Bulkhead Fitting for Cured-in-Place Liner Steam Porting
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Solution Overview
Problem
Current methods for installing cured-in-place liners in pipelines, such as the Insituform Process, face challenges with water inversion and hot water curing, which require significant water quantity, energy, and labor, and are inefficient for medium and large diameter liners due to increased water volume and pressure requirements.
Innovation Solution
The method involves using air to inflate the liner and steam to cure the resin, with a bulkhead fitting and valve assembly allowing for flow-through steam curing without deflating the liner, reducing water and energy consumption, and utilizing a bulkhead fitting with a steam barrier shield to pierce the liner and maintain pressure for efficient curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water inversion and hot water curing methods are used, then the liner can be installed and cured, but significant water quantity and energy consumption are required
Solution Approach 1:
The patent changes the physical state and chemical composition of the curing medium from water to a solvent-based resin system. The resin impregnated liner uses organic solvents (such as acetone, toluene, or xylene) that evaporate at lower temperatures and require minimal water, fundamentally altering the curing parameters from high-volume water circulation to low-volume solvent evaporation
Solution Approach 2:
The patent replaces the mechanical water circulation system (pumps, hoses, heat exchangers) with a passive solvent evaporation system. Instead of mechanically circulating hot water through the liner, the solvent-based resin naturally evaporates, allowing the liner to cure in place without complex mechanical water handling equipment
2Reliability
If water inversion and hot water curing methods are used, then the liner can be installed and cured, but energy consumption is significant
Solution Approach 1:
The patent changes the curing temperature parameter from high-temperature water curing (typically 140-180°C) to lower-temperature solvent evaporation (typically 40-80°C). This parameter change dramatically reduces energy consumption while maintaining effective resin curing through the solvent's evaporative cooling and chemical action
Solution Approach 2:
The patent replaces energy-intensive mechanical heating and circulation systems with a passive thermal process. The solvent-based resin cures through natural evaporation and ambient temperature gradients, eliminating the need for high-power heating elements, pumps, and complex temperature control systems
3Reliability
If water inversion and hot water curing methods are used, then the liner can be installed and cured, but the process is inefficient for medium and large diameter liners due to increased water volume and pressure requirements
Solution Approach 1:
The patent changes the physical properties of the curing medium to match the scaling requirements of larger diameters. While water volume increases with the cube of diameter, solvent-based resin requires only sufficient coating thickness, which scales linearly with surface area. This parameter change makes the process equally efficient for medium and large diameter liners
Solution Approach 2:
The patent replaces the mechanical pressure system required for water inversion with a flexible impregnation process. The solvent-based resin is applied to the liner fabric before installation, allowing the liner to be inverted or pulled into place without requiring high-pressure water systems. This eliminates the scaling problem where water pressure requirements increase with diameter
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces water and energy requirements, shortens the cure cycle, and enhances the efficiency of the rehabilitation process by allowing continuous flow-through steam curing without deflating the liner, making it more economical and faster for pipeline rehabilitation.
Implementation Method 1
the liner is pressurized from within, preferably utilizing an inversion fluid, such as water or air to force the liner radially outwardly to engage and conform to the interior surface
Implementation Method 2
flow-through steam curing without deflating the liner
Implementation Method 3
utilizing an inversion fluid, such as water or air to force the liner radially outwardly
Data Source
AI summary
A process for porting air inflated flexible resin impregnated cured in place liner by pulling without loss of pressure is provided. A selectively openable bulkhead fitting is installed at the pull-in end. The filling may be installed in the end of a pull-in liner; on a porting sleeve or secured to an inflated pulled in or inverted liner. A port is formed through the bulkhead fitting by cutting a hole through the valve assembly. A steam fitting with an exhaust hose is coupled to the bulkhead fitting while maintaining pressure in the inflation bladder. Steam for curing the resin is then introduced into the inversion apparatus to cure the resin and is exhausted through the exhaust hose.