Fusion Welded Cover Systems for Storage Ponds
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Solution Overview
Problem
The existing extrusion welding process for cover systems is labor-intensive, skill-dependent, and prone to leaks and breakage due to contamination and weather conditions, making it inefficient for constructing continuous gas-tight seals in floating cover systems for storage ponds.
Innovation Solution
The use of fusion welds for the cover, liner, and anchor flaps, which are preassembled in a controlled environment and installed using a split wedge fusion welder, allowing for faster and more reliable gas-tight connections, reducing the need for manual labor and minimizing exposure to site conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extrusion welding process is used to weld cover to liner, then gas-tight seal is achieved, but the process is labor-intensive and skill-dependent
Solution Approach 1:
Flaps are pre-assembled and pre-welded in a controlled factory environment before being transported to the construction site. This preliminary preparation includes welding the liner flap to the liner, cover flap to the cover, and anchor flap to the assembly, reducing on-site welding requirements and improving installation speed while maintaining seal integrity
Solution Approach 2:
The patent replaces manual extrusion welding with automated fusion welding processes. Fusion welding uses heat and pressure to melt and join thermoplastic materials directly, eliminating the need for manual extrusion operations and reducing skill-dependency while improving both productivity and reliability
2Ease of manufacture
If extrusion welding is performed at construction site, then installation is completed, but welds are susceptible to contamination and weather conditions
Solution Approach 1:
Critical welding operations are performed in advance in a controlled factory setting where environmental conditions can be precisely controlled. This prevents contamination from debris and adverse weather effects that would occur during on-site construction, ensuring higher weld quality and reliability
Solution Approach 2:
The patent creates a controlled environment for welding operations, effectively shielding the welding process from external contaminants and weather conditions. This controlled atmosphere prevents oxidation and contamination during the welding process, ensuring consistent weld quality
3Reliability
If multiple welds are required for cover system, then gas-tight seal is achieved, but testing time increases significantly
Solution Approach 1:
Multiple flaps (liner flap, cover flap, anchor flap) are welded together as an integrated pre-assembled unit in the factory. This merging of components into a single pre-tested assembly reduces the number of separate welds that need to be tested on-site, significantly reducing testing time while maintaining the gas-tight seal integrity
Solution Approach 2:
Welding and testing of multiple flaps are performed in advance during factory pre-assembly. This preliminary testing identifies and corrects any leaks before the assembly reaches the construction site, eliminating the need for extensive on-site testing of each individual weld
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 the likelihood of leaks and breakage, enabling faster installation with higher quality welds, improving the reliability and efficiency of the cover system by utilizing fusion welding for bulk connections and allowing for extrusion welding where necessary for touch-ups.
Implementation Method 1
The use of fusion welds for the cover, liner, and anchor flaps, which are preassembled in a controlled environment and installed using a split wedge fusion welder
Data Source
AI summary
A cover system for a storage pond formed using a liner is disclosed. A cover flap, a liner flap and an anchor flap are preassembled either off-site at a factory or on-site. The anchor flap is disposed in an anchor trench and the anchor trench is backfilled. The liner is deployed and the perimeter is welded to the liner flap. The cover is deployed and the perimeter is welded to the cover flap. The above welding is preferably fusion welding and could take place in any order.