Friction-Forged Pipe Stud Bracket for In-Service Leak Repair
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Solution Overview
Problem
Existing methods for repairing valves and pipes in hazardous environments are inefficient and pose risks due to the use of combustible processes, leading to hazardous chemical leaks and exposure for technicians, and the need for frequent shutdowns of refineries.
Innovation Solution
A system utilizing a friction welding injection system that maintains positive pressure to contain hazardous materials during repair, using a collet and drill guide to seal the drill bit and inject sealant under pressure, eliminating emissions and allowing for in-service repairs without igniting sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding processes (arc, MIG, TIG, oxy-acetylene) are used to attach fasteners to pipes or valves, then strong mechanical connections are achieved, but hazardous chemicals are ignited and released into the environment
Solution Approach 1:
The patent replaces traditional thermal welding processes (arc, MIG, TIG, oxy-acetylene) with a mechanical friction-based attachment system. A friction welder rotates a stud against the pipe surface, generating friction heat locally at the contact point to forge-bond the stud to the pipe without igniting hazardous chemicals. This substitution of thermal welding with mechanical friction welding eliminates the harmful ignition effect while maintaining strong mechanical connections.
Solution Approach 2:
The patent introduces an inert gas shroud that surrounds the friction welding zone, creating an inert atmosphere that prevents hazardous chemicals from igniting during the attachment process. The shroud directs inert gas (such as nitrogen or carbon dioxide) over the welding area, suppressing combustion and preventing chemical release, thus resolving the contradiction between achieving strong bonds and avoiding hazardous ignition.
2Reliability
If valves are taken out of service for repair to ensure safety and proper repair quality, then technician safety and repair effectiveness are improved, but refinery productivity is severely reduced
Solution Approach 1:
The patent enables valves and pipes to be repaired while remaining in service through the use of a friction welder and injection system that can operate on pressurized, flowing systems. The friction welding process creates secure attachments without requiring system shutdown, and the injection system can introduce sealants or repair materials into the flowing medium, allowing the refinery to maintain continuous operation and productivity during repairs.
Solution Approach 2:
The patent employs preliminary containment measures through the inert gas shroud and controlled friction welding process that prepare the attachment zone in advance, ensuring safety and repair quality are maintained even while the valve remains in service. The friction welding process generates localized heat and bonding conditions that secure the attachment before any potential hazards can arise, enabling safe in-service repair.
3Reliability
If technicians drill into valve housings to inject sealant for leak repair, then valve sealing is improved, but technicians are exposed to hazardous chemicals and fittings may breakage
Solution Approach 1:
The patent introduces a friction-welded stud or boss as an intermediary component that provides a secure attachment point for injection equipment. Instead of drilling directly into the thin valve housing wall (which risks breakage and chemical exposure), the stud is friction-welded to the exterior surface, providing a robust mounting point for sealant injection. This intermediary structure eliminates the need for direct drilling into the housing, preventing both fitting breakage and hazardous chemical exposure while maintaining effective sealing.
4Ease of manufacture
If threads are used to secure fittings to valve housings, then installation is simplified, but connection reliability deteriorates due to corrosion and vibration
Solution Approach 1:
The patent replaces threaded mechanical connections with friction welding for securing fittings and studs to valve housings. The friction welding process creates a forge-bonded, metallurgical connection that is significantly more resistant to corrosion and vibration than threaded connections. This substitution maintains ease of installation through the automated friction welding process while dramatically improving connection reliability in harsh refinery environments.
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 system effectively seals leaks and repairs valves and pipes within hazardous environments without releasing hazardous materials, ensuring technician safety and reducing environmental impact by maintaining positive pressure to prevent chemical emissions during the repair process.
Implementation Method 1
friction forge bonded to a walkway or ladder through a stud and a bracket
Data Source
AI summary
In some implementations, an apparatus comprises a pipe, a stud that is forge-welded to the pipe, creating a forge-welded stud, a bracket that is operably coupled to the forge-welded stud, and a walkway operably coupled to the bracket.