 25 and connected sock section 12 underneath and beyond the cross-lying pipe.

[0079] Alternatively the inflated section 15 is inflated, cured and clamped at clamp 12 within the passageway 23.

[0080] Alternatively the resin-filled section 18 and dry end 14 of sock section 13 are pulled along the passageway beyond the cross-lying pipe 21 and then the inflated section 15 is lowered into the passageway.

[0081 ] Cap 25 is connected to sock section 13 with clamps (not shown). Alternatively cap 25 is connected to sock section 13 with pins or otherwise as understood by the skilled addressee.

[0082] Figure 10 illustrates the sock section 13 being clamped within clamp 22 to be sealed and to be pulled through passageway 23.

[0083] Figure 1 1 illustrates where the resin-filled section 18 has been pulled through the passageway 23, underneath and beyond the cross-lying pipe 21 . The inflated section 15 has been lowered into the passageway 23.

[0084] Figure 12 illustrates after the dry sock section 13 at end 14 and resin-filled section 18 have passed along the passageway 23 underneath the cross-lying pipe 21 . The dry sock section 13 at end 14 and resin-filled section 18 are raised out of the passageway. The sock section 13 and resin-filled section 18 are placed in the compression apparatus 31 between two endless drives 33 so that sock section 13 is beyond the endless drives 33. The two endless drives 33 are arranged so as to create a passage between them to receive the sock section 13. Opposing cleat elements 35 extend into the passageway between the two endless drives to grasp the sock section

13. The clamp 22 is then removed.

[0085] Opposing elements 35 of the endless drives 33 compress the resin-filled section 18 so that the resin-filled section is air tight. The endless drives 33 are driven in reverse to pull the sock section 13 between the endless drives 33 back towards the cross-lying pipe 21 to spread the resin within the sock section 13. The dry end 14 is left beyond the endless drives 33. The end of a new section pipe 43 is spliced onto the dry end 14 to extend the length of the pipe 1 1 . The pipe 1 1 then continues to be formed in the manner as discussed in W0 12/054992 {Graham) and laid into the continuing passageway 23.

[0086] Figure 13 illustrates a new section of pipe 43 being connected to pipe 1 1 at dry end 14 of sock section 13. A drive clamp 37 is placed on dry sock section 13 near end

14. Outer layers 39 of the new section of pipe 43 are overlaid over sock section 13. The outer layers 39 are then welded, bonded, glued, or otherwise joined to sock section 13, each layer is staggered and layered to make new section of pipe 43 part of pipe 1 1 .

[0087] A second embodiment of the invention is illustrated in Figures 14, 15 and 16. For convenience features of the second embodiment that are similar or correspond to features of the first embodiment have been referenced with the same reference numerals.

[0088] Referring to Figures 14, 15 and 16, where the obstacle that the pipe 1 1 is to cross is a road 47, a conduit 45 is laid in the passageway 23 underneath the road portion. A cap 25 is placed on the dry end 14 of the sock section 13. The funicular element 29 is used to pull the dry sock section 13 and resin-filled section 18 through the passageway 23 and conduit 45 beyond the road 47 in the same manner as discussed above for the first embodiment.

[0089] In alternative embodiments of the present invention, the obstacle that the pipe 1 1 is to cross is a tree, a rocky formation, a foundation, a body of water or otherwise as understood by the skilled addressee.

[0090] Modifications and variations such as would be apparent to the skilled addressee are considered to fall within the scope of the present invention. The present invention is not to be limited in scope by any of the specific embodiments described herein. These embodiments are intended for the purpose of exemplification only. Functionally equivalent products, formulations and methods are clearly within the scope of the invention as described herein.

[0091 ] Reference to positional descriptions, such as lower and upper, are to be taken in context of the embodiments depicted in the figures, and are not to be taken as limiting the invention to the literal interpretation of the term but rather as would be understood by the skilled addressee.

[0092] Throughout this specification, unless the context requires otherwise, the word "comprise" or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

[0093] Also, future patent applications maybe filed in Australia or overseas on the basis of, or claiming priority from, the present application. It is to be understood that the following provisional claims are provided by way of example only, and are not intended to limit the scope of what may be claimed in any such future application. Features may be added to or omitted from the provisional claims at a later date so as to further define or re-define the invention or inventions.