Induction-Heated Electrofusion Fittings for Leak-Tight Lined Pipes

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

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 function is achieved, but fluid leak paths are created compromising pipeline integrity

Engineering Contradiction:

Improveelectrical power delivery to heating coilsVSAvoidpipeline integrity

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 electrofusion fitting through electromagnetic induction, eliminating the need for direct electrical connections through the fitting and thereby preventing fluid leak paths

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The direct electrical contact system is replaced with an electromagnetic field-based heating system, where electrical energy is converted to thermal energy through electromagnetic induction rather than direct resistive heating via electrical leads

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 modern closed bevel automatic welding processes cannot be used

Engineering Contradiction:

Improveelectrical power delivery methodVSAvoidcompatibility with modern welding processes

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The induction coil acts as a mediator that enables power delivery through the fitting wall without requiring open bevel preparation, allowing compatibility with closed bevel automatic welding processes by eliminating the need for physical access to heating coils during welding preparation

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If electrical leads are routed through the electrofusion fitting, then heating coils can be energized, but potential leak paths exist for pressurized fluid

Engineering Contradiction:

Improveheating coil energizationVSAvoidfluid ingress through electrical leads

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The induction coil serves as an intermediary that transfers energy through electromagnetic induction across the fitting wall, eliminating the need for penetrations or channels that would create fluid leak paths while still enabling heating coil energization

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mechanical/electrical connection system is replaced with an electromagnetic field system, substituting direct electrical contact with inductive coupling that maintains fitting integrity and prevents fluid ingress

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

PatentUS20240019066A1Methods of Joining or Repairing Lined Pipes and Associated Apparatus

Publication Date: 2024.01.18 PIONEER LINING TECH

AI summary

A method creates a weld between a liner of a section of lined pipe and an electrofusion fitting. The fitting has 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 includes 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.