Method and apparatus for splicing tubular heater sections

Abstract

An apparatus ( 10 ) for splicing a heatable section ( 20 ) of a tubular heater ( 12 ) to a cold section, ( 22 ) the heatable section ( 20 ) includes an outer sheath ( 78 ), which has a heating element ( 84 ) therein. The cold section ( 22 ) includes an outer sheath ( 88 ) which has a cold pin ( 94 ) therein. The apparatus ( 10 ) comprises an enclosure ( 12 ) defining a chamber ( 62 ) which further defines opposed openings in communication with the chamber ( 62 ). A welding tip ( 30 ) extends into the chamber ( 62 ) and is capable of melting the cold pin ( 94 ) and welding the ends ( 80,90 ) of the heatable and cold sections ( 20,22 ) together. When one end ( 80 ) of the heatable section ( 20 ) and one end ( 90 ) of the cold section ( 22 ) is each directed into one of the opposing openings to a predetermined depth, the welding tip ( 30 ) is then placed in close proximity with the end ( 90 ) of the cold section ( 22 ) forming a molten pool ( 128 ) thereon. The ends ( 80,90 ) of the heatable and cold sections are ( 20,22 ) then brought into contact wherein the molten pool ( 128 ) and the heating element ( 84 ) form a weld connection therebetween as the pool solidifies. The welding tip ( 30 ) then forms a weld joint ( 134 ) along the juncture ( 136 ) of the ends ( 80,90 ) of the outer sheaths ( 78,88 ) of the heatable and cold sections ( 20,22 ) thereby establishing a splice therebetween.

I claim:  
     
         1 . An apparatus ( 10 ) for splicing a heatable section ( 20 ) of a tubular heater ( 11 ) to a cold section ( 22 ) thereof, said heatable section ( 20 ) having opposing ends ( 80 , 82 ) including an outer sheath ( 78 ) and a heating element ( 84 ), said heating element ( 84 ) being inside said outer sheath ( 78 ), said cold section ( 22 ) having opposing ends ( 90 , 92 ) including an outer sheath ( 88 ) and a cold pin ( 94 ), said apparatus ( 10 ) comprising: 
 an enclosure ( 12 ) defining a chamber ( 62 ), said enclosure ( 12 ) further defining openings in communication with said chamber ( 62 );    at least one welding tip ( 30 ) extending into said chamber ( 62 ) and capable of melting said cold pin ( 94 ) and welding the ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ) together;    wherein one end ( 80 ) of said heatable section ( 20 ) and one end ( 90 ) of said cold section ( 22 ) are each directed into one of respective said opposing openings to a predetermined depth, said welding tip ( 30 ) being placed in close proximity with said cold pin ( 94 ) of said end ( 90 ) of said cold section ( 22 ) forming a molten pool ( 128 ) thereon, said ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ) being brought into contact wherein said molten pool ( 128 ) and said heating element ( 84 ) form a connection therebetween as said molten pool ( 128 ) solidifies:    
     
     
         2 . The apparatus ( 10 ) of  claim 2  wherein said heatable and cold sections ( 20 , 22 ) are circular in cross section.  
     
     
         3 . The apparatus ( 10 ) of  claim 1  wherein said welding tip ( 30 ) is a Tungston Inert Shielded Gas welder.  
     
     
         4 . The apparatus ( 10 ) of  claim 1  wherein said chamber ( 62 ) is filled with an inert gas.  
     
     
         5 . The apparatus ( 10 ) of  claim 1  wherein said heating element ( 84 ) and said cold pin ( 94 ) are substantially centered within respective outer sheaths ( 78 , 88 ) by a filler material ( 86 ).  
     
     
         6 . The apparatus ( 10 ) of  claim 5  wherein said filler material ( 86 ) is magnesium oxide.  
     
     
         7 . The apparatus ( 10 ) of  claim 1  further comprising a pair of rollers ( 16 , 18 ) in communication with said chamber ( 62 ) and aligned with said opposed openings.  
     
     
         8 . The apparatus ( 10 ) of  claim 7  wherein a platform ( 35 ) extends from said enclosure ( 12 ) in alignment with said pair of rollers ( 16 , 18 ).  
     
     
         9 . The apparatus ( 10 ) of  claim 8  wherein said platform ( 35 ) includes a notched portion ( 37 ) formed therein for alignment with said opposed openings.  
     
     
         10 . The apparatus ( 10 ) of  claim 7  further comprising an actuator ( 24 ) resting on said pair of rollers ( 16 , 18 ) for directing said cold section ( 22 ) therealong.  
     
     
         11 . The apparatus ( 10 ) of  claim 1  wherein said welding tip ( 30 ) being capable of forming a weld joint along a juncture ( 136 ) of said ends ( 80 ,  90 ) of said heatable and cold sections ( 20 , 22 ) thereby establishing a splice therebetween.  
     
     
         12 . The apparatus ( 10 ) of  claim 1  wherein said at least one welding tip ( 30 ) comprises a Tungsten Inert Shielded Gas welder.  
     
     
         13 . The apparatus ( 10 ) of  claim 1  wherein said at least one welding tip ( 30 ) comprises an orbital Tungsten Inert Shielded Gas welder.  
     
     
         14 . A method of splicing a tubular heater ( 11 ) comprising a heatable section ( 20 ) and a cold section ( 22 ) , said heatable and said cold sections ( 20 , 22 ) each having an outer sheath ( 78 , 88 ) with respective first and second ends ( 80 ,  82 ,  90 ,  92 ), said heatable section ( 20 ) having a heating element ( 84 ) for generating heat and said cold section ( 22 ) having a cold pin ( 94 ) for conducting an electrical current using a splicing apparatus ( 10 ) comprising an enclosure ( 12 ) defining a chamber, ( 62 ) said enclosure ( 12 ) further defining openings in communication with said chamber ( 62 ), at least one welding tip ( 30 ) extending into said chamber ( 62 ), said at least one welding tip ( 30 ) being capable of melting said cold pin ( 94 ) and then welding said first ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ) together, comprising the steps of: 
 a) directing said first ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ) toward each other through respective said openings to a predetermined depth;    b) placing said welding tip ( 30 ) in close proximity with said cold pin( 94 );    c) melting a portion of said cold pin ( 94 ) along said first end ( 90 ) of said cold section ( 22 ) with said welding tip( 30 );    d) pressing said first ends ( 80 , 90 ) of said heatable section ( 20 ) and said cold section ( 22 ) together forming a juncture ( 136 ) therebetween; and    e) welding along said juncture ( 136 ) of said outer sheaths ( 78 , 88 ) with said welding tip ( 30 ) to form a weld joint ( 134 ) therebetween.    
     
     
         15 . The method of  claim 14  wherein said step c) is performed using a Tungsten Inert Shielded Gas welder.  
     
     
         16 . The method of  claim 14  wherein said step e) is performed using a Tungsten Inert Shielded Gas welder.  
     
     
         17 . The method of  claim 14  wherein said steps c) and e) are performed in the presence of an inert gas.  
     
     
         18 . The method of  claim 14  wherein said heating element ( 84 ) is centrally coiled along the length of said heatable section ( 20 ).  
     
     
         19 . The method of  claim 14  wherein said step e) is performed using an orbital Tungsten Inert Shielded Gas welder.  
     
     
         20 . The method of  claim 18  wherein a portion of said heating element ( 84 ) is caused to extend outwardly from said first end ( 80 ).  
     
     
         21 . The method of  claim 14  wherein said step d) juncture ( 136 ) is formed so that said heating element ( 84 ) and said melted portion ( 128 ) of said cold pin ( 94 ) contact each other thereby forming a connection between said heating element ( 84 ) and said cold pin ( 94 ) as said cold pin ( 94 ) solidifies.  
     
     
         22 . An apparatus ( 10 ) for splicing a heatable section ( 20 ) of a tubular heater ( 11 ) to a cold section ( 22 ) thereof, said heatable section ( 20 ) having opposing ends ( 80 , 82 ) including an outer sheath ( 78 ) and a heating element( 84 ), said cold section ( 22 ) having opposing ends ( 90 , 92 ) including an outer sheath ( 88 ) and a cold pin, ( 94 ) said apparatus ( 10 ) comprising: 
 an enclosure ( 12 ) defining a chamber ( 62 ), said enclosure ( 12 ) further defining opposed openings in communication with said chamber ( 62 ) for receiving said heatable section ( 20 ) in one of said opposed openings and said cold section ( 22 ) in the other said opening;    a roller assembly ( 14 ) having first and second rollers ( 16 , 18 ), said roller assembly ( 14 ) further including a staging portion ( 15 ) in communication with said enclosure ( 12 ) and a placement portion ( 17 ) extending from said staging portion ( 15 ), said first and second rollers ( 16 , 18 ) being aligned with said opposed openings;    a platform ( 35 ) extending from said enclosure ( 12 ), said platform ( 35 ) having a notched portion ( 37 ) formed therein which is aligned with said first and second rollers ( 16 , 18 ) for carrying said heatable section ( 20 ) therealong;    an actuator ( 24 ) resting between said first and second rollers ( 16 , 18 ) along said placement portion ( 17 ) for directing said cold section ( 22 ) therealong,    at least one welding tip ( 30 ) extending into said chamber ( 62 ) and capable of melting said cold pin ( 94 ) and connecting the ends of said heatable and cold sections ( 20 , 22 ) together;    wherein upon respective ends of said heatable and cold sections ( 20 , 22 ) being placed in each of said opposed openings, said actuator ( 24 ) directing said cold section ( 22 ) so that said welding tip ( 30 ) may be placed in close proximity with said cold pin ( 94 ) for forming a molten pool ( 128 ) thereon, said ends ( 80 ,  90 ) of said heatable and cold sections ( 20 , 22 ) then being brought into contact with one another such that said molten pool ( 128 ) and said heating element ( 84 ) form a connection therebetween as said molten pool ( 128 ) solidifies.    
     
     
         23 . The apparatus ( 10 ) according to  claim 22 , wherein said first and second rollers ( 16 , 18 ) are forced in rotational movement so that said heatable and cold sections ( 20 , 22 ) rotate in unison in an opposing rotational movement along said staging portion ( 15 ).  
     
     
         24 . The apparatus ( 10 ) according to  claim 22 , wherein said welding tip ( 30 ) may form a weld joint ( 134 ) along the juncture ( 136 ) of said ends ( 80 , 82 , 90 , 92 ) of said heatable and cold sections, ( 20 , 22 ) thereby establishing a splice therebetween.  
     
     
         25 . The apparatus ( 10 ) of  claim 22  wherein roller assembly ( 14 ) extends through said enclosure ( 12 ).  
     
     
         26 . The apparatus ( 10 )  claim 22  wherein said actuator ( 24 ) drives said cold section ( 22 ) into one of said opposed openings to a predetermined depth so that cold section ( 22 ) is rotatably carried by said staging portion ( 15 ).  
     
     
         27 . The apparatus ( 10 ) of  claim 26  wherein said actuator ( 24 ) directs the ends ( 80 , 82 , 90 , 92 ) of said heatable and cold sections ( 20 , 22 ) into contact with each other after said welding tip ( 30 ) contacts said cold pin ( 94 ) for forming said molten pool ( 128 ) thereon.  
     
     
         28 . An apparatus ( 10 ) for splicing a heatable section ( 20 ) of a tubular heater ( 12 ) to a cold section ( 22 ) thereof, said heatable section ( 20 ) including an outer sheath ( 78 ) having a heating element ( 84 ) therein substantially extending the length of said outer sheath, ( 78 ) said cold section ( 22 ) including an outer sheath ( 88 ) having a cold pin ( 94 ) therein substantially extending the length of said sheath ( 88 ), said apparatus ( 10 ) comprising: 
 an enclosure ( 12 ) defining a chamber ( 62 ), said enclosure ( 12 ) further defining opposed openings in communication with said chamber ( 62 ) for receiving one said heatable section ( 20 ) in one said opposed opening and one said cold section ( 22 ) in the other said opening;    a platform ( 35 ) having a notch ( 37 ) formed therein extending from said enclosure ( 12 );    first and second rollers ( 16 , 18 ) having a staging portion ( 15 ) in communication with said enclosure ( 12 ) and a placement portion ( 17 ) extending therefrom in an opposing direction from said platform ( 35 ), said first and second rollers ( 16 , 18 ) and said notch ( 37 ) being aligned with said opposed openings;    an actuator ( 24 ) positioned along said placement portion ( 17 );    a rotatable welding tip ( 30 ) and a fixed welding tip ( 124 ) extending into said chamber ( 62 ), said rotatable welding tip ( 30 ) capable of melting said cold pin, ( 94 ) said fixed welding tip ( 124 ) capable of welding the ends of said heatable and cold sections ( 20 ,  22 ) together.    
     
     
         29 . The apparatus ( 10 ) of  claim 28  wherein once said heatable section ( 20 ) reaches said predetermined depth, said actuator ( 24 ) includes a roller ( 120 ) which extends downwardly into rotatable tangential contact with said heatable section ( 20 ) thereby constraining said heatable section ( 20 ) to rotational movement along said staging portion ( 15 ).  
     
     
         30 . The apparatus ( 10 ) of  claim 28  wherein upon respective ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ) being placed in each of said opposed openings, said actuator ( 24 ) capable of directing said cold section ( 22 ) into contact with said rotatable welding tip ( 130 ) for forming a molten pool ( 128 ) thereon and with said fixed welding tip ( 124 ) such that after said molten pool ( 128 ) is formed, said actuator ( 24 ) directs said heatable and cold sections ( 20 , 22 ) into contact for said fixed welding tip ( 124 ) to weld the ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ) together.  
     
     
         31 . The apparatus ( 10 ) of  claim 28  wherein said first and second rollers ( 16 , 18 ) are placed in driven rotational movement so that heatable and cold sections ( 20 , 22 ) rotate in unison in an opposing rotational movement along said staging portion ( 15 ) so that fixed welding tip ( 124 ) forms a weld joint ( 134 ) along the juncture ( 136 ) of said ends ( 80 , 90 ) of said heatable and cold sections ( 20 , 22 ).