METHODS FOR MAKING SAME

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] Not applicable.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not applicable.

BACKGROUND

[0003] Pipelines are typically used to transport fluids between two different locations in a variety of industries such as manufacturing facilities, oil and/or chemical production or processing sites, and the like. Pipelines are usually made of a plurality of individual pipes or tubular members connected together end-to-end. A variety of different types of joints can be used to connect two pipes end-to- end. One common type of joint is a fiange joint formed by bolting flanges disposed at opposed ends of the pipes together.

BRIEF SUMMARY OF THE DISCLOSURE

[0004] Some embodiments disclosed herein are directed to a cover assembly for a flange joint. In an embodiment, the cover assembly includes a unitary cover box including a first open end and an inner cavity. The unitary cover box is configured to receive a flange joint through the first open end into the inner cavity. In addition, the cover assembly includes a first end cap including a throughbore extending axially therethrough. The first end cap is configured to be coupled to first open end.

[0005] Other embodiments are directed to a method for installing a cover assembly. In an embodiment, the method includes (a) translating a unitary cover box along a first tubular member toward a flange joint joining the first tubular member to a second tubular member. The unitary cover box has a first open end. In addition, the method includes (b) receiving the flange joint within an inner cavity of the unitary cover box. Further, the method includes (c) translating a first end cap along the second tubular member toward the flange joint. Still further, the method includes (d) coupling the first end cap with the first open end of the unitary cover box. [0006] Still other embodiments disclosed herein are directed to a tooling assembly for manufacturing a cover box assembly for a flange joint. In an embodiment the tooling assembly includes a driveshaft having a central axis, and a first plate coaxially mounted to the driveshaft. In addition, the tooling assembly includes a drum coaxially positioned about the driveshaft. The drum includes a first end proximate the first plate and a second end axially opposite the first end. Further, the tooling assembly includes a second plate coaxially mounted the driveshaft. The second plate engages the second end of the drum. Still further, the tooling assembly includes a third plate coaxially mounted to the driveshaft. The third plate includes an axial projection that engages with the second plate.

[0007] Embodiments described herein comprise a combination of features and advantages intended to address various shortcomings associated with certain prior devices, systems, and methods. The foregoing has outlined rather broadly the features and technical advantages disclosed herein in order that the detailed description that follows may be better understood. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings. It should be appreciated by those skilled in the art that the conception and the specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes as those disclosed embodiments. It should also be realized by those of ordinary skill in the art that such equivalent constructions do not depart from the spirit and scope of this disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] For a detailed description of various embodiments, reference will now be made to the accompanying drawings in which:

[0009] Figure 1 is a cross-sectional side view of an embodiment of a flange cover assembly in accordance with the principles disclosed herein disposed about a flange joint;

[0010] Figure 2 is an enlarged cross-sectional side view take of the flange cover assembly of Figure 1 taken along section II-II of Figure 1;

[0011] Figures 3 and 4 are sequential perspective views of the flange cover assembly of Figure 1 being installed on the flange joint of Figure 1; [0012] Figure 5 is a perspective view of an embodiment of a tooling assembly for manufacturing the flange cover assembly of Figure 1;

[0013] Figure 6 is a cross-sectional side view of the tooling assembly of Figure 5 taken along section VI- VI of Figure 5;

[0014] Figure 7 is a graphical illustration of an embodiment of a method for manufacturing and installing the flange cover assembly of Figure 1;

[0015] Figure 8 is a schematic cross-sectional side view of the flange cover assembly of Figure 1 being formed with the tooling assembly of Figure 5;

[0016] Figure 9 is a cross-sectional perspective view of an embodiment of a flange cover assembly in accordance with the principles disclosed herein;

[0017] Figure 10 is a perspective view of the flange cover assembly of Figure 9 being installed on the flange joint of Figure 1 ;

[0018] Figure 11 is a cross-sectional side view of an embodiment of a tooling assembly for manufacturing the flange cover assembly of Figure 9; and

[0019] Figure 12 is a schematic cross-sectional side view of the flange cover assembly of Figure 9 being formed on the tooling assembly of Figure 11.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

[0020] The following discussion is directed to various exemplary embodiments. However, one skilled in the art will understand that the examples disclosed herein have broad application, and that the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.

[0021] Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness. [0022] In the following discussion and in the claims, the terms "including" and "comprising" are used in an open-ended fashion, and thus should be interpreted to mean "including, but not limited to... ." Also, the term "couple" or "couples" is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices, components, and connections. In addition, as used herein, the terms "axial" and "axially" generally mean along or parallel to a central axis (e.g., central axis of a body or a port), while the terms "radial" and "radially" generally mean perpendicular to the central axis. For instance, an axial distance refers to a distance measured along or parallel to the central axis, and a radial distance means a distance measured perpendicular to the central axis. The use of the terms "radial," "radially," "axial," "axially," and the like are used herein to refer to the shape, orientation, etc. of structures, surfaces, components, etc. in relation to a central axis, and the use of such terminology should not be interpreted as necessarily requiring or suggesting a circular, cylindrical, or otherwise curved surface, orientation, shape, etc. For example, a square prism has a central axis and a radially outer surface relative to the central axis that is square (i.e., not cylindrical). Further, as used herein, the terms "unitary," "monolithic," and "monolithically formed" refer to a structure or component consisting or made of a single solid and unbroken piece. Still further, as used herein, the term "fire resistant" refers to a material or component that meets establish testing requirements such as for example those found in International Organization for Standardization (ISO) 14692 (First Ed. 2002).

[0023] Due to the nature of the fluids transported in a pipeline (e.g., flammable fluids, chemicals that may present environmental risks, etc.), it is typically desirable to maintain the structural integrity of the pipeline during a fire to prevent a loss of containment of any fluids disposed therein, such fluids may continue to flow through the pipeline even after it has been exposed to fire for a considerable period of time. In many pipelines, the flanged joints between the pipes are the most susceptible to damage by fire. Specifically, when exposed to fire and the associated thermal energy, the bolts holding the flanges together may expand (i.e., thermal expansion), which reduces the compressional loads holding the mating surfaces of the flanges in sealing engagement. In addition, some flange joints include an elastomeric gasket between the two mating flange surfaces to provide a seal therebetween. During a fire, such elastomeric gaskets can lose their structural and sealing integrity. Accordingly, fire resistant flange covers are often employed in pipelines to cover the flange joints and protect them in the event of a fire.

[0024] Conventional flange covers typically comprise two halves that are joined together with bolts and corresponding nuts. As a result, such conventional flange covers include a central seam or junction (between the two halves) that extends circumferentially about the entire cover. Such a seam defines a weak point that can allow the flames and/or heat of a nearby fire to pass between the two halves of the cover generally near the flange joint itself. In addition, the bolts joining the two halves of the cover are susceptible to some of the same issues as the bolts of the underlying flange joint (i.e., loss of compression due to thermal expansion of the bolts). Accordingly, embodiments disclosed herein comprise protective, fire resistant flange joint cover assemblies, and methods for making same, that offer the potential for enhanced protection during a fire.

[0025] Referring now to Figure 1, an embodiment of a flange cover assembly 100 is shown disposed about a flange joint 20 that connects a first tubular member or pipe 13 and a second tubular member or pipe 15 of a pipeline end-to-end. The pipes 13, 15, and hence the pipeline, extend along a common central or longitudinal axis 25. Each pipe 13, 15 includes a central flow bore 17, 19, respectively, that allows the passage of fluids there through during use. Flange joint 20 includes a first flange 22 connected to an end of first pipe 13 and a second flange 24 connected to an end of second pipe 15. Flanges 22, 24 can be secured to pipes 13, 15, respectively, through any suitable method, such as, for example, welding, bonding, threads, etc. In some embodiments, flanges 22, 24 are integrally formed on pipes 13, 15, respectively. To form and make up joint 20, flanges 22, 24 are coaxially aligned (relative to axis 25) and axially opposed mating surfaces 27, 29 of flanges 22, 24, respectively, are compressed together with a plurality of circumferentially-spaced bolts (not visible in the cross-section of Figure 1), thereby connecting pipes 13, 15 together. With joint 20 made up, flow bores 17, 19 are aligned and placed in fluid communication such that fluids may flow freely between pipes 13 and 15. In this embodiment, an annular gasket 30 is disposed between mating surface 27, 29 to restrict and/or prevent the flow of fluid between surfaces 27, 29.

[0026] Referring still to Figure 1, in this embodiment, flange cover assembly 100 includes a single-piece, unitary cover box 120 extending about flange joint 120, a first end cap 140 attached to cover box 120, and a second end cap 141 attached to cover box 120. Cover box 120 includes a central axis 125 aligned with axis 25 of joint 120, a first end 120a, a second end 120b opposite first end 120a, a radially outer surface 120c extending axially between ends 120a, 120b, and a radially inner surface 120d extending axially between ends 120a, 120b. In this embodiment, radially outer surface 120c is a cylindrical surface that extends circumferentially about axis 125. Radially inner surface 120d defines an inner cavity 123 that extends axially between ends 120a, 120b. As will be described in more detail below, inner cavity 123 receives flange joint 20 when cover assembly 100 is mounted thereon. In this embodiment, radially inner surface 120d comprises a first cylindrical surface 124 extending axially from first end 120a, a second cylindrical surface 128 extending axially from second end 120b, and an intermediate frustoconical surface 126 extending axially between cylindrical surfaces 124, 128.

[0027] First cylindrical surface 124 is disposed at a radius Ri ₂₄ measured radially from axis 125, intermediate surface 126 is disposed at a radius Ri ₂₆ measured radially from axis 125, and second cylindrical surface 128 is disposed at a radius Ri ₂ g measured radially from axis 125. Because surface 126 is frustoconical as previously described, radius Ri ₂₆ changes when moving axially along surface 126. In this embodiment, radius Ri ₂₆ increases when moving axially from first end 120a to second end 120b. In addition, in this embodiment, the radius Ri ₂₄ is equal to the radius R ₁₂ 8, and each radius R ₁₂₄ , Ri ₂ g is greater than any value of the radius R ₁₂₆ . As a result, a first shoulder 130 extends radially inward from first cylindrical surface 124 to intermediate frustoconical surface 126 proximal end 120a, and a second shoulder 132 extends radially inward from second cylindrical surface 128 to intermediate frustoconical surface 126 proximal end 120b. In this embodiment, each shoulder 130, 132 comprises an annular planar surface. In addition, as is also shown in Figure 1 , flange joint 20 has an outer radius R ₂ o that is less than radiuses R ₁₂₄ , R ₁₂₆ , R ₁₂₈ such that joint 20 can be axially inserted into cavity 123 of cover box 120 during installation of flange cover assembly 100 as described in more detail below.

[0028] End caps 140, 141 are coupled to ends 120a, 120b of cover box 120. Specifically, in this embodiment, end caps 140, 141 are sized and shaped to be disposed within cavity 123 against shoulders 130, 132, respectively, proximate ends 120a, 120b, respectively. In this embodiment, surfaces 124, 128 are cylindrical and shoulders 130, 132 are annular. Consequently, in this embodiment, end caps 140, 141 are generally circular plates. End caps 140, 141 include corresponding central axes 145 coaxially aligned with axes 25, 125 when assembly 100 is fully installed on flange joint 20. In addition, each end caps 140, 141 includes a first planar face or side 142, a second planar face or side 144 axially opposite first side 142, a radially outer cylindrical surface 146 extending axially between sides 142, 144, and a radially inner frustoconical surface 148 extending axially between sides 142, 144. Radially inner frustoconical surface 148 defines a throughbore 143 extending axially through end cap 140, 141 between sides 142, 144. When end caps 140, 141 are secured to cover box 120 within inner cavity 123 as shown in Figure 1, first side 142 of each cap 140, 141 faces axially outward or away from cavity 123, and thus, may be referred to herein as an "outer" side, and second side 144 of each cap 140, 141 faces axially inward toward cavity 123, and thus, may be referred to herein as an "inner" side. In addition, when end caps 140, 141 are secured to cover box 120 within inner cavity 123, frustoconical surfaces 148 each face axially outward or away from inner cavity 123, and thus, may be referred to herein as "outwardly facing" frustoconical surfaces 148.

[0029] As shown in Figure 1, radially outer cylindrical surface 146 of first end cap 140 is disposed at a radius R140 measured from the corresponding central axis 145, and radially outer cylindrical surface 146 of second end cap 141 is disposed at a radius R141 measured from the corresponding central axis 145. In this embodiment, radius R141 is equal to radius R140. Further, radius R140 is greater than the value of radius R126 of surface 126 at shoulder 130 and less than radius R124 of surface 124, and radius R141 is greater than the value of radius R126 of surface 126 at shoulder 132 and less than radius Ri ₂ 8 of surface 128.

[0030] As previously described, cover box assembly 100 is designed to protect flange joint 20 from fire and associated thermal energy. Accordingly, cover box 120 and end caps 140, 141 are preferably made of fire and flame resistant materials. In this embodiment, cover box 120 and end caps 140, 141 are each made of a fire resistant material comprising an epoxy resin, a fire retardant, and a hardener. More specifically, the fire resistant material making up cover box 120 and end caps 140, 141 comprises 100 parts per hundred (PPH) of epoxy resin, 10-100 PPH of fire retardant, and 20-35 PPH of an amine hardener. The fire retardant may comprise fire resistant compounds such as, for example, melamine polyphosphate, ammonium phosphate, or some combination thereof. Specifically, in one formulation, the fire retardant comprises melamine polyphosphate with a nitrogen content of 40% to 44%, a phosphorus content of 14% to 17%, and a water content of approximately 0.5%. In other formulations, the fire retardant comprises ammonium polyphosphate with a nitrogen content of 14% to 15%, a phosphorus content of 31% to 32%, and a water content of approximately 0.2%. In some embodiments, these fire retardant compound may be in a powder form when mixed with the epoxy resin and amine hardener described above.

[0031] By mixing the fire retardant in with the epoxy resin, the resin is impregnated with the fire retardant and, as a result, emulates the fire resistant properties of the retardant during operations (e.g., during a fire). In addition, without being limited to this or any other theory, when the material making up cover box 120 and end caps 140, 141 is subjected to a fire, a char layer is formed on the outermost surface of these components (i.e., the surface which is subjected to the heat and/or flames in the fire). This char layer acts as a thermal barrier which limits the amount of combustible gases which may pass therethrough. Again without being limited to this or any other theory, because the fire retardant is mixed in with the epoxy resin and hardener as described above, the formed char layer is more closely bonded to the cover box 120, and end caps 140, 141, as compared to the scenario where a fire retardant is simply deposited on an outer surface of these components. Further, the use of the specific fire retardants mention above (e.g., melamine polyphosphate and ammonium phosphate) may also reduce oxidation on the outer surface of the cover box 120 and caps 140, 141 during operations.

[0032] In general, the cover box 120 and end caps 140, 141 can be cast or otherwise formed from the fire resistant materials. As will be described in more detail below, in this embodiment, the resin, flame retardant, and hardener are impregnated into glass-fiber filaments, which is then wound around a tooling assembly to form both cover box 120 and end caps 140, 141.

[0033] Although cover box 120 and end caps 140, 141 are made of a fire resistant material comprising an epoxy resin, a fire retardant, and a hardener in this embodiment, in other embodiments, different fire resistant material(s) can be used to form the cover box (e.g., cover box 120) and the end caps (e.g., end caps 140, 141). In addition, although cover box 120 and end caps 140, 141 are made of the same fire resistant material in this embodiment, in other embodiments, the cover box and end caps can be made of different fire resistant materials.

[0034] Referring now to Figures 1 and 2, inner surfaces 144 of end caps 140, 141 axially abut shoulders 130, 132, respectively. As is best shown in Figure 2, to secure end caps 140, 141 to cover box 120, a fire resistant adhesive 150 is disposed between the inner surfaces 144 on end caps 140, 141 and shoulders 130, 132, respectively. In addition, in this embodiment, adhesive 150 is disposed between radially outer cylindrical surfaces 146 on end caps 140, 141 and cylindrical surfaces 124, 128, respectively, and between cylindrical surfaces 124, 128 and radially outer portions of outer surfaces 142 of end caps 140, 141, respectively.

[0035] Referring again to Figure 1, in this embodiment, adhesive 150 is also disposed between frustoconical surfaces 148 defining throughbores 143 of end caps 140, 141 and the pipes 13, 15, respectively. Without being limited to this or any other theory, the use of adhesive 150 between inner surfaces 144 on end caps 140, 141 and shoulders 130, 132 as well as between surfaces 148 and pipes 13, 15 effectively seals and isolates inner cavity 123 and joint 20 from flames present outside of flange cover assembly 100 during a fire, as well as inhibits the transfer of thermal energy from such flames to flange joint 20. Without being limited to this or any other theory, by positioning all of the seams or junctions of cover flange assembly 100 at the junction between cover box 120 and end caps 140, 141, proximal ends 120a, 120b, the seams are located distal the flange joint 20. This is in contrast with convention flange cover assemblies, which typically include a central circumferential seam or junction radially adjacent the flange joint disposed therein.

[0036] In general, adhesive 150 can comprise any suitable fire resistant adhesive configured to maintain a bond between two or more surfaces or components in elevated temperatures (e.g., 1200°C). For example, in some embodiments, adhesive 150 comprises a fire retardant, such as, for example melamine polyphosphate, ammonium phosphate, or some combination thereof. In addition, in some embodiments, adhesive 150 comprises a resin (e.g., Epoxy), silica, calcium silicate, colloidal silica, methanol, and/or metal fibers (e.g., stainless steel). In one specific formulation, adhesive 150 comprises a fire resistant material as described above mixed with a commercially available adhesive (e.g., epoxy based) such as, for example, BONDSTRAND™ adhesive available from National Oilwell Varco (NOV) located in Houston, Texas. In at least some embodiments, a hardener is added to adhesive 150 either just prior to the application of adhesive 150 within assembly 100.

[0037] Referring now to Figures 3 and 4, to install flange cover assembly 100 onto flange joint 20, cover box 120 is first disposed about one of the pipes 13, 15. For example, in the embodiment of Figure 3, cover box 120 is disposed about pipe 13 such that pipe 13 extends through cavity 123. Then cover box 120 is translated axially relative to pipe 13 (or pipe 15 in other embodiments) in the direction of arrow 160 toward joint 20 until joint 20 is received within cavity 123 as is shown in Figure 1. Thereafter, as shown in Figure 4, end caps 140, 141 are disposed about pipes 13, 15, respectively, such that pipes 13, 15 extend through throughbores 143 of end caps 140, 141, respectively. Then, end caps 140, 141 are translated axially relative to pipes 13, 15, respectively, in the direction of arrows 170, 180 toward cover box 120, until they too are received within cavity 123 in the manner described above. Specifically, end cap 140 translates in the direction of arrow 170 until its inner surface 144 engages or abuts first shoulder 130, and end cap 141 translates in the direction of arrow 180 until its inner surface 144 engages or abuts second shoulder 132. Thereafter, adhesive (e.g., adhesive 150 shown in Figures 1 and 2) is applied to end caps 140, 141, cover box 120, and pipes 13, 15 in the manner described above to thereby secure end plates 140, 141 and cover box 120 to one another and complete the construction of flange cover assembly 100. Specifically, adhesive 150 is applied between inner surfaces 144 of end caps 140, 141 and shoulders 130, 132, respectively, and between frustoconical surfaces 143 of end caps 140, 141 and pipes 13, 15, respectively, to effectively seal off cavity 123 from the outer environment surrounding flange cover assembly 100 as previously described.

[0038] Without being limited to this or any other theory, the engagement of inner surface 144 of caps 140, 141 with shoulders 130, 132, respectively, offers the potential to enhance the structural integrity of flange cover assembly 100 during a fire. Specifically, during a fire, the environment surrounding flange joint 20 and assembly 100 may experience an increase in pressure (e.g., due to the pressure created by the fire itself). As a result of this increase in pressure, end caps 140, 141 (particularly surfaces 144) are further engaged with shoulders 130, 132, respectively, such that this increase in pressure does not threaten the overall structural integrity of cover assembly 100. This is in contrast with conventional flange cover assemblies, which typically include a central circumferential seam or junction that may be susceptible to implosion as a result of this increase in pressure during a fire.

[0039] Referring now to Figures 5 and 6, a manufacture tooling assembly 200 for forming the components of flange cover assembly 100 (e.g., cover box 120, end plates 140, 141, etc.) is shown. Tooling assembly 200 includes a driveshaft 210 and a form or mold 202 mounted to driveshaft 210. In this embodiment, mold 202 includes a drum 220 disposed about driveshaft 210, a first plate 230 disposed about driveshaft 210 adjacent drum 220, a second plate 240 disposed about driveshaft 210 adjacent drum 220, a third plate 250 disposed about driveshaft 210 adjacent second plate 240, and a fourth plate 260 disposed about driveshaft 210 adjacent drum third plate 250.

[0040] Referring specifically to Figure 6, driveshaft 210 is an elongate member including a central or longitudinal axis 215, a first end 210a, a second end 210b opposite first end 210a, and a radially outer surface 210c extending axially between ends 210a, 210b. Outer surface 210c includes an annular shoulder 212 extending radially outward with respect to axis 215 proximate to end 210a. In addition, a threaded counterbore 214, coaxially aligned with axis 215, extends axially from second end 210b.

[0041] A support or connection flange 216 is fixably secured to first end 210a of driveshaft 210. Flange 216 includes a central throughbore 218 and a plurality of circumferentially-spaced apertures or holes 217 extending axially through flange 216. A shoulder 219 extends radially inward from flange 216 into throughbore 218. As shown in Figure 6, first end 210a of driveshaft 210 is received within throughbore 218 such that end 210a axially engages or abuts shoulder 219. In general, end 210a of driveshaft 210 can be secured to flange 216 within throughbore 218 through any suitable fashion, such as, for example, engaged threads on outer surface 210c of driveshaft 210 and within throughbore 218, welding, adhesive(s), etc. Regardless of the securing method used, driveshaft 210 is secured to flange 216 such that driveshaft 210 and flange 216 are configured to rotate together about axis 215 (i.e., driveshaft 210 may not rotate about axis 215 relative to flange 216 when flange 216 is secured to first end 210a).

[0042] First plate 230 is a generally circular member that includes a central axis 235 coaxially aligned with axis 215, a first face or side 230a, a second face or side 230b axially opposite first side 230a, and a throughbore 232 extending axially between sides 230a, 230b. Driveshaft 210 extends axially through throughbore 232 such that plate 230 is concentrically disposed on driveshaft 210 between ends 210a, 210b. First side 230a includes an engagement surface 234 that engages and is seated against annular shoulder 212 of driveshaft 210, and second side 230b includes an engagement surface 236 and an axial projection 238 extending axially from engagement surface 236. Engagement surface 236 extends to an outer radius R ₂₃₆ measured from axes 215, 235 that is the same as radius Ri ₂₄ of first cylindrical surface 124 of cover box 120 (Figure 1).

[0043] A support plate 231 is seated against engagement surface 236 and projection 238 within drum 220. Specifically, support plate 231 includes a first face or side 231a, a second face or side 231b opposite first side 231a, and a throughbore 233 extending axially between sides 231a, 231b. Driveshaft 210 extends axially through throughbore 233 such that support plate 231 is concentrically disposed on driveshaft 210 between first plate 230 and second end 210b. First side 231a includes an engagement surface 237 and an axial recess 239 extending axially from engagement surface 237. Second side 231b includes an annular planar engagement surface 235. When support plate 231 is installed on driveshaft 210, engagement surface 237 of support plate 231 engages or abuts engagement surface 236 of first plate 230 with projection 238 of first plate 230 seated in mating recess 239 of support plate 231.

[0044] Referring still to Figure 6, second plate 240 is also a generally circular member that includes a central axis 245 coaxially aligned with axis 215 of driveshaft 210, a first face or side 240a, a second face or side 240b axially opposite first side 240a, and a throughbore 242 extending axially between sides 240a, 240b. Driveshaft 210 extends axially through throughbore 242 such that plate 240 is concentrically disposed on driveshaft 210 between drum 220 and end 210b. First side 240a includes an engagement surface 244 and an axial projection 246 extending axially from engagement surface 244. Second side 240b includes an annular planar surface 248 and an axial recess 249 extending axially from surface 248.

[0045] Drum 220 is a cylindrical, tubular member that includes a central axis 225 coaxially aligned with axis 215 of driveshaft 210, a first end 220a, a second end 220b axially opposite first end 220a, a radially outer surface 220c extending axially between ends 220a, 220b, and a radially inner surface 220d extending axially between ends 220a, 220b. Radially inner surface 220d includes a pair of annular shoulders 222, 224 extending radially inward - with annular shoulder 222 being disposed proximate first end 220a and annular shoulder 224 being disposed proximate second end 220b. Radially outer surface 220c includes a first cylindrical surface 226 extending axially from second end 220b, and a second frustoconical surface 228 extending axially from first end 220a. Cylindrical surface 226 is disposed at a radius R ₂₂₆ and surface 228 is disposed at a radius R ₂₂ g, both being measured from axes 215, 225. Because surface 228 is frustoconical as previously described, radius R ₂₂₈ changes when moving axially along surface 228. In this embodiment, radius R ₂₂ 8 increases when moving axially from first end 220a toward second end 220b. In addition, in this embodiment radius R ₂₂₆ is equal to radius Ri ₂ g of surface 128 of cover box 120 (Figure 1), and all values of radius R ₂₂ g are less than radius R ₂₂₆ . In addition, radius R ₂₂ g is equal to radius Ri ₂₆ of intermediate frustoconical surface 126 of cover box 120 along all portions thereof (Figure 1). As a result, radially outer surface 220c includes an annular shoulder 227 proximate second end 220b that extends radially between cylindrical surfaces 226, 228. Also, all values of radius R ₂₂ g are less than radius R ₂₃₆ of engagement surface 236 of first plate 230, and thus, an annular shoulder 243 is formed between surface 228 and engagement surface 236 when tooling assembly 200 is fully constructed as shown in Figures 5 and 6.

[0046] Drum 220 is concentrically disposed about driveshaft 210 with first end 220a engaging surface 236 of first plate 230, annular shoulder 222 engaging surface 235 of support plate 231 , second end 220b engaging surface 244 of second plate 240, and annular shoulder 224 engaging projection 246 of second plate 240. As a result, drum 220 is axially compressed between first plate 230 and second plate 240.

[0047] Referring still to Figure 6, third plate 250 and fourth plate 260 are each circular members that include central axes 255, 265, respectively, coaxially aligned with axis 215 of driveshaft 210. In addition, third plate 250 includes a first face or side 250a, a second face or side 250b axially opposite first side 250a, and a throughbore 252 extending axially between sides 250a, 250b. Fourth plate 260 includes a first face or side 260a, a second face or side 260b axially opposite first side 260a, and a throughbore 262 extending axially between sides 260a, 260b. First sides 250a, 260a of plates 250, 260, respectively, each include an annular planar surface 254 and an axial projection 256 extending axially from surface 254. In addition, each side 250a, 260a also includes a frustoconical surface 257 extending between engagement surface 254 and projection 256. Second side 250b, 260b of each plate 250, 260 includes an annular planar surface 258 and a central recess 259 extending axially from surface 258.

[0048] Third plate 250 is positioned axially adjacent second plate 240 and fourth plate 260 is positioned axially adjacent fourth plate 250. Specifically, axial projection 259 of third plate 250 is received in mating axial recess 249 of second plate 240 such that an annular gap or recess 264 is formed axially between surface 248 of second plate 240 and surface 254 of third plate 250. Gap 264 extends radially outward from frustoconical surface 257 of plate 250. In addition, axial projection 259 of fourth plate 260 is received in mating axial recess 256 of third plate 250 such that an annular gap or recess 266 is formed axially between surface 258 of third plate 250 and surface 254 of fourth plate 260. Gap 266 extends radially outward from frustoconical surface 257 of fourth plate 260. [0049] Referring still to Figure 6, a support sleeve 270 is mounted on second end 210b of driveshaft 210 and axially compresses drum 220, and plates 230, 231, 240, 250, 260 of tooling assembly 200. Sleeve 270 is an elongate tubular member that includes a central axis 275 coaxially aligned with axis 215 of driveshaft 210, a first end 270a, a second end 270b axially opposite first end 270a, and a central cavity 272 extending axially between ends 270a, 270b. An internal partition 274 extends radially into cavity 272, thereby separating cavity 272 into a first portion 272a extending axially from first end 270a to partition 274 and a second portion 272b extending axially from second end 270b to partition 274. A central bore 276 extends axially through partition 274 along axes 275, 215, thereby linking portions 272a, 272b of cavity 272 together. Support sleeve 270 is installed on driveshaft 210 such that second end 210b is received within first portion 272a of cavity 272 and threaded counterbore 214 is aligned with central bore 276 in partition 274. In addition, first end 270a of sleeve 270 axially engages or abuts fifth plate 260. A connection member 280, which in this embodiment is an elongate threaded bolt is inserted through the aligned bores 276, 214 and threadably engaged within threaded counterbore 214 such that head 282 on member 280 engages with partition 274 and axially compresses drum 220 and plates 230, 231, 240, 250, 260 against annular shoulder 212 previously described. For clarity, connection member 280 is shown removed from bores 214, 276 in Figure 6.

[0050] Referring now to Figure 7, an embodiment of a method 300 for manufacturing fire resistant flange cover assembly 100 with tooling assembly 200, and then installing cover assembly 100 on flange joint 20 is shown. During the following description of method 300, reference will also be made to tooling assembly 200 and flange cover assembly 100 as previously described.

[0051] Method 300 begins by assembling manufacturing tooling assembly 200 at block 305. In particular, with specific reference to Figures 6, to assemble tooling assembly 200, driveshaft 210 is mounted to a driver (not shown) such as, for example a motor that is configured to rotate an output shaft about a central axis. Specifically, flange 216 is mounted to the output shaft (not shown) of the driver (e.g., via bolts extending through apertures 217). Thereafter, mold 202 (e.g., drum 220, plates 230, 231, 240, 250, 260, and sleeve 270) is assembled onto driveshaft 210 in the manner described above to form tooling assembly 200.

[0052] Referring again to Figure 7, method 300 next includes forming the cover box 120 by wrapping or winding a fire resistant material around drum 220 at block 310. Specifically, as shown in Figure 8, tooling assembly 200 is rotated, via rotation of flange 216 and driveshaft 210 while glass-fibers impregnated with the fire resistant material (e.g., the fire resistant material discussed above) are wrapped or wound onto drum 220 between first plate 230 and second plate 240 to form cover box 120. During this process, annular shoulders 243, 227 on tooling assembly 200 form annular shoulders 130, 132, respectively on cover box 120, and frustoconical surface 228 on drum 220 forms intermediate frustoconical surface 126 on cover box 120 (see Figure 1).

[0053] Referring again to Figure 7, method 300 then includes forming the ends caps 140, 141 by rotating flange 216 and driveshaft 210 while wrapping or winding the glass-fibers impregnated with the fire resistant material (e.g., the fire resistant material discussed above) around surfaces 257 within recesses 264, 266 between plates 240, 250 and 250, 260, respectively, to form end caps 140, 141, respectively at block 315. During this process, the frustoconical surfaces 257 form frustoconical surfaces 148 on end plates 140, 141, respectively (see Figure 1).

[0054] Referring again to Figure 7, method 300 next includes curing the fire resistant material of cover box 120 and end caps 140, 141 in block 320. In particular, once cover box 120 and end plates 140, 141 are formed on tooling assembly 200 as described above, these components (i.e., box 120, plates 140, 141) are cured. In general, cover box 120 and end plates 140, 141 can be cured on tooling assembly 200 using any suitable curing method known in the art. For example, box 120 and end caps 140, 141 can be cured with, for example, radiative energy (e.g., in an oven), ultraviolet light, heat, or some combination thereof. Also, box 120 and end caps 140, 141 can also be cured utilizing a passive curing technique (e.g., storing newly formed box 120 and plates 140, 141 at room temperature for an extended period of time).

[0055] Referring again to Figure 7, following curing in block 320, method 300 next includes removing the newly formed and cured cover box 120 and end caps 140, 141 from tooling assembly 200 in block 325. Specifically, end caps 140, 141 are removed from tooling assembly 200 by, for example, sequentially removing sleeve 270, and then plates 260, 250 from assembly 200, thereby releasing end caps 140, 141 from recesses 264, 266, respectively. Thereafter, second plate 240 is removed from driveshaft 210 such that drum 220 and cover box 120 can be removed from driveshaft 210 and separated thereafter (e.g., by sliding cover box 120 axially off of drum 220).

[0056] Referring again to Figure 7, method 300 includes installing the cover box 120 and end caps 140, 141 onto a flange joint (e.g., flange joint 20) at block 330. Specifically, once cover box 120 and end caps 140, 141 are removed from tooling assembly 200, they may be installed onto a flange joint such as, for example, flange joint 20 (Figure 1) in the manner described above and shown in Figures 3 and 4.

[0057] In the embodiment of cover box assembly 100 previously described, a pair of end caps 140, 141 are attached to cover box 120. However, in other embodiments, only one end cap (e.g., end cap 140, 141) is provided. For example, referring now to Figure 9, an embodiment of a flange cover assembly 400 for disposal about a flange joint (e.g., flange joint 20) is shown. Flange cover assembly 400 includes a cover box 420 and a single end cap 450 (rather than the two end caps 140, 141 of assembly 100 previously described).

[0058] In this embodiment, cover box 420 is an elongate generally cylindrical member that includes a central or longitudinal axis 425, a first or closed end 420a, a second or open end 420b axially opposite closed end 420a, and an inner cavity 423 extending axially from open end 420b toward closed end 420a. In addition, cover box 420 includes a radially outer surface 420c extending axially between ends 420a, 420b, and a radially inner surface 420d extending axially from open end 420b toward closed end 420a. An annular flange 442 extends radially inward at end 420a, thereby at least partially closing end 430a.

[0059] Referring still to Figure 9, outer surface 420c is a cylindrical surface extending axially between ends 420a, 420b. Inner surface 420d includes a first cylindrical surface 428 extending axially from open end 420b, a second frustoconical surface 426 extending axially from flange 442, and an annular shoulder 432 extending radially from surface 426 to surface 428. First cylindrical surface 428 is disposed at a radius R ₄₂ g measured radially from axis 425 and second frustoconical surface 426 is disposed at a radius R ₄₂₆ measured radially from axis 425. Because surface 426 is frustocoical as previously described, radius R ₄₂₆ changes when moving axially along surface 426. In this embodiment, radius R ₄₂₆ increases when moving axially from flange 442 toward cylindrical surface 428. However, all values of radius R ₄₂₆ are less than radius R ₄₂ g. As a result, shoulder 432 extends radially inward from first cylindrical surface 428 to second frustoconical surface 426. In this embodiment, shoulder 432 is an annular planar surface. Flange 442 includes a throughbore 433 concentrically arranged about axis 425. In this embodiment, throughbore 433 is defined by a radially inner frustoconical surface 438 extending axially between the inner and outer sides or faces of flange 442. Frustoconical surface 438 generally faces away or outward from cavity 423, and thus may be referred to herein as an "outwardly" facing frustoconical surface.

[0060] End cap 450 is substantially the same as end plates 140, 141 previously described. Specifically, end cap 450 is an annular member sized and shaped to be positioned in cavity 123 against shoulder 432 proximate open end 420b when assembly 400 is fully constructed. End cap 450 includes a central axis 455 coaxially aligned with axis 425 when assembly 400 is fully constructed, a first face or side 454, a second face or side 452 axially opposite first side 454, a radially outer cylindrical surface 458 extending axially between sides 454, 452, and a radially inner frustoconical surface 453 extending axially between sides 454, 452. Radially inner frustoconical surface 453 defines a throughbore 456 extending between sides 454, 452. When end cap 450 is installed within inner cavity 423, first side 452 faces axially inward or toward cavity 423 and thus may be referred to herein as an "inner" side, and second side 454 faces axially outward or away from cavity 423 and thus may be referred to herein as an "outer" side. In addition, when end cap 450 is installed within inner cavity 423 as shown, frustoconical surface 453 faces axially outward or away from inner cavity 423, and thus may be referred to herein as "outwardly" facing frustoconical surface 453. As shown in Figure 9, radially outer cylindrical surface 458 of end cap 450 is disposed at a radius R458 measured radially from axis 425 that is greater than all values of radius R426 of surface 426 and less than radius R428 of surface 428. When assembly 400 is fully constructed, end cap 450 is inserted within cavity 423 until inner surface 452 engages or abuts shoulder 432 in a manner similar to that described above for end caps 140, 141 and cover box 120.

[0061] Referring now to Figures 9 and 10, to install flange cover assembly 400 onto flange joint 20 (see Figure 1), cover box 420 is first disposed about one of the pipes 13, 15. For example, in the embodiment of Figure 10, cover box 420 is disposed about pipe 15 such that pipe 15 extends through cavity 423 and throughbore 433 of flange 442 at closed end 420a (see Figure 9). Then, cover box 420 is translated axially relative to pipe 15 (or pipe 13 in other embodiments) in the direction of arrow 460 toward flange joint 20 (not shown in Figure 10) until joint 20 is received within cavity 423. Thereafter, as shown in Figure 10, end cap 450 is disposed about pipe 13, such that pipe 13 extends through throughbore 456. Then, end cap 450 is translated axially relative to pipe 13 in the direction of arrows 470 toward cover box 420, until cap 450 is received within cavity 423 and inner surface 452 engages or abuts shoulder 432 in the manner described above. Thereafter, a fire resistant adhesive 150 as previously described is applied between engaged and opposing surfaces of cover box 420 and end cap 450 in a manner similar to that described above for assembly 100. For example, adhesive 150 can be applied between shoulder 432 of cover box 420 and a radially outer portion of inner surface 452 of end cap 450. In addition, adhesive 150 can also be applied between first cylindrical surface 428 on cover box 420 and each of outer cylindrical surface 458 and outer surface 454 of end cap 450. In this embodiment, adhesive 150 is also applied between frustoconical surface 433 of cover box 420 and the outer surface of pipe 13 and between frustoconical surface 453 and the outer surface of pipe 15. Without being limited to this or any other theory, adhesive 150 is applied to assembly 400 in the manner described above to effectively seal and isolate cavity 423 from the outer environment surrounding flange cover assembly 400 to protect flange joint 20 from the flames and heat generated by a nearby fire as previously described.

[0062] Referring now to Figure 11, a manufacture tooling assembly 500 for manufacturing the components of flange cover assembly 400 (e.g., cover box 420, end cap 450, etc.) is shown. Tooling assembly 500 includes similar components to tooling assembly 200 previously described, and thus, like components are given like reference numerals and the description below will focus on the differences between tooling assembly 200 and tooling assembly 500. In particular, tooling assembly 500 includes a driveshaft 210 and a form or mold 502 mounted to driveshaft 210. In this embodiment, mold 502 includes, a drum 220 disposed about driveshaft 210, a first plate 530 disposed about driveshaft 210 adjacent drum 220, a second plate 240 disposed about driveshaft 210 adjacent drum 220, and a third plate 550 disposed about driveshaft 210 adjacent second plate 240.

[0063] First plate 530 is a generally circular member that includes a central axis 535 coaxially aligned with axis 215, a first face or side 530a, a second face or side 530b axially opposite first side 530a, and a throughbore 532 extending axially between sides 530a, 530b. Driveshaft 210 extends axially through throughbore 532 such that plate 530 is concentrically disposed on driveshaft 210 between ends 210a, 210b. First side 530a includes an engagement surface 534 that engages annular shoulder 212 of driveshaft 210. Second side 530b includes an annular planar surface 536, an axial projection 538 axially spaced from surface 536, and a frustoconical surface 537 extending between surface 536 and projection 538. [0064] A support plate 531 is disposed about driveshaft 210 axially adjacent first plate 530 within drum 220. Support plate 531 engages projection 538 of first plate 530. Specifically, support plate 531 includes a first face or side 531a, a second face or side 531b axially opposite first side 531a, and a throughbore 533 extending axially between sides 531a, 531b. Driveshaft 210 extends axially through throughbore 533 such that support plate 531 is concentrically disposed about driveshaft 210 between first plate 530 and second end 210b. First side 531a includes an annular planar surface 521 and an axial recess 539 extending axially from surface 521. Second side 531b includes an annular planar engagement surface 535. When support plate 531 is installed on driveshaft 210, projection 538 of first plate 530 is seated in mating recess 539 and a recess 564 is formed between planar surface 521 on support plate 531, first end 220a of drum 220, and surface 536 on first plate 530. Recess 564 extends radially outward from frustoconical surface 537.

[0065] Referring still to Figure 11, drum 220 is concentrically disposed about driveshaft 210 with shoulder 222 engaging or abutting engagement surface 535 of support plate 531, second end 220b engaging or abutting engagement surface 244 of second plate 240, and annular shoulder 224 engaging or abutting projection 246 of second plate 240. As a result, drum 220 is axially compressed between plates 531, 240.

[0066] Third plate 550 is a generally circular member that includes a central axis 555 coaxially aligned with axis 215, a first face or side 550a, a second face or side 550b axially opposite first side 550a, and a throughbore 552 extending axially between sides 550a, 550b. Driveshaft 210 extends axially through throughbore 552 such that plate 550 is concentrically disposed on driveshaft 210 between second plate 240 and end 210b. First side 550b includes an annular planar surface 554, an axial projection 556 axially spaced from surface 554, and a frustoconical surface 557 extending between surface 554 and projection 556. Second side 550b includes an annular planar surface 558. Projection 556 is seated in mating recess 249 of second plate 240 such that a gap or recess 566 is formed between surface 248 on second plate 240 and surface 554 on third plate 550. Gap 566 extends radially outward from frustoconical surface 557.

[0067] During construction of tooling assembly 500, second end 210b of driveshaft 210 is received within first portion 272a of cavity 272 in sleeve 270 and secured therein by securing member 280 in the same manner as previously described above for tooling assembly 200. In addition, as securing member 280 is advanced within counterbore 214 of driveshaft 210, first end 270a engages or abuts surface 558 on third plate 550 thereby axially compressing plates 530, 531, 240, 550 and drum 220 between sleeve 270 and shoulder 212.

[0068] Referring now to Figure 12, manufacturing of flange cover assembly 400 is similar to the manufacturing method 300 previously described for flange cover assembly 100. Specifically, cover box 420 is formed by rotating tooling assembly 500 about axis 215 of driveshaft 210 and wrapping or winding glass-fibers impregnated with the fire resistant material described above around drum 220 between first plate 530 and second plate 240 to form cover box 420. During this process, annular shoulder 227 on tooling assembly 500 forms annular shoulder 432 on cover box 420, flange 442 of cover box 420 is formed about shoulder 438 within recess 564, and frustoconical surface 228 on drum 220 forms frustoconical surface 426 of cover box 120 (see Figure 9). In addition, the frustoconical surface 537 on first plate 530 forms frustoconical surface 438 on cover box 420. To form end cap 450 the same fire resistant material used to form cover box 420 material is wrapped or wound shoulder into recesses 566 between plates 240, 550. During this process, the frustoconical surfaces 557 in recess 566 forms frustoconical surface 453 on end plates 450 (see Figure 9).

[0069] Once cover box 420 and end cap 450 have been formed per the winding process described above, these newly formed components are cured in the same manner as described above for the components of flange cover assembly 100. Subsequently, cover box 420 and end cap 450 are removed from tooling assembly 500 in a similar manner to that described above for assembly 100. Thereafter, cover box 420 and end cap 450 may then be installed on a flange joint (e.g., flange joint 20) as previously described.

[0070] Embodiments of flange cover assemblies described herein (e.g., cover assemblies 100, 400), offer the potential for enhanced protection of flange joints along pipelines (e.g., joint 20) from the flames and/or heat generated during a fire. In particular, embodiments of flange cover assemblies as described herein locate seams and junctions away from the underlying flange joint such that any potential leak points in the cover assembly for flames and heat generated in a nearby fire are spaced from the flange joint itself. In addition, in some embodiments described herein, the flange cover assemblies are joined or constructed of single-piece or unitary components that are adhered to one another with a fire resistant adhesive. Thus, no bolts or other connecting member are used to connect the components of the flange cover assembly that could fail (e.g., as a result of thermal expansion) during a fire. Still further, in some embodiments described herein, the flange cover assembly includes one or more engagement shoulder that resist the collapse or implosion of one or more end caps secured thereto (e.g., end caps 140, 141, 450), thereby enhancing the durability and structural integrity of the flange cover assembly. Also, while surfaces 126, 426 on flange cover assemblies 100, 400 are shown and described above as frustoconical surfaces, it should be appreciated that these surfaces may be formed as cylindrical surfaces while still complying with the principles disclosed herein. Moreover, while embodiments disclosed herein have included end caps (e.g., end caps 140, 141, 450) that are disposed within an inner cavity of a cover box (e.g., cavities 123, 423 or cover boxes 120, 420, respectively), it should be appreciated that in other embodiments, such end caps may be mounted or coupled to the outer surface of the corresponding cover boxes (e.g., the end caps may be formed as a lid which includes an axially extending cylindrical surface which receives an end of the cover box).

[0071] While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the systems, apparatus, and processes described herein are possible and are within the scope of the disclosure. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims. Unless expressly stated otherwise, the steps in a method claim may be performed in any order. The recitation of identifiers such as (a), (b), (c) or (1), (2), (3) before steps in a method claim are not intended to and do not specify a particular order to the steps, but rather are used to simplify subsequent reference to such steps.