Ceramic-Coated Weld Support Blocks for Sour Service Pipe Alignment

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Solution Overview

Problem

Existing welding support systems for pipelines, particularly those operating under sour service conditions, face challenges with copper contamination and thermal management, as copper support pads risk melting and contaminating the weld, while ceramic alternatives suffer from thermal shock and high heat insulation, leading to welding defects and increased maintenance costs.

Innovation Solution

A ceramic-coated steel welding support block with a ceramic layer thickness of 0.25mm to 1.5mm provides thermal insulation and prevents copper contamination, allowing for efficient heat conduction and reduced maintenance needs, as the steel underlying the ceramic layer is less likely to melt and contaminate the weld if exposed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If copper support pads are used to support the weld pool, then thermal conductivity is improved and heat is efficiently conducted away, but copper may melt and contaminate the weld pool during welding

Engineering Contradiction:

Improveheat conductionVSAvoidcopper contamination

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The invention uses a composite structure consisting of a copper support pad with a ceramic coating layer. The copper base provides high thermal conductivity to manage heat during welding, while the ceramic coating prevents copper from melting and contaminating the weld pool. This composite material approach resolves the contradiction by combining materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If ceramic material is used to support the weld pool, then copper contamination is prevented, but thermal shock causes breakdown and spalling of the ceramic material

Engineering Contradiction:

Improvecopper contaminationVSAvoidceramic material durability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The ceramic-coated copper support pad creates a composite structure where the ceramic layer protects against contamination while the copper substrate provides thermal stability. The copper base absorbs thermal shock, preventing the ceramic from breaking down and spalling, thus improving the reliability of the ceramic material during welding operations.

Inventive Principle:

Principle #40Composite materials

3Object-affected harmful factors

If ceramic material is used to support the weld pool, then copper contamination is prevented, but heat insulation properties increase causing welding defects such as porosity

Engineering Contradiction:

Improvecopper contaminationVSAvoidheat insulation

Core Design Contradiction:

Object-affected harmful factorsVSLoss of energy

Solution Approach 1:

The composite structure of ceramic-coated copper balances the opposing thermal properties. The copper base maintains high thermal conductivity to prevent heat insulation and welding defects like porosity, while the ceramic coating provides contamination protection. This combination allows the system to benefit from both materials' advantages without their respective drawbacks.

Inventive Principle:

Principle #40Composite materials

4Temperature

If copper support pads are used, then heat conduction is improved, but maintenance frequency increases due to melting and contamination risks

Engineering Contradiction:

Improveheat conductionVSAvoidmaintenance frequency

Core Design Contradiction:

TemperatureVSProductivity

Solution Approach 1:

The ceramic coating on the copper support pad creates a protective barrier that prevents copper from melting and contaminating the weld pool. This extends the service life of the support pads and reduces maintenance frequency, while the copper base continues to provide efficient heat conduction during welding operations.

Inventive Principle:

Principle #40Composite materials

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

The ceramic-coated steel support blocks enhance welding productivity by preventing copper contamination, reducing the need for frequent inspection and replacement, and maintaining weld quality, while allowing for faster welding processes without compromising thermal management.

Implementation Method 1

A ceramic-coated steel welding support block with a ceramic layer thickness of 0.25mm to 1.5mm provides thermal insulation and prevents copper contamination

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

allowing for efficient heat conduction and reduced maintenance needs, as the steel underlying the ceramic layer is less likely to melt and contaminate the weld if exposed

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Data Source

PatentEP3568255B1Internal line-up clamp for holding two pipes in alignment ; method of welding together two pipes using such internal line-up clamp

Publication Date: 2021.10.06 SAIPEM SPA

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AI summary

A welding support block (10) supports, from the rear surface (16) of a joint to be welded, a weld pool created during a welding process. The welding support block (10) comprises a block of metal and an outer layer (24) of ceramic material providing a supporting surface (26). The ceramic material layer (24) has a thickness between 0.25 mm and 1.5 mm. The metal material (22) immediately beneath the ceramic material layer (24) is made of steel. An internal line-up clamp for holding pipes in end-to-end alignment ready for welding includes multiple such welding support blocks (10). The use of such welding support blocks (10) is particularly useful when laying a sour service carrying pipeline (high H2S content).