GB2551781B

GB2551781B - Safety installation method and apparatus

Info

Publication number: GB2551781B
Application number: GB1611378.9A
Authority: GB
Inventors: Young Iain; Milne Alan; Johnson Howard; Johnson Andrew
Original assignee: Blaze Manufacturing Solutions Ltd
Current assignee: Blaze Manufacturing Solutions Ltd
Priority date: 2016-06-30
Filing date: 2016-06-30
Publication date: 2019-10-23
Anticipated expiration: 2036-06-30
Also published as: GB2551781A; GB201611378D0

Description

SAFETY INSTALLATION METHOD AND APPARATUS

This invention relates to a method of installation of a safety system and a safety apparatus associated with the system. This invention relates to a method of construction and installation of a flexible pipework system and apparatus associated with the system. More particularly the invention relates to the installation of a deluge system and particularly to the installation of a flexible hose of a deluge system particularly but not exclusively on an onshore or offshore production or drilling facility. The invention also relates to a nozzle connector used in the installation method for providing firewater to specific areas protected by the deluge system.

Onshore production, storage and distribution facilities and offshore environments such as oil and gas installations, vessels including floating production storage and offloading (FPSO) vessels, oil rigs and the like, present a dangerous environment with hazardous materials being handled where care must be taken to ensure that any risk of fire is mitigated.

In the event of a fire breaking out in such an environment, deluge systems are available to ensure that firewater is provided over or around the area being protected. This will assist in the recovery from fire by applying cooling water thereby limiting escalation, protecting personnel, and helping to extinguish hydrocarbon and no hydrocarbon fires. Deluge systems may utilise rigid pipework and can be of metallic or rigid composite material. These systems are often expensive to design and install or in the case of carbon steel will experience significant corrosion, associated blockage and maintenance problems during its operational lifetime. A more cost effective and maintenance efficient system utilises flexible pipework with embedded fire resistant properties or layers of fire resistant coatings which is installed on and around the working area of the platform or vessel to provide a drenching operation from nozzles mounted at intervals along the hose. In an emergency situation, firewater flowing through the flexible hose can be sprayed from the nozzles to drench and cool the area around which the system is installed. This can mitigate the effects of the fire in a particular area of the installation by providing cooling water to structures and surrounding equipment thus maintaining an escape route for personnel.

This can provide valuable time for personnel to evacuate the area and also allow emergency services to access the area to help put out the fire.

Due to the nature of flexible pipework it is unable to support its own weight therefore a support structure is required. These supports are secured to sound structural steel of the asset requiring protection. The support structure can utilise various components, however this application utilises a modular support structure specifically designed for the flexible pipework deluge system. Known support structures may incorporate triangular or prismatic components although others designs may be used.

With the support structure in place, to minimise any margin for error the flexible hose is laid out to facilitate ease of measurement, cutting and fabrication of the deluge system. The flexible hose is cut to appropriate length, heat resistant sleeves applied, then the appropriate hose and nozzle connector is attached and secured in place by a clamping system. Further heat protection and sealing compounds are then applied. Historically this assemble process has been a complex and time consuming operation with many stages.

With the flexible hose I nozzle section now ready for installation it is raised aloft into position and secured temporarily within the pipe clamps previously installed on the support structure. Due to the flexible nature of the hose, one end is then secured and the hose is pulled through the semi-secured clamps to remove the natural undulation.

The flexible nature of the hose means it is susceptible to environmental temperature effects which lead to overall change in hose length when tensioned appropriately and clamps secured. If nozzle positions change as a result this would require remedial action to ensure appropriate deluge coverage and protection. As a result of current installation methodology, nozzle positioning can be problematic and the overall installation is time consuming.

The present invention aims to provide a method of construction and installation of a flexible pipework system and apparatus associated with the system which overcomes or at least mitigates the problems associated with known installation methods. It seeks to provide a more cost effective and efficient installation method in terms of reduction in its complexity, installation times and associated costs. It is envisaged that this will also lead to a reduction in wastage of materials and to provide an installation method that allows for modification of the installation process to deal with changes in the specification of the system over time. A further aim is to provide an installation with an extended life period as the installation can be modified over time without having to be reinstalled as a new system.

It is a further aim of the present invention to provide an improved method of installing nozzles into a flexible hose of a fire protection system and an improved nozzle connector for such a system.

As per known installation methods, due to the nature of flexible pipework it is unable to support its own weight therefore a support structure is required. These supports are secured to sound structural steel of the asset requiring protection. It is a further aim of the present invention to provide an installation method which enables extensive sections of flexible hose to be raised aloft into position and secured temporarily within the pipe clamps previously installed on the support structure.

According to a first aspect of the present invention there is provided a nozzle connector for insertion into a flexible hose or pipe of a deluge system, the nozzle connector comprising a housing for application externally through an aperture in the side wall of the hose or pipe and an annular sealing member mounted internally of the hose or pipe, the housing having a tubular skirt and a bore for receiving a nozzle, wherein the inner diameter of the sealing member is smaller than the outer diameter of the tubular eskirt of the housing.

Advantageously the housing comprises a base member which is substantially rectangular in form, although may be of an alternative shape and dimension.

Conveniently the base member is curved to match the outer curvature of a flexible hose or pipe to which it is to be applied.

Preferably the base member is formed of a resilient material.

Advantageously the base member is formed of rubber. More preferably the base material is formed of a nitrile rubber.

Conveniently the base member has a central aperture with a boss extending from the upper surface of the base member around the aperture.

Conveniently the skirt depends from the lower surface of the base member around the aperture, a bore being defined within the base member between the boss and the skirt.

Advantageously the skirt comprises an inner concave circular end remote from the base member.

Preferably the boss is integrally formed with the base member.

Preferably the nozzle connector further comprises a cover plate.

Advantageously the cover plate is substantially rectangular in form and of a similar shape and size as the base member.

Conveniently the cover plate has a central aperture which is of a size to allow the boss of the base member to extend therethrough when the cover is placed over the base member.

According to a further aspect of the present invention there is provided a method of installing a nozzle in a flexible hose or pipe of a deluge system, the method comprising the steps of drilling a hole into the side wall of the flexible hose or pipe, introducing an annular sealing member having an internal diameter smaller than the diameter of the hole through the hole and adhering the sealing member to the internal surface of the flexible hose or pipe surrounding the drilled hole such that a portion of the sealing member overlies the hole and mounting a housing for a nozzle nozzle into the hole in the side wall of the flexible hose or pipe and adhering the housing to the sealing member.

Advantageously an adhesive is applied to the inner surface of the flexible hose or pipe around the drilled hole and an accelarant is applied to the sealing member.

Alternatively an accelerant may be applied to the inner surface of the flexible hose or pipe and an adhesive applied to the sealing member.

Advantageously the method further comprises passing an inflatable bladder though the drilled hole and inflating the bladder within the flexible hose or pipe to apply a force to the sealing member. This holds the sealing member in position around the drilled hole until the adhesive cures and ensures a tight seal between the sealing member and the wall of the flexible hose or pipe.

Conveniently the method further includes the step of applying an adhesive to the surface of the wall of the flexible hose or pipe.

Advantageously the nozzle connector is secured in position on the hose or pipe by a strap or tie or clamp or a combination of such means while the adhesive cures to firmly set the nozzle connector in position.

Advantageously the method further comprises applying a protective jacket over the nozzle connector.

According to a further aspect of the present invention there is provided a method of installing a deluge system in a require location, the method comprising the steps of mounting a flexible deluge hose or pipe around or above an area to be protected in the event of a fire, subsequently drilling at least one hole into the flexible hose or pipe, mounting a nozzle connector according to the first aspect of the inventioninto the hole and sealing the nozzle connector in place within the hole in the flexible hose.

An embodiment of the present invention will now be described with reference to and as shown in the accompanying drawings in which:

Figure 1 is a perspective view from above of a nozzle connector according to one aspect of the present invention for use in the installation method of the invention;

Figure 2 is a perspective view from below of the nozzle connector or figure 1;

Figure 3 is a schematic cross sectional view of the nozzle connector of figure 1;

Figure 4 is a schematic perspective view of the nozzle connector-of figure 1 mounted on a flexible hose,

Figure 5 is a schematic view of a sealing element of the nozzle connector of figure 1,

Figure 6 is a schematic perspective view of the nozzle connector-of figure 1 with a cover plate to help secure the nozzle connector on a hose;

Figure 7 is a schematic cross sectional view through a flexible hose used in the installation method described with the sealing element of figure 5 in place;

Figure 8 is a schematic view of the nozzle connector of figure 1 clamped onto a flexible hose, and

Figure 9 is a schematic view of the nozzle connecor of figure 1 with a protective jacket applied over the connector.

Turning to the figures, figure 1 shows a nozzle connector 1 for use in the installation of a fire deluge system particularly by not exclusively on board an oil or gas installation for example or some other environment where a fire may break out. The nozzle connector is intended to be inserted into a flexible hose or pipe which is installed around, above or on the installation to carry water for use in fire prevention as will be described below.

The nozzle connector comprises a housing for mounting a nozzle. The housing comprising a base member 2 which is preferably formed of a moulded, resilient rubber material. In the preferred embodiment the base member is formed of a moulded plastics or rubber material such as nitrile shore 90. Shore is the measure of hardness of a rubber and shore 90 is a very stiff rubber which gives greater resistance to abrasion. The base member is arcuate to allow the base member to sit on the outer surface of a tubular flexible hose.

The upper surface 3 of the base member has a central upstanding boss 4 formed of the same material. The central boss is preferably integrally formed with the base member. The base member has a central bore 5 which extends through the base member and continues through the boss.

The lower surface 6 of the base member has a depending tubular skirt 7 that is preferably integrally formed with the base member. The central bore 5 of the base member is continued through the skirt 7. In the illustrated embodiment the outer surface of the skirt is shown as having concentic ribs or undulations 8 however this surface may be smooth in other embodiments.

The distal end 9 of the skirt, remote from the base member 2 is formed with an inner concave circular surface 10 which defines side lobes 11a and 11b. The surface 10 is shaped to mirror the internal cut diameter of the flexible hose liner to which the nozzle connector will be mounted and may be chamfered in some embodiments.

The diameter of the central bore 5 through the boss may be larger than the diameter of the bore through the skirt as shown in Figure 2.

The lower surface of the base member may be provided with ribs or channels 12 on either side of the depending skirt.

The upper surface 3 of the base member may be provided with grooves or channels 13 on either side of the central boss. The grooves, ribs or channels preferably have a similar arcuate profile as the base member itself as will be described further below.

The housing further comprises a hollow tubular body 14 which is mounted in the bore in the base member and boss and extends through the boss and skirt. The tubular body has an enlarged outer diameter in the region of the boss and a reduced outer diameter in the region of the skirt. The tubular body sits securely within the base member. Preferably the tubular body is vulcanised into the base member. The tubular body is preferably formed of a metal and in the embodiment shown may be formed of stainless steel. The upper portion of the internal surface of the tubular body may be threaded to cooperate with a corresponding thread of a deluge nozzle which will be described further below. Alternative embodiments may have a push fit or interference fit between the tubular body and the nozzle or an alternative mounting arrangement.

The outer surface 15 of the tubular mbody as it extends through the boss may be substantially tubular however preferably opposing side portions 16 of the outer surface are flattened to provide anchoring surfaces for cooperating with a tool utilsed during insertion of a nozzle to prevent the tubular body from rotating during this process. A cover plate 17 is provided which fits over the upper surface 3 of the base member. The cover plate has an arcuate form to match the curvature of the upper surface of the base member. The underside of the cover plate may be formed with ribs which extend into the grooves or channels in the upper surface of the base member to assist in placement of the cover plate. A central aperture 18 is provided in the cover plate which has a diameter slightly larger than the diameter of the boss 4 to allow the boss of the base member to extend through the aperture 18 in the cover plate when the cover plate is mounted over the base member as shown in figure 6. The cover plate is generally rectangular and has a similar size to the base member.

Turning to figure 5, an annular sealing element 19 is provided which cooperates with the housing to form the nozzle connector as will be described further below. The sealing element is formed of a thin resilient rubber material. The inner diameter 20 of the sealing element is substantially the same as the outer diameter of the tubular body 14 of the base member and therefore smaller than the inner diameter of the bore 5 passing through the depending skirt.

In use, the nozzle connector 1 described above facilitates an improved installation method for providing a deluge system on a vessel or off shore installation. The sealing element 19 is designed to be mounted internally of the flexible hose with the housing of the nozzle connector mounted on and extending through a side wall of the flexible hose.

The installation of a flexible deluge system including placement of the nozzle connector s described above will now be described. A length of flexible deluge hose H is deployed to the required location and the hose is mounted to a support infrastructure such as for example a framework or gantry built on the installation. This mounts the flexible hose at the required height above or around the area to be protected. Unlike standard installations, the flexible hose can be installed in a single length around the required area without being pre cut to fit nozzle attachments between cut the pre-cut ends of the flexible hose.

This avoids the problems associated with measuring and pre-cutting individual lengths of hose, reduces wastage of hose, reduces the time required in treating the cut ends of the hose and also reduces the health and safety risks in having pre cut lengths of hose lying around on the surface of the installation before they are installed in position above or around the area to be protected. This also avoids problems associated with changes in hose length due to environmental temperature effects.

Once the flexible hose has been mounted in position, an operator can turn to placement of the nozzles of the deluge system. It will be appreciated that the precise placement of the nozles can be altered at this point which allows for redesigning of the system during installation which provides a further cost saving in terms of wastage of materials, particularly wastage of lengths of flexible hose and installation time. As a deluge system is typically designed off-site for installation, this means than any minor inconsistencies in the information supplied to the system designer does not require major changes in the installation itself. If the flexible hose has to pass over or around any unexpected surfaces, this can be incorporated without changing the individual lengths of hose that would normally have to be cut and prepared.

In order to place a nozzle connector into the hose, the operator first uses a drill to drill a hole through the side wall of the hose. This may be done with a vacuum brazed diamond carbide hole saw to ensure a clean hole is drilled through the hose. The diameter of the drill is selected to be similar to and preferably slightly larger than the outer diameter of the skirt 7 of the nozzle connector. This cutting operation will expose the laminated layers L of the flexible hose which will be then be sealed by the nozzle connector when in position.

Once the hole is formed, a flexible, inflatable bladder is placed onto an inflation tool such as an air pump.

The internal sealing element 19 of the nozzle connector is then prepared. This involves cleaning the surface of the sealing element which will contact the inner surface of the flexible hose or example using an isopropyl alcohol wipe to remove any dirt, waxes, sealants or contaminants from the sealing element. Once the surface of the sealing element has dried it is sprayed with an accelerant.

An adhesive is then applied internally within the hose, around the area surrounding the hole that has been cut. A small amount of the adhesive can be applied using the tip of a finger or an applicator. This applies an adhesive to the internal hose liner or wall. The sealing element 19 is then passed through the hole in the side wall of the hose and centralised around the hole such that the surface of the sealing element upon which the accelerant was applied overlays the adhesive applied around the hole in the hose. As the diameter of the hole is determined by the diameter of the skirt of the base member, and this is larger than the internal diameter 20 of the annular sealing member, when the sealing member is in position around the hole, a portion of the under side of the sealing element, with adhesive applied thereon, overlies the hole.

Once the sealing element 19 is centred in position, the bladder of the inflator tool is inserted through the hole in the side wall of the hose and through the sealing member into the interior of the flexible deluge hose. Air is then pumped into the bladder to inflate the bladder within the hose which applies a force to the annular sealing element 19 to push the sealing element into contact with the inner surface of the hose around the drilled hole. The bladder is held inflated for a sufficient time within the flexible hose to allow the adhesive to bond the sealing element to the internal wall of the hose.

The bladder is then deflated and removed from the drilled hole and the operator can check that the sealing element is correctly seated around the aperture in the hose. A small amount of adhesive is then applied to the side walls of the hole drilled into the hose.

Two stainless steel tie wraps 21 are loosely applied over the flexible hose H, one on either side of the drilled hole.

The cover plate 17 of the nozzle connector is mounted over the base member 2. In some embodiments the cover plate may be secured in position using an adhesive. A thin layer of adhesive is then applied over the external surface of the skirt 7 of the base member of the nozzle connector including the distal end 9 of the skirt, the surface 10 and the lower surface of the base member. The base member is then pushed into the drilled hole in the side wall of the flexible hose. The skirt 7 of the base member sits within the drilled hole and the concave surface 10 at the distal end of the skirt abuts the portion of the internal sealing element 19 which overlies the drilled hole. This ensures that the distal end of the skirt of the base member firmly adhers to the sealing element 19 to provide a seal between the skirt and the sealing element 19 which prevents fluids passing through the hose flowing between the sealing element and the outer surface of the skirt. A G-clamp or similar device may be used to temporarily secure the nozzle connector 1 in position within the drilled hole. The tie wraps 21 can then be moved over the cover plate and secured using a tool such as a banding tool.

The G-clamp may be removed between securement of the first and second tie wraps and will typically then be reattached and left in position for up to 48 hours to allow the adhesive to reach its full cure strength.

Once the adhesive is fully cured, the G-clamp can be removed and the nozzle connector will be sealed and secured in position. A protective jacket 22 is then applied over the nozzle connector to provide fire resistant protection to the nozzle connector 1. This protects the connector and is capable of withstanding temperatures similar to the specification of the flexible hose used in the deluge system, which ensures that the deluge system can operate in the harshest of environments and under the toughest emergency conditions to allow personnel working in the area to escape in the event of such an emergency occurring.

Preferably the protective jacket 22 has an aperture for the nozzle connector 23 and is formed of a flexible fire proof material which can be wrapped around the nozzle connector and hose and secured in position by releasable fastening means thereby allowing for quick installation and protection of the nozzle connector and also providing easy access in the event of maintenance and repair for example. The material may also have heat shielding properties in that the outer layer may be exposed to significantly high temperatures without dissipating the heat to the inner surface of the jacket. A deluge nozzle can then be mounted into the nozzle connector. This may be screwed or push fit for example into the tubular body depending on the connections provided.

It will be appreciated that the installation method described above provides significant improvements over known installation methods of flexible deluge systems. Preinstalling the flexible hose before installing any nozzles in the hose provides the advantages already described above in terms of reduction in wastage, reduction in installation time and manpower and improvements in health and safety.

The nozzle connector of the present invention provides further significant advantages over known components as it ensures a strong and effective seal is provided around the nozzle connector thereby mitigating any leakage from around the nozzle connector 1 and also ensures that fluids cannot flow along the hose and down between the hole drilled in the hose wall and the skirt 7 of the base member of the nozzle connector. This prevents water from travelling between the layers L of the flexible hose and so prevents any delamination of the layers of the flexible hose which is likely to occur when screwing a drainage port into the wall of the hose for example. In fact, the weight of the fluid flowing through the flexible hose acts to provide a further means for holding the sealing element 19 in position around the hole provided for the housing of the nozzle connector and provides a permanent pressure to hold the sealing element in the correct position.

It is estimated that the known described installation methods can take at least 20-25 minutes to install each nozzle tee connector including cutting and preparing the flexible hose, preparing the nozzle connectors and flame proofing the resulting structure and anything up to 2 hours depending on the installation method and hose diameter. This time is increased if any adjustments are required due to changes in hose length or nozzle alignment due to environmental temperature effects. It is envisaged that the installation method of the present invention as described above will reduce the timing for installing individual nozzle connectors to about 10 minutes which is a significant saving over the time required to install a deluge system as a whole.

The installation method has been described in relation to an off shore installation such as an oil platform, FPSO, drilling rig or marine vessel but it is envisaged that a fire deluge system as described may be installed in any location where a deluge fire system may be required such as a storage facility, wind or wave turbines, mines, warehouse, factory, workshop or even sports events arena to provide a fire safety system.

Claims

1. A nozzle connector for insertion into a flexible hose or pipe of a deluge system, the nozzle connector comprising a housing for application externally through an aperture in the side wall of the hose or pipe and an annular sealing member mounted internally of the hose or pipe, the housing having a tubular skirt and a bore for receiving a nozzle, wherein the inner diameter of the sealing member is smaller than the outer diameter of the tubular skirt of the housing.

2. A nozzle connector according to claim 1, wherein the housing comprises a base member which is substantially rectangular in form.

3. A nozzle connector according to claim 2, wherein the base member is curved to match the outer curvature of a flexible hose or pipe to which it is to be applied.

4. A nozzle connector according to claim 2 or 3, wherein the base member is formed of a resilient material.

5. A nozzle connector according to claim 4, wherein the base member is formed of rubber.

6. A nozzle connector according to claim 5, wherein the base material is formed of a nitrile rubber.

7. A nozzle connector according to any of claims 2-6, wherein the base member has a central aperture.

8. A nozzle connector according to claim 7, wherein the base member comprises a boss extending from the upper surface of the base member around the aperture.

9. A nozzle connector according to claim 8 when dependent on any of claims 2-6, wherein the skirt dependis from the lower surface of the base member around the aperture.

10. A nozzle connector according to any of claims 9 where the base member further comprises a bore defined within the base member between the boss and the skirt.

11. A nozzle connector according to claim 9 or 10, wherein the skirt comprises an inner concave circular end remote from the base member.

12. A nozzle connector according to any of claims 8-11, wherein the boss is integrally formed with the base member.

13. A nozzle connector according to any of the preceding claims, further comprising a cover plate.

14. A nozzle connector according to claim 13 when dependent upon any of claims 2-12, wherein the cover plate is substantially rectangular in form and of a similar shape and size as the base member.

15. A nozzle connector according to any of claims 13 or 14 when dependent upon any of claims 8-12, wherein the cover plate has a central aperture which is of a size to allow the boss of the base member to extend therethrough when the cover is placed over the base member.

16. A method of installing a nozzle in a flexible hose or pipe of a deluge system, the method comprising the steps of drilling a hole into the side wall of the flexible hose or pipe, introducing an annular sealing member having an internal diameter smaller than the diameter of the hole through the hole and adhering the sealing member to the internal surface of the flexible hose or pipe surrounding the drilled hole such that a portion of the sealing member overlies the hole and mounting a housing for a nozzle into the hole in the side wall of the flexible hose or pipe and adhering the housing to the sealing member.

17. A method according to claim 16, wherein an adhesive is applied to the inner surface of the flexible hose or pipe around the drilled hole and an accelarant is applied to the sealing member.

18. A method according to claim 16, wherein an accelerant may be applied to the inner surface of the flexible hose or pipe and an adhesive applied to the sealing member.

19. A method according to any of claims 16-18, wherein the method further comprises passing an inflatable bladder though the drilled hole and inflating the bladder within the flexible hose or pipe to apply a force to the sealing member.

20. A method according to any of claims 16-19, wherein the method further includes the step of applying an adhesive to the surface of the wall of the flexible hose or pipe.

21. A method according to any of claims 16-20, wherein the nozzle connector is secured in position on the hose or pipe by a strap or tie or clamp or a combination of such means while the adhesive cures to firmly set the nozzle connector in position.

22. A method according to any of claims 16-21, wherein the method further comprises applying a protective jacket over the nozzle connector.

23. A method of installing a deluge system in a require location, the method comprising the steps of mounting a flexible deluge hose or pipe around or above an area to be protected in the event of a fire, subsequently drilling at least one hole into the flexible hose or pipe, mounting a nozzle connector according to any of claims 1-15 into the hole and sealing the nozzle connector in place within the hole in the flexible hose.