Induction-Heated Electrofusion Fittings for Leak-Tight Lined Pipes

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Solution Overview

Problem

Existing electrofusion fitting methods for joining lined pipes face challenges such as potential fluid leaks due to electrical leads and limitations in modern pipeline welding processes, particularly in subsea applications where closed bevel automatic welding is common.

Innovation Solution

The method employs electromagnetic induction to energize heating elements within electrofusion fittings, eliminating the need for direct electrical connections by using induction coils to generate heat, which are isolated from the inner surface, thereby minimizing fluid leak paths and simplifying the welding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If electrical leads are extended through the electrofusion fitting to supply power to heating coils, then the heating process can be completed, but fluid leakage paths are created through the fitting

Engineering Contradiction:

Improveelectrical power delivery to heating coilsVSAvoidfluid tightness of pipe joint

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

An induction coil is introduced as an intermediary device that generates an electromagnetic field to indirectly heat the heating coils through electromagnetic induction, eliminating the need for direct electrical connections through the fitting and thus preventing fluid leakage paths

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The direct electrical contact system is replaced with an electromagnetic field-based heating system, where the induction coil generates electromagnetic fields that induce currents in the heating coils without physical contact, thereby maintaining fluid tightness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If open bevel weld preparation is used to access heating coils, then electrical power can be delivered externally, but the method is incompatible with modern closed bevel automatic welding processes

Engineering Contradiction:

Improveexternal electrical power deliveryVSAvoidcompatibility with closed bevel welding

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The induction coil acts as an intermediary that enables power delivery through the closed bevel structure via electromagnetic fields, making the process compatible with modern closed bevel automatic welding while maintaining ease of operation

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical open bevel access method is replaced with an electromagnetic field-based system that can penetrate and energize heating coils through closed bevel structures, enabling compatibility with automated welding processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If electrical leads are routed through the fitting, then power can be supplied to heating elements, but the complexity of ensuring leak-free electrical connections increases

Engineering Contradiction:

Improveelectrical connection installationVSAvoidelectrical lead routing and sealing

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The induction coil serves as an intermediary that eliminates the need for complex electrical lead routing and sealing operations by transferring energy through electromagnetic fields, thereby simplifying the manufacturing process

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical electrical connection system with its complex routing and sealing requirements is replaced with an electromagnetic field-based system that requires no physical penetration or sealing, reducing device complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances the integrity of pipe linings and host pipes by ensuring reliable welds without direct electrical contact, reducing manufacturing complexity, and eliminating the risk of fluid ingress through internal electrical contacts, while allowing for more efficient and consistent heating across the fitting.

Implementation Method 1

supplying electrical power to the induction coil to energise the heating element by electromagnetic induction

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11739876B2Methods of joining or repairing lined pipes and associated apparatus

Publication Date: 2023.08.29 PIONEER LINING TECH

AI summary

A method of creating a weld between a liner of a section of lined pipe and an electrofusion fitting. The fitting comprises at least one heating element, which is suitably disposed on or in an outer surface of the electrofusion fitting and is electrically isolated from an inner surface of the fitting. The method comprises locating an end of the electrofusion fitting within an end of the section of lined pipe, locating an induction coil within a bore of the electrofusion fitting in the vicinity of the at least one heating element, and supplying electrical power to the induction coil to energise the at least one heating element by electromagnetic induction.