Near-weld purge gas delivery system
Apparatus, systems, processes, control systems, means and methods for near-weld gas purging and welding. A focused circumferential near-weld purge gas delivery system for pipeline welding. A near-weld purge rig which has a near-weld purge gas channel and which achieves a low oxygen concentration proximate to a pipe gap for welding. The gas used for purging is also directed against an interior surface of the pipe to be welded. The directed gas cools the pipe to a desired temperature.
1. A purge rig, the purge rig for insertion into a pipeline having a pipe interior, the pipeline including a first pipe end abutting a second pipe end to define a pipe end interface, the purge rig comprising:
a core for at least partially defining a purge space;
a purge dam extending from the core;
a purge gas distributor supported on the core and longitudinally offset from the purge dam for discharging gas into the purge space;
a purge gas supply passage supported on the core, the purge gas supply passage supplying purge gas to the purge gas distributor;
wherein the near weld purge rig is positioned in the pipe interior such that the gas distributor is generally aligned longitudinally with the pipe end interface and at least a portion of the core, at least a portion of the purge dam, and at least a portion of the pipe interior define the purge space; and
wherein the purge gas distributor includes at least two discharge nozzles having overlapping spray patterns and that direct purge gas against a portion of the interior surface at the pipe end interface.
2. The purge rig according to claim 1 , wherein the directed purge gas exits the gas distributor to form a defined discharge pattern at every circumferential portion of the vertical weld run.
3. The purge rig according to claim 2 , wherein the defined discharge pattern is generally v-shaped.
4. The purge rig according to claim 2 , wherein the defined discharge pattern is generally cone-shaped.
5. The purge rig according to claim 4 , wherein the directed purge gas impacts a defined surface portion of the pipe interior in the pattern at the pipe end interface.
6. The purge rig according to claim 5 , wherein the gas distributor is defined by at least two radially outwardly directed gas distribution nozzle for impacting the defined surface portion.
7. The purge rig according to claim 6 , wherein the defined surface portion of each of the nozzles together combine to impact the entire pipe interior at the pipe end interface, and wherein an end of the defined surface portion of each nozzle overlaps an end of the defined surface portion of each of the adjacent defined surface portions.
8. The purge rig according to claim 6 , wherein the defined surface portion is an entire vertical weld run and the directed purge gas cools the defined surface portion to control weld material temperatures near the defined surface portion.
9. The purge rig according to claim 5 , wherein the flow rate of the directed purge gas is controlled to cool the defined surface portion.
10. The purge rig according to claim 6 , wherein a spray gap is defined as the radial distance between a tip of the nozzle and the pipe interior and the spray gap is between 0.25 and 1.5 inches.
11. The purge rig according to claim 1 , wherein said near-weld purge gas space has a purge gas space pressure which is greater than an ambient pressure, when the near-weld purge rig is placed into the pipeline at the interface.
12. The purge rig according to claim 11 , wherein during a gas purge, purge gas flows from the gas supply passage, through the purge gas distributor, into the purge space and out of the pipe interior to the atmosphere.
13. The purge rig according to claim 1 , wherein said near-weld purge gas space achieves an oxygen concentration of about 100 to 200 ppm or less.
14. The purge rig according to claim 1 , wherein the controller is an electronic control system; and
wherein during a gas purge, purge gas flows from the gas supply passage, through the purge gas distributor, into the purge space and out of the pipe interior to the atmosphere.
15. The purge rig according to claim 14 , wherein the purge dam acts as a barrier disrupting the flow of at least a portion of the purge gas in the purge space from flowing longitudinally down the pipe in a direction from the purge gas distributor toward the purge dam.
16. A purge rig, the purge rig for insertion into a pipeline having a pipe interior, the pipeline including a first pipe end abutting a second pipe end to define a pipe end interface, the purge rig comprising:
a core for at least partially defining a purge space;
a purge dam extending from the core;
a purge gas distributor supported on the core and longitudinally offset from the purge dam for discharging gas into the purge space;
a purge gas supply passage supported on the core, the purge gas supply passage supplying purge gas to the purge gas distributor;
wherein the near weld purge rig is positioned in the pipe interior such that the gas distributor is generally aligned longitudinally with the pipe end interface and at least a portion of the core, at least a portion of the purge dam, and at least a portion of the pipe interior define the purge space; and
wherein the purge gas distributor includes at least two discharge nozzles having overlapping spray patterns and that direct purge gas against an entire length of a pipe interior surface at vertical weld runs where heated weld material is most susceptible to gravitational forces.
17. The purge rig of claim 16 , wherein the purge dam extending from the core is a single purge dam extending from the core.