Epoxy Sealing for Illicit Pipe Tap Removal

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Solution Overview

Problem

Current methods for sealing illicit taps in petroleum pipes are costly, hazardous, and do not address the weakness created around the coupling weld, leading to potential pipeline leaks or ruptures.

Innovation Solution

Sealing the valve outlet of the illicit tap with epoxy and wrapping the entire tap and surrounding pipe area with epoxy-impregnated fiberglass or carbon composite fabric, eliminating the need for pipeline shutdown and expensive equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the pipeline is shut down to repair the illicit tap by cutting out the tap and welding a patch, then the repair can be made safely, but the pipeline productivity is reduced and the repair cost increases

Engineering Contradiction:

Improverepair safetyVSAvoidpipeline operation continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The method applies preliminary sealing action by injecting epoxy resin into the tap hole before any cutting or welding operations. This preliminary sealing stops fuel flow and secures the area, allowing subsequent repair operations to proceed safely without shutting down the pipeline.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If cutting methods are used to remove the illicit tap, then the tap can be removed, but sparks and heat are generated creating safety hazards

Engineering Contradiction:

Improvetap removal capabilityVSAvoidsparks and heat

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The method replaces mechanical cutting operations with chemical sealing using epoxy resin. Instead of using cutting tools that generate sparks and heat, the patent uses a chemical injection process that seals the tap hole without any thermal or mechanical contact, eliminating the hazard of sparks and heat generation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If welding is used to repair the pipe, then the structural integrity is restored, but the repair cost and complexity increase

Engineering Contradiction:

Improvepipe structural integrityVSAvoidrepair equipment and procedure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The method uses a disposable epoxy resin sealant instead of expensive welding equipment and procedures. The epoxy provides sufficient sealing functionality without requiring the complex equipment, skilled labor, or high costs associated with welding operations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Ease of manufacture

If the valve outlet is not sealed before wrapping, then the wrapping process is simpler, but fuel leakage occurs through the valve

Engineering Contradiction:

Improvewrapping process simplicityVSAvoidfuel leakage

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The method performs preliminary sealing of the valve outlet with epoxy resin before the wrapping process. This preliminary action prevents fuel leakage during wrapping while the external wrap provides additional containment and structural reinforcement.

Inventive Principle:

Principle #10Preliminary action

5Productivity

If only the tap hole is sealed without addressing the coupling weld area, then the sealing process is faster, but the pipe may fail due to weakness around the coupling

Engineering Contradiction:

Improvesealing process speedVSAvoidpipe integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The method merges the sealing of the tap hole with the reinforcement of the coupling weld area by using the same epoxy resin injection process to address both locations simultaneously. This combined approach ensures comprehensive sealing and structural reinforcement without requiring separate operations.

Inventive Principle:

Principle #5Merging (Combining)

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

Provides a safe, inexpensive, and effective repair that prevents reusability of the tap and ensures the pipe's integrity by avoiding heat and sparks, making the repair process safer and more cost-effective.

Implementation Method 1

seals the valve outlet of the illicit tap with epoxy

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

the entire tap including the valve and surrounding pipe area is wrapped with an epoxy impregnated material such as fiberglass or carbon composite fabric

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Data Source

PatentUS7938136B1Method for sealing taps

Publication Date: 2011.05.10 HENKEL KGAA

AI summary

An inexpensive method for quickly and safely sealing illicit taps in a pipe, such as for example a pipe through which a combustible material like oil or gasoline is flowing. The method first seals the valve outlet of the illicit tap with epoxy and removes the valve handle from the valve. Finally the entire tap including the valve and surrounding pipe area is wrapped with an epoxy impregnated material such as fiberglass or carbon composite fabric.