Coating Repair Kit for Pipeline Membrane Defects
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Solution Overview
Problem
There is no standardized solution for repairing small area defects or holidays on pipeline coatings, tank linings, or structural steel, leading to time-consuming and labor-intensive processes with potential for repair failure due to variability in methods and personnel.
Innovation Solution
A repair kit comprising a patch member with a protective outer wrap and a patch applicator, which includes a support member with an adhesive layer and a removable protective film, allows for efficient application and sealing of defects on metal pipes and storage tanks using a polymeric material that conforms to the defect site, with optional features like a unique identifier and a syringe for injecting a sealant material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standardized repair procedures are implemented, then repair reliability and consistency improve, but device complexity increases
Solution Approach 1:
The repair device is divided into distinct functional components: a patch member for sealing defects, a support member with aperture for positioning, adhesive layers for bonding, and protective films for preservation. This segmentation allows each component to perform its specific function reliably while keeping the overall device manageable and not excessively complex.
2Adaptability or versatility
If manual repair processes are used by different personnel, then flexibility in repair methods is maintained, but repair consistency and quality control deteriorate
Solution Approach 1:
The patch applicator is designed as a self-contained device that guides the repair process. The aperture positions the defect centrally, the adhesive layers automatically bond components, and the protective films preserve the patch until application. This self-service design ensures consistent results regardless of which personnel perform the repair, while still allowing flexibility in when and where repairs are conducted.
3Productivity
If repair processes are made more efficient and standardized, then productivity improves, but the ease of operation may worsen due to additional components
Solution Approach 1:
Multiple repair functions are merged into a single integrated patch applicator device. The support member with aperture, adhesive layers, patch member, and protective films are combined into one unit that performs positioning, bonding, sealing, and protection in a single application process. This merging improves productivity by eliminating multiple separate steps while maintaining ease of operation through the unified design.
4Manufacturing precision
If protective films and wraps are used to protect adhesive layers, then manufacturing precision and protection improve, but the time required for film removal and application increases
Solution Approach 1:
Protective films are applied to adhesive layers during manufacturing before the device is used. This preliminary action protects the adhesive from contamination and damage during storage and transport, ensuring manufacturing precision. The films are designed to be easily removable at the point of use, minimizing the time penalty for their removal during the repair process.
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 kit provides a standardized, efficient, and effective method for repairing membrane defects on metal pipes and storage tanks, ensuring reliable sealing and reducing the risk of repair failure, while allowing for tracking and documentation of repairs through unique identifiers.
Implementation Method 1
an adhesive layer coated on the bottom surface
Implementation Method 2
the conforming material fills, seals or covers a void produced by the defect
Data Source
AI summary
There is disclosed a coating/membrane device for repairing defects such as holes or cracks in the membranes used to coat oil and gas metal pipes used in oil and gas pipelines and other metal based holding tanks, metal water pipes and the like. In one embodiment the device includes an applicator for applying a patch over a defect in the membrane. The device is placed over the defect and is temporarily bonded to the membrane, and an applicator having a patch removably attached thereto is activated to apply the patch to the membrane covering the defect. In another embodiment the device is placed over the defect and is temporarily bonded to the membrane, and a liquid sealant is injected into a chamber which then sets to seal the sealant over the defect and the device is removed.