SYSTEM AND METHOD OF PLATING PIPE

Abstract

A pipe plating rack assembly configured to position a pipe to receive a surface plating is described. The pipe defines a first end, a second end opposite the first end, and an opening extending therebetween. The pipe plating rack includes a first pipe racking component positioned at the first end of the pipe, and a second pipe racking component positioned at the second end of the pipe, wherein the first and second pipe racking components are rotatable about an axis and configured to intermittingly contact the pipe. The first and second pipe racking components are configured to position the pipe at a desired angle relative to a horizontal plane of the pipe plating rack.

Description

FIELD OF THE DISCLOSURE

The field of disclosure relates generally to system and methods of plating pipe, and more particularly, to a pipe racking assembly configured to intermittingly contact a pipe.

BACKGROUND OF THE DISCLOSURE

Existing steel pipe plating techniques utilize a galvanizing process where the pipe is first hot-dipped galvanized in melted zinc and then the threads of the pipe are cut in a secondary step. The zinc layer offers corrosion protection through two mechanisms, including galvanic protection, where the zinc sacrificially corrodes to protect underlying steel, and barrier protection, where the zinc layer seals the steel pipes and prevents moisture and oxygen from the air to reach the steel and start electrochemical corrosion. The threads are cut into the recently galvanized pipe surface and a zinc-rich paint or zinc spray is applied to the threads to produce a superficial coating along the threads. The existing techniques oftentimes utilize fixturing for supporting the pipe during the galvanizing process that causes ‘bare spots’ where little or no coating is applied. The disrupted zinc coverage over the steel pipe, whether caused by the process of cutting the threads or by the fixturing which causes bare spots, creates microscopic points for electrochemical corrosion that propagates under the zinc coating and rusts the steel pipes. Alternatives to current processes include cutting/forming the threads prior to hot dip galvanizing, which leads to excess zinc in threads, but gives a continuous uninterrupted zinc layer that is superior in corrosion protection. Furthermore, zinc galvanizing is costly and produces a high carbon footprint as the kettles holding the melted zinc are typically heated with hydrocarbons to temperatures greater than or equal to 450^oC, without interruption.

Electroplating zinc is an alternative to hot dip galvanizing, but to date has not been used over pipes for several reasons. One of the reasons is that the inside surface of the pipe cannot be covered by zinc. Traditional electroplating systems utilize a rack, connected to the cathode (-) terminal of a DC source, that clamps onto the pipe as the pipe is introduced into the plating bath containing an aqueous electroplating solution or electrolyte. Another reason is that where the clamp touches the pipe, the plating material is not adequately applied.

Based on the foregoing, a need exists for a plating rack that enables a pipe to be plated with sufficient coverage and with minimal secondary processes, thereby reducing plating costs, time, and improving corrosion protection of the pipe.

This background section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with supporting information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.

SUMMARY OF THE DISCLOSURE

In one aspect, a pipe plating rack assembly configured to position a pipe to receive a surface plating is described. The pipe defines a first end, a second end opposite the first end, and an opening extending therebetween. The pipe plating rack includes a first pipe racking component positioned at the first end of the pipe, and a second pipe racking component positioned at the second end of the pipe, wherein the first and second pipe racking components are rotatable about an axis and configured to intermittingly contact the pipe. The first and second pipe racking components are configured to position the pipe at a desired angle relative to a horizontal plane of the pipe plating rack.

In another aspect, a pipe racking component configured for use with a pipe plating rack assembly, wherein the pipe racking component is configured to intermittingly contact a pipe. The pipe racking component includes an engagement insert defining a first insert surface, an opposite second insert surface, and an axis extending therebetween. The engagement insert defines a pocket that extends a distance from the first insert surface in the direction of the second insert surface. The engagement insert defines a feature along the periphery of the pocket, wherein the feature is configured to disrupt the rotation of the pipe. The pipe racking component includes a conduit cap defining a first cap surface, an opposite second cap surface, and an axis extending therebetween. The conduit cap defines a pocket that extends a distance from the first cap surface in the direction of the second cap surface, wherein the pocket is sized and shaped to receive the engagement insert such that the second insert surface is inserted into the pocket of the conduit cap. The engagement insert is configured to receive an end of the pipe and provide intermittent contact with an outer surface of the pipe.

In yet another aspect, a method of electroplating a pipe using a pipe rack assembly is described. The pipe rack assembly includes a first pipe racking component and a second opposite pipe racking component. The method includes positioning the pipe within the first pipe racking component at a first end of the pipe and the second pipe racking component at a second opposite end of the pipe, the pipe being positioned at a desired angle relative to a pipe rack assembly. The method includes rotating the first pipe racking component such that the pipe rotates therein, wherein the pipe racking component is configured to intermittingly contact the pipe. The method includes applying a plating material to a surface of the pipe.

As used herein, “a”, “an”, and “the” refer to both singular and plural referents unless the context clearly dictates otherwise.

As used herein, the term “about” refers to a measurable value such as a parameter, an amount, a temporal duration, and the like and is meant to include variations of +/- 15% or less, preferably variations of +/- 10% or less, more preferably variations of +/- 5% or less, even more preferably variations of +/- 1% or less, and still more preferably variations of +/- 0.1% or less of and from the particularly recited value, in so far as such variations are appropriate to perform in the one or more embodiments of the disclosure described herein. Furthermore, it is also to be understood that the value to which the modifier “about” refers is itself specifically disclosed herein.

As used herein, spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper”, “front”, “back”, “side”, “left”, “right”, “rear”, “top”, “bottom”, and the like, are used for ease of description to describe one element or feature’s relationship to another element(s) or feature(s). It is further understood that the terms “front”, “back”, “left”, and “right” are not intended to be limiting and are intended to be interchangeable, where appropriate. Further, it should be noted that the terms “first,” “second,” and the like herein do not denote any order, quantity, or relative importance, but rather are used to distinguish one element from another.

As used herein, the terms “comprise(s)”, “comprising”, and the like, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

As used herein, the terms “configure(s)”, “configuring”, and the like, refer to the capability of a component and/or assembly, but do not preclude the presence or addition of other capabilities, features, components, elements, operations, and any combinations thereof.

Chemical compounds are described using standard nomenclature. For example, any position not substituted by any indicated group is understood to have its valency filled by a bond as indicated, or a by hydrogen atom.

All ranges disclosed herein are inclusive of the endpoints, and the endpoints are independently combinable with each other. Each range disclosed herein constitutes a disclosure of any point or sub-range lying within the disclosed range.

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”), is intended merely to better illustrate the present disclosure and does not pose a limitation on the scope of the present disclosure or any embodiments unless otherwise claimed.

Any combination or permutation of features, functions and/or embodiments as disclosed herein is envisioned. Additional advantageous features, functions and applications of the disclosed systems, methods and assemblies of the present disclosure will be apparent from the description which follows, particularly when read in conjunction with the appended figures. All references listed in this disclosure are hereby incorporated by reference in their entireties.

BRIEF DESCRIPTION OF THE DRAWINGS

Features and aspects of embodiments are described below with reference to the accompanying drawings, in which elements are not necessarily depicted to scale. Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.

Exemplary embodiments of the present disclosure are further described with reference to the appended figures. It is to be noted that the various features, steps and combinations of features/steps described below and illustrated in the figures can be arranged and organized differently to result in embodiments which are still within the scope of the present disclosure.

To assist those of ordinary skill in the art in making and using the disclosed assemblies, systems and methods, reference is made to the appended figures, wherein:

FIG. 1 depicts a side view of a pipe plating rack including pipe racking assembly, according to the present disclosure;

FIG. 2 depicts a side view of the pipe plating rack including an angled pipe racking assembly, according to the present disclosure;

FIG. 3 depicts a side view of the pipe racking assembly of FIGS. 1 and 2;

FIG. 4 depicts a perspective view of the pipe racking assembly of FIG. 3 including a plurality of ribs;

FIG. 5A depicts a cross-sectional perspective view of the pipe racking assembly of FIG. 4 taken along line 5-5;

FIG. 5B depicts a cross-sectional side view of the pipe racking assembly of FIG. 4 taken along line 5-5;

FIG. 6 depicts a partial cross-sectional view of the pipe racking assembly of FIG. 5B taken within Detail A;

FIG. 7 depicts a partial exploded side view of the pipe racking assembly of FIG. 3;

FIG. 8 depicts a front view of a pipe engagement feature of the pipe racking assembly;

FIG. 9A depicts a perspective view of the a pipe racking component of the pipe racking assembly including the pipe engagement feature of FIG. 8;

FIG. 9B depicts a cross-sectional view of the pipe racking component of FIG. 9A taken along line 9-9;

FIG. 9C depicts an exploded cross-sectional view of the pipe racking component of FIG. 9B;

FIG. 10 depicts a side view of a partial pipe racking assembly, according to the present disclosure;

FIG. 11 depicts a perspective view of a pipe racking carousel assembly, according to the present disclosure;

FIG. 12 depicts a side view of the pipe racking carousel assembly of FIG. 11;

FIG. 13 depicts a partial side view of the pipe racking carousel assembly of FIG. 12;

FIG. 14 depicts a partial side view of the pipe racking carousel assembly of FIG. 13 taken within Detail B;

FIG. 15 depicts a perspective view of a pipe racking component of the pipe racking carousel assembly including the pipe engagement feature of FIG. 8;

FIG. 16 depicts a front view of the pipe racking component of FIG. 15;

FIG. 17 depicts a side exploded view of a pipe racking component of the pipe racking carousel assembly;

FIGS. 18A-18C depict a pipe at various positions within the pipe engagement feature of FIG. 8, wherein FIG. 18A depicts the pipe at a first position within the pipe engagement feature, FIG. 18B depicts the pipe at a second position within the pipe engagement feature, and FIG. 18C depicts the pipe at a third position within the pipe engagement feature; and

FIG. 19 depicts a schematic outline of the operation of the pipe racking assembly and the pipe racking carousel assembly, according to the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The exemplary embodiments disclosed herein describe an advantageous system and method of plating a pipe.

Referring to FIGS. 1 and 2, a pipe plating rack 10 is depicted. The pipe plating rack 10 includes a structure 12 that is configured to support at least one pipe racking assembly 100. The structure 12 of the plating rack 10 may be configured to support a plurality of pipe plating assemblies 100. The pipe racking assembly 100 is configured to support at least one pipe 101. The pipe racking assembly defines a longitudinal axis (L) along the length of the at least one pipe 101. The structure 12 of the plating rack 10 may be configured to engage with, either directly or indirectly, one or more external and/or internal features/components of the pipe racking assembly 100.

In non-limiting examples, FIGS. 1 and 2 depict various positions of the pipe racking assembly 100 relative to the structure 12 of the pipe plating rack 10. Referring to FIG. 1, the plating rack 10 may be configured to position and orient the pipe racking assembly 100 such that the pipe 101 is substantially parallel to a horizontal plane H-H. Thus, the pipe 101 is positioned at an angle (A1) relative to the horizontal plane H-H that is about 0 degrees. Referring to FIG. 2, the plating rack 10 may be configured to position and orient the pipe racking assembly 100 such that the pipe 101 is positioned and oriented at an angle (A1) relative to the horizontal plane H-H. The angle A1 has a magnitude in the range between about 0 degrees and about 90 degrees. In some instances the angle A1 has a magnitude in the range of about 15 degrees and about 90 degrees. In some embodiments, at least two pipe racking assemblies 100 may positioned relative to the structure 12 of the pipe plating rack 10. For example, the at least two pipe racking assemblies 100 may positioned in a stacked configuration. Discussion of the plating rack 10 is best understood with a discussion of the at least one pipe racking assembly 100.

Referring to FIGS. 3-7, the pipe racking assembly 100 includes at least one racking component 102 (e.g., an end cap) positioned in proximity to an end 103 of the pipe 101. In some instances, the pipe racking assembly 100 includes a pair of racking components 102 spaced a distance from each other along the longitudinal axis L of the pipe 101. In some instances, each racking component 102 of the pair of racking components 102 is positioned in proximity to an end of the pipe 101. At least one racking component 102 is configured to engage with the plating rack 10 either directly or indirectly. In some instances, the pair of racking components 102 is configured to engage with the plating rack 10, either directly or indirectly.

The racking component 102 includes a body 104 that defines a first end 106 and an opposite second end 108. The body 104 may define vent openings 109 extending through the body 104. The body 104 may be configured to engage with the end 103 of the pipe 101, the plating rack 10, or the end of the pipe 101 and the plating rack 10, either directly or indirectly. The body 104 defines a cavity 110 that extends a distance from a first surface 112 located in proximity to the first end 106 in the direction of a second surface 114 located in proximity to the second end 108. The cavity 110 may define a cross-sectional opening relative to the longitudinal axis L that is equal to or greater than the diameter of at least the end 103 of the pipe 101. The cavity 110 may define a distance between the first surface 112 and the second surface 114 that is configured to receive at least a portion of the end 103 of the pipe 101. The cavity 110 may be sized and shaped to at least partially engage with at least a portion of the end 103 of the pipe 101. In a non-limiting example, as shown in FIGS. 3-5B, each racking component 102 of the pair of racking components 102 is positioned in proximity to the end 103 of the pipe 101 such that at least a portion of the end 103 is positioned within the cavity 110 of the body 104.

In proximity to the second end 108 of the body 104, at least one of the racking components 102 includes a feature 116 that is configured to engage with the plating rack 10, either directly or indirectly. The feature 116 may enable the pipe racking assembly 100 to be rotated about the longitudinal axis L. The feature 116 may be selected from the group including a gear (e.g., to engage with a chain and/or gear), a groove (e.g., to engage with a belt), and combinations and variations thereof. For ease of explanation, the feature 116 may be referred to throughout as a gear feature 116. However, it should be understood that any feature may be substituted with the gear feature 116 to rotate the pipe racking assembly 100. The gear feature 116 defines at least one tooth 118 extending outwardly from the body 104 in a direction away from the longitudinal axis L. As shown in FIGS. 3-6 and 9A, a plurality of teeth 118 may be spaced around the periphery of the body 104.

The pipe racking assembly 100 includes/defines a pipe engagement feature 120 (FIG. 8) that is configured to directly/indirectly interact with the pipe 101. The racking fixture component 102 of the pipe racking assembly 100 may include/define the pipe engagement feature 120. The pipe engagement feature 120 may be part of the racking fixture component 102 and/or may be a separate component mounted with respect to the racking fixture component 102. The pipe engagement feature 120 may be configured to intermittingly contact the pipe 101 as the pipe racking assembly 100 rotates. The pipe engagement feature 120 may be configured to intermittingly contact the pipe 101 and a cathode (-) DC terminal of the plating racking 10.

Referring to FIGS. 3-9C, the pipe engagement feature 120 is a feature of an engagement insert 122. Thus, the engagement insert 122 defines at least a portion of the pipe engagement feature 120. The engagement insert 122 defines an outer surface 124 which is spaced a distance from the pipe engagement feature 120 in a radial or lateral direction relative to the longitudinal axis L. The engagement insert 122 defines a plurality of protrusions 126 extending radially outwardly from the outer surface 124 and are spaced circumferentially along the periphery of the engagement insert 122. The protrusions 126 may be sized and spaced to engage with corresponding pockets 129 defined relative to the cavity 110 of the racking fixture component 102 (FIG. 9A). The engagement insert 122 may be permanently or semi-permanently mounted with respect to the racking fixture component 102. For example, the engagement insert 122 may be permanently or semi-permanently mounted with respect to the cavity 110 of the racking fixture component 102. The protrusions 126 may align the engagement insert 122 within the cavity 110 of the racking fixture component 102 and secure the engagement insert 122 relative to the racking fixture component 102 during rotation. In some embodiments, the engagement insert 122 may electrically connect the cathode of the pipe plating rack 10 to the pipe racking assembly 100. The engagement insert 122 may be referred to as a cathode, without departing from the spirit/scope of this disclosure. The engagement insert 122 may be at least partially fabricated from an electrically conductive material (e.g., copper). For example, at least a portion of the engagement feature 120 may be fabricated from an electrically conductive material (e.g., copper).

Referring to FIGS. 8 and 9A-9C, the engagement insert 122 defines a first insert surface 125 that is spaced a distance from an engagement surface 127 positioned within a cavity 130 of the pipe engagement feature 120. The pipe engagement feature 120 is positioned such that the longitudinal axis L extends therethrough. Although depicted with axis L extending therethrough, it should be understood that at least the pipe engagement feature 120 may be offset from the axis L. The engagement insert 122 defines at least one opening 131 extending from the cavity 130 and through the engagement surface 127. The at least one opening 131 may be sized, shaped, and positioned to circulate a fluid (e.g., plating material, electrolyte) throughout the cavity 130. The engagement feature 120 defines at least one recess 128 at a position around the longitudinal axis L. In some instances, the engagement feature 120 defines a plurality of discrete recesses 128 spaced around the longitudinal axis L. In a non-limiting example, the engagement feature 120 may define at least three (3) recesses 128 spaced around the longitudinal axis L, as shown in FIG. 8 and represented as 128A, 128B, and 128C. Each of the recesses defines a recess surface 132 that is in proximity to the engagement surface 127 (FIG. 9A). In some instances, the recess surface 132 may be angled relative to the engagement surface 127. For example, the recess surface 132 may be angled relative to the engagement surface 127 between about 5 degrees and about 175 degrees. In a non-limiting example, the recess surface 132 may be angled relative to the engagement surface 127 by about 90 degrees. The recess surface 132 may define a curved surface, a planar surface, and combinations thereof. In some instances, the engagement feature 120 along the recess surface 132 may be configured to at least partially engage with an outer surface 105 of the pipe 101. The outer surface 105 may be at any position on the pipe 101 along the longitudinal length, including, but not limited to, the end 103. The engagement feature 120 along the recess surface 132 may be configured to at least partially contact with the outer surface 105 of the pipe 101 in proximity to the end 103. The engagement feature 120 along the recess surface 132 and the engagement surface 127 may at least partially contact with the pipe 101 

The engagement feature 120 defines at least one protuberance 134 positioned along the periphery of the cavity 130 and extending in a direction towards the longitudinal axis L. The engagement feature 120 may at least one protuberance 134 positioned between each of the recess surfaces 132. The engagement feature 120 may define a plurality of protuberances 134, each protuberance 134 is positioned adjacent to the recess surface 132. The protuberance 134 defines an edge/surface 136 that is positioned in closer proximity to the longitudinal axis L than the recess surface 132. Each protuberance 134 may act as an impediment between adjacent recess surfaces 132. However, the protuberance 134 is not intended to be a complete barrier between the adjacent recess surfaces 132. The cross-sectional distance of two opposing points within the engagement feature 120 may be greater than the diameter of the pipe 101. The cross-sectional diameter between each of the edges 136 of the protuberances 134 is configured to be greater than or at least equal to the diameter of the pipe 101. In some instances, the distance (D) between each adjacent protuberance 134 is greater than or at least equal to the diameter of the pipe 101. For example, the distance (D) between the edge 136 of each adjacent protuberance 134 is greater than or at least equal to the diameter of the pipe 101. Although distance (D) is depicted as being greater than or at least equal to the diameter of the pipe 101, it should be understood that any distance (D) between each adjacent protuberance 134 is appreciated. Therefore, the distance (D) may be less than, equal to, or greater than the diameter of the pipe 101. The distance (D) may be correlated to the number of protuberances 134. Each protuberance 134 may be spaced at an angle of about 120 degrees from the adjacent protuberance 134 as the protuberances are spaced around the longitudinal axis L. However, it should be understood that each protuberance 134 may be spaced at an angle greater than or less than 120 degrees from the adjacent protuberance 134. Therefore, the engagement feature 120 may include additional protuberances 134 without departing from the spirit/scope of this disclosure. Thus, in operation, the pipe 101 may rotate within the engagement feature 120 and in contact with at least one protuberance 134 as the engagement insert 122 of the racking fixture component 102 rotates around the longitudinal axis L. In some instances, the pipe 101 may be in contact with at least one of the protuberances 134 to maintain electrical contact with the engagement feature 120, which may be the cathode. In some instances, the vent openings 109 of the body 104 may ensure a fluid (e.g., plating material, electrolyte) is directed into the engagement feature 120 to contact the pipe 101.

The pipe racking assembly 100 includes an internal anode 138 positioned within an opening of the pipe 101, along the longitudinal axis L, and at least partially in proximity with the racking fixture component 102 (FIGS. 4-7). The internal anode 138 extends through an opening 140 of the engagement insert 122, as shown in FIGS. 5A-6 and 8, and a distance that enable the internal anode 138 to be located at least partially within the racking fixture component 102 (FIGS. 4-6). The opening 140 of the engagement insert 122 may be larger than an opening 141 in the racking component 102. In some instances where the pipe racking assembly 100 includes two racking components 102, the internal anode 138 extends between the first and second racking components 102 (FIGS. 4-5B). In some instances, as shown in FIGS. 4, 5A, and 5B, the internal anode 138 may extend entirely through the first and second racking components 102. The internal anode 138 may be fabricated from a variety of materials depending on the desired plating process. For example, in alkaline zinc plating, the anode 138 may be fabricated from a steel rod that may be plated with zinc.

To ensure the internal anode 138 remains in the desired position within the pipe racking assembly 100, one or more components/features may be utilized to maintain the internal anode 138 in a longitudinal orientation relative to the longitudinal axis L. For example, to ensure the internal anode 138 does not contact the engagement insert 122, one or more components/features may be utilized. Referring to FIGS. 4-6 and 10, the pipe racking assembly 100 may include one or more spacers 142 positioned between the internal anode 138 and the pipe 101. The one or more spacers 142 may be positioned to electrically insulate the internal anode 138 from the engagement feature 120. As depicted in FIG. 10, the spacer 142 may be a rubber O-ring, a disc-shape defining an opening 144 sized and shaped to enable the internal anode 138 to pass therethrough. Although depicted as a disc-shape, the spacer 142 may resemble any shape so long as the spacer 142 may separate the internal anode 138 from the pipe 101. The pipe racking assembly 100 may include a plurality of spacers 142 spaced along the longitudinal axis L of the internal anode 138 and positioned such that at least a portion of the spacer 142 is between the internal anode 138 and the pipe 101.

In some instances, one or more ribs 146 may be coupled to and extend between the first and second racking fixture components 102, as shown in FIGS. 4-6. Each of the one or more ribs 146 may extend between the first and second racking fixture components 102 parallel to the longitudinal axis L. In some instances, a plurality of ribs 146 may be spaced around the racking fixture component 102 along the periphery of the engagement feature 120. The plurality of ribs 146 may be spaced from each other to allow the fluid to pass therethrough. The ribs 146 may be configured to protect the pipe 101 during the plating procedure. For example, the ribs 146 may be configured to secure the pipe 101 in a desired position during rotation of the pipe 101. The ribs 146 may define a cross-sectional shape that is quadrilateral, circular, triangular, and combinations and variations thereof. The ribs 146 may be fabricated from a non-conductive material. For example, the ribs 146 may be fabricated from a plastic material.

The pipe racking assembly 100 described with reference to the plating rack 10 may be substituted with or combined with a pipe racking carousel assembly 200, without departing from the spirit/scope of this disclosure. Therefore, although FIGS. 1 and 2 depict the pipe racking assembly 100 of FIGS. 3-7, the pipe racking carousel assembly 200 of FIGS. 11-14, as described below, may be substituted into or combined into the plating rack 10. In some instances, the plating rack 10 may include the pipe racking assembly 100, as described above, alone or with two or more pipe racking assemblies 100 stacked relative to the structure 12 of the plating rack 10. In some instances, the plating rack 10 may include the pipe racking carousel assembly 200, as described below. In some other instances, the plating rack 10 may include the pipe racking assembly 100 and the pipe racking carousel assembly 200. Like parts are numbered throughout and the description of the parts discussed above further applies to the part mentioned below, unless expressly stated otherwise.

Referring to FIGS. 11-14, the pipe racking carousel assembly 200 includes at least one racking component 202 (e.g., an end cap) positioned in proximity to an end 103 of the pipe 101. In some instances, the pipe racking carousel assembly 200 includes a pair of racking components 202 spaced a distance from each other and aligned with the longitudinal axis L. In some instances, each racking component 202 of the pair of racking components 202 is positioned in proximity to the end of the pipe 101. At least one racking component 202 is configured to engage with the plating rack 10, either directly or indirectly. In some instances, the pair of racking components 202 is configured to engage with the plating rack 10, either directly or indirectly.

Referring to FIGS. 15-17, the racking fixture component 202 includes a body 204 that defines a first end 206 and an opposite second end 208. The body 204 may define vent openings 209 extending through the body 204. The body 204 may be configured to engage with the end 103 of the pipe 101, the plating rack 10, or the end of the pipe 101 and the plating rack 10, either directly or indirectly. The body 204 defines a plurality of cavities 210 that extend a distance from a first surface 212 located in proximity to the first end 206 in the direction of a second surface 214 located in proximity to the second end 208. The plurality of cavities 210 may be positioned relative to the body 204 of the racking component 202. For example, the plurality of cavities 210 may be spaced around the longitudinal axis in a circular configuration, as depicted in FIGS. 15 and 16.

Each of the cavities 210 may define a cross-sectional opening that is equal to or greater than the diameter of at least the end 103 of the pipe 101. Each of the cavities 210 may define a distance between the first surface 212 and the second surface 214 that is configured to receive at least a portion of the end 103 of the pipe 101. Each of the cavities 210 may be sized and shaped to at least partially engage with at least a portion of the end 103 of the pipe 101. In a non-limiting example, as shown in FIGS. 11-14, each racking component 202 of the pair of racking components 202 is positioned in proximity to the end 103 of the pipe 101 such that at least a portion of the end 103 is positioned within the corresponding cavity 210 of the body 204. As depicted, a plurality of pipes 101 may be positioned within the corresponding cavity 210 of the body 204.

In proximity to the second end 208 of the body 204, at least one of the racking components 202 includes a feature 216 that is configured to engage with the plating rack 10, either directly or indirectly. The feature 216 may enable the pipe racking carousel assembly 200 to be rotated around the longitudinal axis L. The feature 216 may be selected from the group including a gear (e.g., to engage with a chain and/or gear), a groove (e.g., to engage with a belt), and combinations and variations thereof. For ease of explanation, the feature 216 may be referred to throughout as gear feature 216. However, it should be understood that any feature may be substituted with the gear feature 216 to rotate the pipe racking carousel assembly 200. The gear feature 216 defines at least one tooth 218 extending radially outwardly from the body 204 in a direction away from the longitudinal axis L. As shown in FIGS. 11, 15, and 16, a plurality of teeth 218 may be spaced along the periphery of the body 204.

The pipe racking carousel assembly 200 includes/defines a plurality of pipe engagement features 120 that are configured to directly/indirectly interact with the pipe 101 (see FIGS. 8, 15, and 16). The plurality of pipe engagement features 120 enables a plurality of pipes to be plated in an electroplating bath by being connected to the cathode. The racking component 202 of the pipe racking carousel assembly 200 may include/define the plurality of pipe engagement features 120. The pipe engagement features 120 may be part of the racking component 202 and/or may be a separate component mounted with respect to the racking component 202. The pipe engagement features 120 may be configured to intermittingly contact the pipe 101 as the pipe racking carousel assembly 200 rotates.

Referring to FIGS. 11-17, the pipe engagement feature 120 is a feature of the engagement insert 122. Thus, the engagement insert 122 defines at least a portion of the pipe engagement feature 120. The pipe racking carousel assembly 200 includes a plurality of pipe engagement inserts 122, each of the pipe engagement inserts 122 are electrically connected to each other and connected to the cathode (-) of the plating rack 10. Each of the plurality of pipe engagement inserts 122 are positioned within the corresponding cavity 210 of the body 204. Therefore, the plurality of pipe engagement inserts 122 may be spaced in a circular configuration around the longitudinal axis, as shown in FIGS. 15 and 16. Referring to FIGS. 15 and 16, the racking component 202 is depicted with several engagement features 120 of the plurality of engagement features 120. Thus, as depicted, several engagement features 120 are removed for clarity to more clearly illustrate the cavity 210 of the racking component 202.

As depicted in FIGS. 11-14, a plurality of pipes 101 may be positioned within the pipe racking carousel assembly 200, in a similar manner as described with the single pipe 101. As noted above, the plurality of engagement inserts 122 may each be a cathode for the pipe racking carousel assembly 200. Thus, in operation, each pipe 101 of the plurality of pipes 101 may independently rotate within each of the engagement features 120 and in contact with at least one protuberance 134 as the engagement insert 122 of the racking component 202 rotates around the longitudinal axis L. In some instances, the vent openings 209 of the body 204 may ensure a fluid (e.g., plating material, electrolyte) is directed into the engagement feature 120 to contact the pipe 101.

The pipe racking carousel assembly 200 includes the internal anode (not shown), referenced above as reference number 138, within each pipe 101 and positioned along the longitudinal axis of each pipe. The racking carousel assembly 200 includes an auxiliary anode (not shown) that extends along the longitudinal axis L of the racking components 202. The auxiliary anode may be positioned at least partially within a mesh housing 238. The mesh housing 238 may electrically isolate the auxiliary anode (not shown) from at least the engagement features 120. The mesh housing 238 may be fabricated from a non-conductive material. For example, the mesh housing 238 is fabricated from a plastic. The auxiliary anode may be positioned along the longitudinal axis L and substantially parallel to the pipes 101. The auxiliary anode and/or the internal anode(s) may extend entirely through the first and second racking components 202. The auxiliary anode and/or the internal anode(s) may be fabricated from a variety of materials depending on the desired plating process. For example, in alkaline zinc plating, the auxiliary anode and/or the internal anode may be fabricated from a steel rod that may be plated with zinc. In some instances, one or both of the auxiliary anode and/or the internal anode may be fabricated from a steel basket that contains zinc nuggets or balls.

The pipe racking assembly 100 and the pipe racking carousel assembly 200 may operate in a similar manner. Thus, the following operation is not limited to one assembly, unless expressly stated otherwise. The pipe rack assembly 10 is configured to rotate the pipe racking assembly 100 and/or the pipe racking carousel assembly 200. Referring to FIG. 19, method 300 describes that one end 103 of the pipe 101 or plurality of pipes 101 are positioned within a corresponding engagement feature 120 of the first racking component 102/202 and another end 103 of the pipe 101 or plurality of pipes 101 are positioned within a corresponding engagement feature 120 of the second racking component 102/202 such that the pipe 101 or plurality of pipes 101 are positioned at a desired angle relative to the pipe rack assembly 10, as denoted by reference number 302. As indicated by reference number 304, the first pipe racking component 102/202 is rotated such that the pipe 101 or plurality of pipes 101 rotate(s) within the corresponding engagement feature(s) 120, wherein the pipe racking component 102/202 is configured to intermittingly contact the pipe 101 or plurality of pipes 101 as the pipe rotates and is coated with a barrier layer/plating material. As indicated by reference number 306, a plating material is applied to the exterior and interior of the pipe 101 or plurality of pipes 101. In some instances, a pump (not shown) may be positioned in fluid communication with the interior of the pipe 101 to replenish the electrolyte inside the pipe. The pump may be used to agitate the electrolyte to properly circulate inside the pipe 101. In electroplating, movement between an anode and a cathode is crucial to renew the metallic ions supply to the cathode (i.e., the pipe), otherwise the electroplating process is stopped.

In operation, the pipe 101 rotates within the engagement feature 120 of the racking component 102/202 such that the pipe intermittently contacts the racking component 102/202. For example, the end 103 of the pipe 101 may define threads 107 (FIG. 6) and the threads 107 may intermittently contact the racking component 102/202 as the pipe 101 rotates within the engagement feature 120 as the electrolyte is being applied. This enables even and consistent plating of the pipe 101, including the threads 107 of the pipe 101. The movement of the pipe 101 within the engagement feature 120 may be in a clockwise motion, in a counterclockwise motion, in a back-and-forth (e.g., rocking) motion, and combinations and variations thereof. As the racking component 102/202 rotates, the pipe 101 within the engagement feature 120 also rotates into contact with the protuberance 134. As the system operates the pipe rotates and maintains contact with at least one protuberance 134 of the engagement feature 120. The relatively loose fit between the pipe and racking component 102/202 enables the electroplating solution (e.g. Zn, Ni, or Cu) to flow between the pipe 101 and racking component 102/202 to cover the pipe 101 both internally and externally. Gas escapes through openings 109/209 as the solution circulates. The system enables the coating process to be completed without interruption, for example, to coat the threaded portion 107 of the pipe 101. The intermittent contact between the engagement feature 120 of the racking component 102/202 and the pipe 101 may be sufficient such that the pipe 101 maintains electrical contact with the cathode of the plating rack 10 through the racking component 102/202. As the description proceeds, for simplicity, the movement/rotation of a section of the pipe end will be described. However, it should be understood that the entirety of the pipe end 103 follows the same path through the engagement feature 120 as the pipe 101 contacts the protuberances 134, as described relative to a portion/section/arc length of the pipe 101.

In one embodiment, the pipe 101 begins in contact with a first protuberance 134A, as shown in FIG. 18A, and as the racking component 102/202 rotates in a clockwise rotation, the pipe is in contact with the protuberance 134A positioned adjacent to the first recess 128A in a counterclockwise direction. It should be understood that the racking component 102/202 may rotate in a counterclockwise direction where the pipe rotates over the protuberance 134C. The section of the pipe 101 then continues to move in the direction of the adjacent protuberance 134B, as shown in FIG. 18B. The movement of the pipe 101 between the first protuberance 134A and the second protuberance 134B may be a predictable movement, may be an unpredictable movement (e.g., a jogging movement), or may be a semi-predictable movement. The pipe 101 then rotates over the second protuberance in the direction of the adjacent protuberance 134C, as shown in FIG. 18C. The movement of the pipe 101 between the second protuberance 134B and the third protuberance 134C may be a predictable movement, may be an unpredictable movement (e.g., a jogging movement), or may be a semi-predictable movement. The rotation of the pipe 101 continues until the plating process is complete. By contacting the pipe with the protuberances 134, the rotation of the pipe 101 is disrupted which causes the racking component 102/202 to intermittingly contact the section of the pipe 101. The intermittent contact with the section of the pipe 101 ensures the entirety of the pipe 101 is plated with the electrolyte as the pipe 101 does not remain in contact with the racking component 102/202 for an extended period of time, thereby causing ‘bare spots’ or spots of reduced plating material. Instances where the pipe 101 is positioned and oriented at the angle (A1), as shown in FIGS. 1 and. 2, the angled pipe 101 promotes venting of a byproduct of the plating process, such as, for example, a fluid (e.g., hydrogen). The pipes 101 positioning may promote circulation of the electrolyte within the pipe 101.

In another embodiment, the pipe 101 begins in a first recess 128A and as the racking component 102/202 rotates in a clockwise rotation, the pipe section rotates over the protuberance 134A positioned adjacent to the first recess 128A in a counterclockwise direction. It should be understood that the racking component 102/202 may rotate in a counterclockwise direction where the pipe begins in the first recess 128A and rotates over the protuberance 134C. A portion of the outer surface 105 of the pipe 101 contacts the recess surface 132 of the first recess 128. As the pipe 101 contacts the protuberance 134A, the rotation of the pipe 101 is at least partially disrupted.

The section of the pipe 101 then continues to rotate to a second recess 128B, which is adjacent to the protuberance 134A in a counterclockwise direction. At least a portion of the outer surface 103 that contacts the recess surface 132 of the second recess 128B is different from the portion of the outer surface (103) that contacted the recess surface 132 of the first recess 128A. The section of the pipe 101 then rotates over the protuberance 134B, which causes the rotation of the pipe 101 to be at least partially disrupted. The section of the pipe 101 then continues to rotate to a third recess 128C adjacent the protuberance 134B in a counterclockwise direction. At least a portion of the outer surface 105 that contacts the recess surface 132 of the second recess 128C is different from the portion of the outer surface 105 that contacted the recess surface 132 of the second recess 128B. The section of the pipe 101 then rotates into contact with the protuberance 134C positioned adjacent to the third recess 128C in the counterclockwise direction. The section of the pipe 101 then continues to rotate to the first recess 128A adjacent the protuberance 134C in a counterclockwise direction. The rotation of the pipe 101 continues until the plating process is complete. By contacting the pipe with the protuberances 134, the rotation of the pipe 101 is disrupted which causes the racking component 102/202 to intermittingly contact the section of the pipe 101. The intermittent contact with the section of the pipe 101 ensures the entirety of the pipe 101 is plated with the plating material as the pipe 101 does not remain in contact with the racking component 102/202 for an extended period of time, thereby causing ‘bare spots’ or spots of reduced plating material. Instances where the pipe 101 is positioned and oriented at the angle (A1), as shown in FIGS. 1 and 2, the angled pipe 101 promotes venting of a byproduct of the plating process, such as, for example, a fluid (e.g., hydrogen).

It should be understood that although much of the disclosure describes zinc plating over steel pipe, the systems and methods described herein may apply to other types of plating, such as, for example, nickel plating over brass pipe and copper plating over steel pipe. The plating material and pipe material are not intended to be limiting factors and are provided to further enhance the description of the disclosure.

While the disclosure has been described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes may be made, and equivalents may be substituted for the elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt the teaching of the disclosure to particular use, application, manufacturing conditions, use conditions, composition, medium, size, and/or materials without departing from the essential scope and spirit of the disclosure. Therefore, it is intended that this disclosure is not limited to the exemplary embodiments and best mode contemplated for carrying out the embodiments of this disclosure as described herein. Since many modifications, variations, and changes in detail can be made to the described examples, it is intended that all matters in the preceding description and shown in the accompanying figures be interpreted as illustrative and not in a limiting sense.

Claims

1. A pipe plating rack assembly configured to position a pipe to receive a surface plating, wherein the pipe defines a first end, a second end opposite the first end, and an opening extending therebetween, the pipe plating rack comprising:

a first pipe racking component positioned at the first end of the pipe, and a second pipe racking component positioned at the second end of the pipe, wherein the first and second pipe racking components are rotatable about an axis and configured to intermittingly contact the pipe;

wherein the first and second pipe racking components are configured to position the pipe at a desired angle relative to a horizontal plane of the pipe plating rack.

2. The pipe plating rack assembly according to claim 1, wherein the desired angle is between about 0 degrees and about 90 degrees.

3. The pipe plating rack assembly according to claim 1, wherein the desired angle is between about 15 degrees and about 45 degrees.

4. The pipe plating rack assembly according to claim 1, wherein the first and second pipe racking components are configured such that the pipe rotates within each of first and second pipe racking components.

5. The pipe plating rack assembly according to claim 1, wherein the first pipe racking component defines a pocket configured to receive the corresponding first end of the pipe, wherein the first pipe racking component defines a feature along the periphery of the pocket, wherein the feature is configured to disrupt the rotation of the pipe such that the first pipe racking component intermittingly contacts the pipe.

6. The pipe plating rack assembly according to claim 5, wherein the feature is a protuberance, wherein the first pipe racking component defines at least three protuberances along the periphery of the pocket, each protuberance positioned at an angle of about 120 degrees from the adjacent protuberance around the axis.

7. The pipe plating rack assembly according to claim 1, wherein the first pipe racking component defines a pocket configured to receive the corresponding first end of the pipe, wherein the first pipe racking component defines a feature along the periphery of the pocket, wherein the feature is configured to disrupt the rotation of the pipe such that the first pipe racking component intermittingly contacts the pipe, and wherein the second pipe racking component defines a pocket configured to receive the corresponding second end of the pipe, wherein the second pipe racking component defines a feature along the periphery of the pocket, wherein the feature is configured to disrupt the rotation of the pipe such that the second pipe racking component intermittingly contacts the pipe.

8. The pipe plating rack assembly according to claim 7, wherein the feature is a protuberance, wherein the first pipe racking component and the second pipe racking component each define at least one protuberance along the periphery of the pocket.

9. The pipe plating rack assembly according to claim 1, wherein the first pipe racking component and the second pipe racking component each define a portion that is electrically conductive.

10. A pipe racking component configured for use with a pipe plating rack assembly, the pipe racking component is configured to intermittingly contact a pipe, the pipe racking component comprising:

an engagement insert defining a first insert surface, an opposite second insert surface, and an axis extending therebetween, the engagement insert defines a pocket that extends a distance from the first insert surface in the direction of the second insert surface, the engagement insert defines a feature along the periphery of the pocket, wherein the feature is configured to disrupt the rotation of the pipe; and

a conduit cap defining a first cap surface, an opposite second cap surface, and an axis extending therebetween, the conduit cap defines a pocket that extends a distance from the first cap surface in the direction of the second cap surface, wherein the pocket is sized and shaped to receive the engagement insert such that the second insert surface is inserted into the pocket of the conduit cap,

wherein the engagement insert is configured to receive an end of the pipe and provide intermittent contact with an outer surface of the pipe.

11. The pipe racking component according to claim 10, wherein the engagement insert is at least partially electrically conductive.

12. The pipe racking component according to claim 10, wherein the feature is a protuberance wherein the engagement insert defines at least three protuberances spaced along the periphery of the pocket, each protuberance positioned at an angle of about 120 degrees from the adjacent protuberances around the axis.

13. The pipe racking component according to claim 10 further comprising an anode that extends through an axially aligned opening in both the conduit cap and the engagement insert.

14. The pipe racking component according to claim 10, wherein the conduit cap further comprises a plurality of pockets spaced around the axis, wherein each of the pockets is sized and shaped to receive the engagement insert, wherein each engagement insert is positioned within a corresponding pocket of the conduit cap, wherein each engagement insert is configured to receive a pipe therein.

15. The pipe racking component according to claim 14, wherein the engagement insert is configured to position each pipe axially around an anode that extends through an axially aligned opening in both the conduit cap and the engagement insert.

16. A method of electroplating a pipe using a pipe rack assembly, the pipe rack assembly including a first pipe racking component and a second opposite pipe racking component the method comprising:

positioning the pipe within the first pipe racking component at a first end of the pipe and the second pipe racking component at a second opposite end of the pipe, the pipe being positioned at a desired angle relative to a pipe rack assembly;

rotating the first pipe racking component such that the pipe rotates therein, wherein the pipe racking component is configured to intermittingly contact the pipe; and

applying a plating material to a surface of the pipe.

17. The method according to claim 16, wherein the desired angle is between about 0 degrees and about 90 degrees.

18. The method according to claim 16, wherein the desired angle is between about 15 degrees and about 45 degrees.

19. The method according to claim 16, wherein the first pipe racking component defines a pocket configured to receive the corresponding first end of the pipe, wherein the first pipe racking component defines a feature along the periphery of the pocket, wherein the feature is configured to disrupt the rotation of the pipe such that the first pipe racking component intermittingly contacts the pipe.

20. The method according to claim 16 further comprising a pump in fluid communication with an interior of the pipe.