Method and system for forming a pipeline

1. A method of forming a pipeline comprising fused pipe laid in an upstream direction along a predetermined path having at least one design elevation, the pipeline comprising straight pipe elements and at least one non-linear pipe subassembly positioned at a preselected location on the predetermined path, the method comprising:

(a) providing a loader module for loading the straight pipe elements;

(b) positioning a plurality of the straight pipe elements in the loader module;

(c) providing a first fusing module connected to the loader module and configured for fusing the straight pipe elements together, the loader module and the first fusing module comprising a straight pipe processing subassembly;

(d) with the first fusing module, fusing the straight pipe elements together in series to form a first portion of the fused pipe;

(e) in an inspection module attached to the first fusing module, inspecting the fused pipe;

(f) in a finishing module attached to the inspection module, applying coating to the fused pipe, to form finished pipe segments, the inspection module and the finishing module comprising a finishing subassembly;

(g) moving the straight pipe processing subassembly and the finishing subassembly relative to the predetermined path in the upstream direction along the predetermined path to allow the finished pipe segments to be lowered to said at least one design elevation along the predetermined path under the influence of gravity;

(h) substantially at the preselected location, detaching the first fusing module from the inspection module;

(i) moving the straight pipe processing subassembly in the upstream direction apart from the finishing subassembly, to provide a gap between the first fusing module and the inspection module substantially at the preselected location;

(j) positioning at least one support element in the gap;

(k) moving a second fusing module into a predetermined position in the gap relative to the inspection module, and attaching the second fusing module with the inspection module, the second fusing module being at least partially supported by said at least one support element;

(l) fusing a downstream end of said at least one non-linear pipe subassembly located in the second fusing module to an upstream end of the first portion of the fused pipe supported by the inspection module, to provide a second portion of the fused pipe that comprises said at least one non-linear pipe subassembly;

(m) moving the second fusing module in the upstream direction to position said at least one non-linear pipe subassembly at least partially in the inspection module, in which the second portion of the fused pipe, comprising said at least one non-linear pipe subassembly, is inspected;

(n) moving the second fusing module in the upstream direction to position said at least one non-linear pipe subassembly at least partially in the finishing module, in which a coating is applied to said at least one non-linear pipe subassembly, to include said at least one non-linear pipe subassembly in the finished pipe segments;

(o) detaching the second fusing module from the inspection module;

(p) moving the second fusing module away from the predetermined path;

(q) attaching the first fusing module to the inspection module;

(r) fusing a downstream end of a selected one of the straight pipe elements with the upstream end of said at least one non-linear pipe subassembly to include said at least one non-linear pipe subassembly in the fused pipe;

(s) moving the straight pipe processing subassembly and the finishing subassembly in the upstream direction along the predetermined path, to allow the finished pipe segment including said at least one non-linear pipe subassembly to be positioned in the preselected location on the predetermined path.

2. The pipeline formed according to the method of claim 1 .