GB2599725A

GB2599725A - Pipe manufacturing Jig

Info

Publication number: GB2599725A
Application number: GB2016140.2A
Authority: GB
Inventors: Bilsby Adrian
Original assignee: BAE Systems PLC
Current assignee: BAE Systems PLC
Priority date: 2020-10-12
Filing date: 2020-10-12
Publication date: 2022-04-13
Also published as: GB202016140D0

Abstract

An apparatus for pipe manufacture, the apparatus comprising: a base section rotatable about a first axis; a crossbar mounted to the base section, and rotatable about a second axis normal to the first axis; and a flange head suitable for retaining a pipe-end flange, and mounted to the crossbar, wherein the flange head is rotatable about a third axis normal to the second axis. The apparatus can be adjusted to mimic the pose of an adjacent flange to which the pipe to be manufactured will abut in use. Embodiments include a related method and system for pipe manufacture wherein a plurality of apparatus are placed in the correct pose on a reconfigurable floor wherein a pipe is manufactured between the apparatus.

Description

PIPE MANUFACTURING JIG

The present invention relates generally to a pipe manufacturing fixture and a related system and method for manufacturing a pipe.

BACKGROUND

Platforms containing large pipe work systems, for example ships, submarines, oil platforms and such like, often require pipes to be replaced multiple times during the lifetime of said platforms due to malfunction, corrosion or material lifespan etc. Pipes are often complex assemblies of a multitude of sections which translate and rotate through a number of bends in order that the flanges, i.e. the end of the pipes, are positioned at poses to mate with adjacent pipe sections.

For safety or operational reasons, many of these pipes are manufactured off-platform before being brought on board for final fitment.

It has been found that replacement of these pipes is often difficult as many of these pipes, especially on older platforms, are handmade bespoke pipes which are not stored as engineering drawings or CAD files. It is therefore difficult to manufacture an exact replica pipe off-platform which mates with the adjacent pipes on-platform when fitment occurs.

A known method of replacement pipe manufacture involves removing a pipe (which has been labelled for replacement) from a platform and manufacturing a rudimentary mock-up using a malleable metal pole with wooden end flanges to approximate the overall shape of the pipe to be replaced. The wooden end flanges are then mated with metallic end flanges which replicate the mating surfaces of the adjacent pipe flanges. The metallic end flanges are then held rigidly in place by a plurality of temporary angle bar welds to create a temporary fixture which holds the metallic end flanges in the correct pose. The rudimentary mock up is then removed and the replacement pipe is manufactured between the metallic end flanges, following the same or -2 -similar path as before. The metallic end flanges and associated temporary fixture is then cut, ground and recycled to release the manufactured pipe.

It will be appreciated that such process is prone to tolerance errors leading to excess rework in addition to wastage of associated temporary fixture 5 for each replacement operation.

It is an example aim of the present invention to at least partially solve or avoid one or more problems or disadvantages with manufacturing pipes, whether identified herein or elsewhere, namely that of replacing pipes without the use of rudimentary mock ups and associated temporary fixtures.

SUMMARY OF INVENTION

According to a first aspect, there is provided an apparatus for pipe manufacture. The apparatus comprises a base section which is rotatable about a first axis, and a crossbar, mounted to the base section, which is rotatable about a second axis normal to the first axis. The apparatus also comprises a flange head suitable for retaining a pipe-end flange, the flange head mounted to the crossbar, and rotatable about a third axis normal to the second axis.

It has been found by the present inventors that such apparatus may substantially reduce manufacturing costs of pipes when compared to existing processes as is known in the art by reducing the time to manufacture pipes, and eliminates waste such as temporary angle bar welds.

Moreover, it has been found that use of the apparatus in controlling tolerances in manufacturing pipes have been substantially increased leading to less re-work and final finishing of said pipes to enable fitment with adjacent pipework in use.

The first axis may be in any axis, for example, the X, Y and Z axes where plane XY is substantially coplanar to the earth's surface and axis Z is the normal to the earth. Preferably, the base section rotates about axis Z such that the base is able to yaw on the plane XY. -3 -

In one example, the apparatus is adjustable to translate the flange head along at least one of the first, second and third axes. Such feature allows additional degrees of freedom to fine tune of the pose of the flange head in free space.

In another example, the apparatus comprises means for translation measurement of the flange head along at least one of the X, Y and Z axes Optionally, the apparatus comprises a securing means to prevent further movement of the flange head along any of the X, Y or Z axes after adjustment Optionally, the apparatus comprises a securing means to prevent further rotation of the flange head about any of the X, Y or Z axes after adjustment.

The apparatus may be arranged such that the flange head comprises an adapter to allow mating with a variety of pipe-end flange fittings. For example, there may be provided different flange heads according to diameter of the pipe to be manufactured or according to the shape of the pipe-end flange, for example circular, square or oblong or according to the connection type of the pipe-end flange, for example, the number of bolted connections, a petrochemical standard or a custom fit flange.

Alternatively, the apparatus may comprise a multi-purpose flange head suitable to engage with a variety of pipe-end flange fittings. For example, the flange head may be able to engage with different diameters of pipe-end flanges without being swapped between manufacturing operations. Alternatively, the flange head may contain a variety of standard arrangements of bolt patterns to enable fitment with a variety of standard pip-end flange connections.

Optionally, the base section of the apparatus may comprise a fitting mechanism to allow detachable mounting to a reconfigurable floor. Such mechanism allows rapid addition and removal of apparatus to a reconfigurable floor between manufacturing operations dependent on the need of the operation in question. -4 -

Optionally, the apparatus comprises a means for angular measurement of the flange head about at least one of the first, second and third axes allowing for accurate positioning of the pose of the flange head.

According to a second aspect, there is provided a system for pipe manufacture, the system comprising at least two apparatus and a reconfigurable floor wherein the at least two apparatus are detachably affixed to the reconfigurable floor. The reconfigurable floor may be a manufacturing sandbox kit which allows rapid addition, removal and repositioning of apparatus into different spatial locations between manufacturing operations and may be able to supply services to the apparatus such as power, fluid or Ethernet connectivity.

According to a third aspect, there is provided a method for pipe manufacture, the method having the following steps; Step 1: determining the orientation and spatial position of each pipe-end flange of a pipe to be manufactured; Step 2: positioning at least two apparatus on a reconfigurable floor as determined by the orientation and spatial position of the pipe-end flanges of the pipe to be manufactured; Step 3: detachably affixing the base sections of the at least two apparatus to the reconfigurable floor; Step 4: adjusting the axes of the at least two apparatus such that the orientation and spatial position of each flange head is correctly aligned to mate with a pipe-end flange of the pipe to be manufactured in free space; Step 5: reversibly affixing the pipe-end flanges of the pipe to be manufactured to each flange head of the at least two apparatus; and, Step 6: manufacturing a pipe between the affixed end flanges.

Optionally, the method may comprise the step of determining the orientation and spatial position of each pipe-end flange is carried out by CMM. -5 -

Optionally, the method may comprise the step of determining the orientation and spatial position of each pipe-end flange comprises tracing the outer surface of an existing pipe with a hand held CMM wand.

Optionally, the method may comprise the step of adjusting the axes of 5 the at least two apparatus comprise securing the axes to prevent further movement of the axes after adjustment.

Optionally, the method may comprise the step of determining the orientation and spatial position of each pipe-end flange of a pipe to be manufactured comprises determining the orientation and spatial position of the o corresponding flanges to which pipe to be manufactured will mate with in use.

FIGURES

Several arrangements of the invention will now be described by way of example and with reference to the accompanying drawings of which: Figures la & lb show an example of a generic arrangement of the apparatus with axes of rotation and translation; Figure 2 shows an example of an alternative arrangement of the apparatus with a flange head comprising an adapter and pipe-end flange; Figure 3 shows an example system of the apparatus in use; and Figure 4 shows a flow-chart of an example method of pipe manufacture.

DESCRIPTION

Figures la & lb show an example apparatus for pipe manufacture 100. The apparatus 100 comprises a base section 102 which is rotatable about a first axis Z, and a crossbar 104, mounted to the base section 102, which is rotatable about a second axis X normal to the first axis Z. In the present arrangement, the base section 102 has two arms 108, 110 extending upwards from the base section 102 with the crossbar 104 placed there-between to create a gantry-type structure. The crossbar 104 is attached to the respective arms 108, 110 by way -6 -of a pinned joint 112, which allows the crossbar 104 to rotate freely about an axis X which is normal to the axis Z of rotation of the base section 102. Alternatively, the joint between the arms 108, 110 and the crossbar 104 may be a ball bearing joint, a universal joint or any other suitable joint which allows the crossbar 104 to rotate freely on an axis X normal to the axis Z of rotation of the base section 102.

The apparatus 100 also comprises a flange head 106 suitable for retaining a pipe-end flange (not shown). The flange head 106 is mounted to the crossbar 104, and is also rotatable about a third axis Y normal to the second axis X. In the present arrangement, the flange head 106 is attached to the crossbar 104 by way of a threaded shaft 114. Said threaded shaft allows translational movement of the flange head 106 along the Y axis denoted by the arrow symbol B thus allowing the displacement between the crossbar 104 and flange head 106 to be selectively increased or decreased by moving the threaded shaft through an elongate channel within the crossbar 104. Although a threaded shaft is used in the present embodiment, this example is non-limiting and translation movement may be achieved by any suitable means, for example, a shaft or a telescopic mechanism.

In the present arrangement shown in Figures la and 1 b, the axis denoted by symbol Z is the Z axis such that the base section 102 is able to freely yaw on the plane XY, plane XY being substantially coplanar to the earth's surface.

In the present arrangement, the flange head 106 is able to translate along the X axis, denoted by the arrow C, using a slide arrangement by moving the threaded shaft 114 along the elongate channel of the crossbar 104. Said translation is limited by the bounds of the two arms 108, 110. Alternatively, where the attachment is a shaft or a threaded shaft, the flange head 106 is able to translate along the X axis by way of a series of holes along the length of crossbar 104 such that the threaded shaft 114 can be selectively positioned along the length of crossbar 104. It will be appreciated in this arrangement that -7 -skilled person will select the distance between the holes as is required by the manufacturing operation, for example the spacing of the holes may be 5mm, lOmm, 15mm etc. Where the attachment is a telescopic mechanism, there may be a series of attachment points along the length of the crossbar 104 at similar intervals. Preferably, the flange head 106 translates along the X axis by way of a slide arrangement.

The flange head 106 is arranged to rotate about an axis Y normal to the axis X of rotation of the crossbar 104.

In the present arrangement, the base section 102, crossbar 104 and flange head 106 are made from metal, and in a preferable arrangement, from mild steel. It will be appreciated however that the skilled person may use any material suitable for supporting the weight of any pipe to be manufactured, depending on the application of the invention, for example metals, metal alloys, composites, polymers or wood.

The apparatus 100 also comprises securing means 116, 118, 120 to prevent further movement of the flange head along any of the X, Y or Z axes after adjustment. In the present arrangement, the securing means is a double nut and bolt configuration located at the connections between the ground plane and the base section 102, and between the base section 102 and the crossbar 104. The securing means 120 between the crossbar 104 and the flange head 106 is also essentially a double nut and bolt configuration wherein a nut is located either side of the crossbar 104 and wherein there is provided torque handles 122 for ease of operation to increase the rigidity of the connection and prevent unintended slippage. Whilst a double nut and bolt securing means is used in the present embodiment, this example is non-limiting and the means may be provided by any suitable mechanism or electro mechanism which prevents further movement after setting at each pinned joint.

In an alternative arrangement, the apparatus 100 may also comprise a means to prevent rotation of the flange head about the X, Y or Z axes after adjustment. This may be instead of, or in addition to, the securing means to prevent further movement along the X Y or Z axes. The means to prevent -8 -rotation of the flange head may be provided by any suitable mechanism or electro mechanism which prevents further movement after setting at each pinned joint, for example, a double nut and bolt configuration.

In the present arrangement, the flange head 106 is a multi-purpose flange head suitable to engage with a variety of pipe-end flange diameters by way of elongate extrusions 124 which allow different sized pipe end flanges to be bolted through the elongate extrusions 124. The same flange head 106 can therefore be used between manufacturing operations without being replaced to accommodate different pipe-end flange diameters. Whilst the elongate extrusions 124 are shown to be at 90 degree intervals relative to the centre point of flange head 106, this is considered non-limiting and there may be provided any number of elongate extrusions at any angle interval relative to the centre point of flange head 106, for example eight elongate extrusions at 45 degree intervals. The angle intervals need not be the same and may be for example 30 degrees between two elongate extrusions and 50 degrees between another pair of elongate extrusions.

In the present arrangement, the base section 102 comprises a plurality of fitting mechanisms 126 in the form of lug and void connections located at the corners of the base section 102 to allow detachable mounting to a reconfigurable floor (not shown) by sliding the lugs into pre formed voids within the reconfigurable floor. Although a lug and void connection is shown, any other suitable connection which allow the apparatus 100 to be rigidly held in place on reconfigurable floor, for example a bolted connection, magnetic or electromagnetic fixings, may be used. Whilst the fitting mechanisms 126 are shown at the corners of the base section 102, they may be provided at any suitable point on the base section 102 which allows detachable mounting to a reconfigurable floor.

In the present arrangement, the apparatus comprises means 128 for angular measurement of the base section 102 about the first axis Z. Said means 128 for angular measurement is located on the base section 102 in the form of a protractor etched into the base section 102 although it will be appreciated that any angular measurement device may be used and may be -9 -located on any one or more moving rotational interface of the apparatus, for example between the base section 102 and crossbar 104, the crossbar 104 and flange head 106 etc. Further, there may be provided means for translational measurement on the apparatus, for example, a ruler, Vernier callipers or laser measurement or any other suitable means for measuring translational distances. The translational measurement may be provided on any translational interface of the apparatus, for example, between the crossbar 104 and the flange head 106.

The rotational and translational movement axes herein described so far effectively allow five degrees of freedom in the apparatus 100 such that the flange head 106 can be positioned into any pose to mimic the pipe end flange of an adjacent pipe to which the pipe to be manufactured will abut in use. Further, the rotational and translational movement axes allow fine tuning of the positioning of the pose of the flange head 106 in order to be correctly configured accurately in free space where other existing axes of rotation and movement are incapable of moving the flange head to the desired position. For example, when the apparatus is used in conjunction with a reconfigurable floor, the base section may only be moved spatially in increments of 50 cm, the extra translation in the X,Y,Z of the flange head allows spatial movement in the fine tuning range of 0 to 50cm thus allowing the flange head to be positioned in any required pose.

Figure 2 shows an alternative apparatus 200 wherein the base section 202 comprises a height adjustable section 230 such that the height of the crossbar 204 from the plane XY may be varied along arrow A. For example, the adjustable section may be a telescopic section, a sliding arrangement, a rack and pinion arrangement or merely a selection of connections displaced at various heights wherein the crossbar 204 can be selectively attached depending on the clearance required. In the example shown, the height adjustable section 230 is provided on each arm of the base section in the form of a selection of connections displaced at various heights along the length of the arm thus allowing the height of crossbar, relative to the base 202 and plane XY, -10 -to be selectively increased or decreased depending on the manufacturing operation need.

In the present arrangement, the flange head 206 comprises an adapter 234 to allow mating with a variety of pipe-end flange fittings 232. For example, there may be provided different adapters 234 according to diameter of the pipe to be manufactured or according to the shape of the pipe-end flange, for example circular, square or oblong, or according to the connection type of the pipe-end flange, for example the number of bolted connections, a petrochemical standard or a custom fit flange.

In an alternative arrangement, the flange head 206 may take the form of a vice, a grip or any other suitable geometry which may rigidly support a pipe during manufacture. For example, the flange head 206 may be a vice which rigidly holds any part of a pipe in place whilst the pipe-end flange of the pipe is retained by a separate apparatus.

Figure 3 shows an example system 300 comprising at least two apparatus 302a, 302b as herein described and a reconfigurable floor 304.

In the present arrangement, there is provided a partially fabricated pipe 306 whose pipe-end flanges engage with the respective flange heads of apparatus 302a, 302b.

In the present arrangement, the reconfigurable floor 304 is a specialised floor system used in high-value manufacturing which allows rapid addition and removal of the apparatus 302a, 302b to the reconfigurable floor 304 between manufacturing operations. The apparatus 302a, 302b are able to be detachably secured to the reconfigurable floor 304 by way of a bolted connection (not shown). The reconfigurable floor 304 is able to supply services to the apparatus in the form of electrical power 308. In an alternative arrangement, the reconfigurable floor 304 may supply fluids & Ethernet connectivity to the apparatus 302a, 302b. Further, the reconfigurable floor 304 is designed to withstand harsh manufacturing processes such as welding and grinding. In the present arrangement, the reconfigurable floor 304 is modular in the form of rectangular sections 316 which can be rapidly joined to each other such that the footprint of the reconfigurable floor may be selectively increased and decreased depending on the requirements of the manufacturing operation.

In the present arrangement, the reconfigurable floor 304 comprises spatial measurement equipment in addition to the measurement equipment of 5 the apparatus 302a, 302b in the form of a mobile CMM laser scanner 310 adjacent to the reconfigurable floor 304. The mobile CMM scanner 310 interacts with reflective surfaces 312a, 312b on the apparatus 302a, 302b and reflective surface 314 on the reconfigurable floor 304 to ensure correct spatial orientation for the manufacturing operation and allow greater precision in positioning the 10 apparatus. In an alternative arrangement, the measurement equipment may be a LIDAR detector. In an alternative arrangement, the measurement equipment may be located on the reconfigurable floor or adjacent to it.

Whilst only two apparatus are shown in this figure, there may be provided a plurality of apparatus depending on the need of the manufacturing operation, for example for a pipe to be manufactured which includes three pipe-end flanges, there is provided three apparatus, four pie-end flanges, there is provided four apparatus etc. Figure 4 shows a flowchart of a method 400 of pipe manufacture, the method comprising the following steps: 410: Determining the orientation and spatial position of each pipe-end flange of a pipe to be manufactured by measuring the pose of the existing flanges to which the pipe to be manufactured will mate with.

420: Positioning at least two apparatus on a reconfigurable floor as determined by the orientation and spatial position of the pipe-end flanges of the pipe to be manufactured such that the flange head of each of the apparatus is arranged in the position of the pipes to which the pipe to be manufactured will mate with in use.

430: Detachably affixing the base sections of the two apparatus to the reconfigurable floor.

-12 - 440: Adjusting the axes of the two apparatus such that the orientation and spatial position the flange head of each apparatus is correctly aligned to mate with a pipe-end flange of the pipe to be manufactured in free space.

450: Reversibly affixing the pipe-end flanges of the pipe to be manufactured to each flange head of the two apparatus.

460: Manufacturing a pipe between the affixed end flanges.

The method may also comprise the step of determining the orientation and spatial position of each pipe-end flange is carried out by CMM. For 10 example, the CMM may be a gantry type CMM.

The method may also comprise the step wherein the step of determining the orientation and spatial position of each pipe-end flange comprises tracing the outer surface of an existing pipe with a hand held CMM wand. A hand held CMM wand is particularly effective in measuring restricted access spaces on platform or where removal of a pipe before a replacement is manufactured is not possible for operational reasons.

The method may also comprise the step of adjusting the axes of the at least two apparatus comprise securing the axes to prevent further movement of the axes after adjustment.

The method may also comprise the step of determining the orientation and spatial position of each pipe-end flange of a pipe to be manufactured by determining the orientation and spatial position of the corresponding flanges to which pipe to be manufactured will mate with in use.

Although a few preferred arrangements have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and -13 -the contents of all such papers and documents are incorporated herein by reference.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive.

Each feature disclosed in this specification (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise.

Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

The invention is not restricted to the details of the foregoing arrangement(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

-14 -CLAIMS 1 An apparatus for pipe manufacture, the apparatus comprising: a base section rotatable about a first axis; a crossbar mounted to the base section, and rotatable about a second axis normal to the first axis; and a flange head suitable for retaining a pipe-end flange, and mounted to the crossbar, wherein the flange head is rotatable about a third axis normal to the second axis.
2. The apparatus according to claim 1 wherein the flange head may be translated along at least one of the first, second and third axes.
3. The apparatus according to claim 2 wherein the apparatus comprises means for measurement of the flange head translation along the at least one axis.
4. The apparatus according to any of claims 2 or 3 wherein the apparatus comprises a securing means to prevent further translation of the flange head along any of the X, Y or Z axes after adjustment.
5. The apparatus according to any preceding claim wherein the apparatus comprises a securing means to prevent further rotation of the flange head about any of the X, Y or Z axes after adjustment.
6. The apparatus according to any preceding claim wherein the flange head comprises an adapter to allow mating with a variety of pipe-end flange fittings.
-15 - 7 The apparatus according to any preceding claim wherein the flange head is a multi-purpose flange head suitable to engage with a variety of pipe-end flange fittings.
8. The apparatus according to any preceding claim wherein: the base section comprises a fitting mechanism and the base section is detachably mountable to a reconfigurable floor.
9. The apparatus according to any preceding claim wherein the apparatus o comprises a means for angular measurement of the flange head about at least one of the first, second and third axes.
10.A system for pipe manufacture, the system comprising: at least two apparatus according to any preceding claim; and a reconfigurable floor, wherein the at least two apparatus are detachably affixed to the reconfigurable floor.
11. A method for pipe manufacture, the method comprising: determining the orientation and spatial position of each pipe-end flange of a pipe to be manufactured; positioning at least two apparatus according to any of claims 1 to 10 on a reconfigurable floor as determined by the orientation and spatial position of the pipe-end flanges of the pipe to be manufactured; detachably affixing the base sections of the at least two apparatus to the reconfigurable floor; -16 -adjusting the orientation and spatial position of each flange head so as to be correctly aligned to mate with a pipe-end flange of the pipe to be manufactured in free space; reversibly affixing the pipe-end flanges of the pipe to be manufactured to each flange head of the at least two apparatus; and, manufacturing a pipe between the affixed end flanges.
12.The method according to claim 11 wherein the step of determining the orientation and spatial position of each pipe-end flange is carried out by CMM.
13.The method according to any of claims 11 to 12 wherein the step of determining the orientation and spatial position of each pipe-end flange comprises tracing the outer surface of an existing pipe with a hand held CMM wand.
14.The method according to any of claims 11 to 13 wherein the step of adjusting the axes of the at least two apparatus comprise securing the axes to prevent further movement of the axes after adjustment.
15.The method according to any of claims 11 to 14 wherein the step of determining the orientation and spatial position of each pipe-end flange of a pipe to be manufactured comprises determining the orientation and spatial position of the corresponding flanges to which pipe to be manufactured will mate with in use.