Oblong Composite Plug for High-Pressure Pipeline Leak Repair
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Solution Overview
Problem
Existing methods for repairing holes in high-pressure tubular pipelines are inadequate as they often require welding, are not suitable for all pipe geometries, or pose risks due to flammable fluids, and existing composite repair systems are not effective for high-pressure pipes with large diameter holes.
Innovation Solution
A composite plug system involving an oblong inner plate with a beveled opening, a threaded fastener, and an outer plate secured with a wing nut, using fibrous materials and adhesives to create a non-welding, high-pressure capable repair method that does not require evacuation of fluids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding patches or replacement is used to repair pipeline holes, then the repair is effective and strong, but welding equipment and access are required and the pipeline must be shut down or evacuated
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical fastening system consisting of a bolt, oblong plate, and wing nut assembly. This substitution eliminates the need for welding equipment, specialized access, and pipeline evacuation while maintaining repair effectiveness through mechanical clamping force that seals the hole without requiring the pipeline to be shut down or evacuated.
2Ease of manufacture
If pipe clamps are used for repair, then welding is avoided, but the system is limited to straight sections with uniform outer diameter
Solution Approach 1:
The patent employs an oblong (non-circular) plate geometry instead of a conventional circular clamp. This asymmetric shape allows the plate to conform to various pipe geometries including curved sections and pipes with non-uniform outer diameters. The oblong shape can be oriented to match the specific geometry of the damaged area, providing adaptability across different pipe configurations while maintaining the no-welding advantage.
Solution Approach 2:
The repair system is designed as a universal solution that can be applied to various pipe types and geometries. The combination of the oblong plate, threaded fastener, and wing nut creates a multi-functional assembly that works on straight sections, curved sections, and pipes with varying diameters, eliminating the geometric limitations of traditional pipe clamps while continuing to avoid welding requirements.
3Ease of manufacture
If existing composite repair sleeves are used, then no welding is required, but they are not suitable for high pressure pipes with holes greater than 0.75 inches
Solution Approach 1:
The patent utilizes a dynamic fastening system where the wing nut can be tightened progressively to apply increasing clamping force. This dynamic adjustment capability allows the repair assembly to generate sufficient radial pressure to seal high-pressure holes of any size, overcoming the pressure limitations of existing composite sleeves. The system adapts to the specific pressure requirements by adjusting the tightness of the wing nut rather than relying on fixed-pressure design.
Solution Approach 2:
The patent changes the key parameter from fixed-size composite sleeves to an adjustable mechanical fastening system. By using a threaded fastener with wing nut, the system can generate variable clamping forces and adapt to different hole sizes and pressure conditions. This parameter change enables the repair method to handle high-pressure applications with large holes (greater than 0.75 inches) that were previously beyond the capability of existing composite repair systems.
4Ease of operation
If a wooden plug is hammered into the hole for emergency repair, then the repair can be performed without welding equipment, but fires and explosions occur due to remaining petroleum products
Solution Approach 1:
The patent introduces an intermediary mechanical fastening system (oblong plate and wing nut assembly) that acts as a safe barrier between the repair operation and the hazardous petroleum products. Unlike direct insertion methods (wooden plugs) that generate sparks or heat, this intermediary system provides a controlled, spark-free mechanical seal that prevents ignition of remaining hydrocarbons while maintaining ease of operation for emergency repairs.
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 repairs high-pressure pipeline holes without welding, maintaining operational safety and functionality, with a significant increase in failure pressure compared to traditional methods, and compatibility with various pipe geometries.
Implementation Method 1
an adhesive filler is applied over the oblong inner plate through and over the pipe hole. The adhesive filler is an initially high viscosity liquid adhesive which cures to a solid.
Implementation Method 2
a fabric material is impregnated with a lower viscosity epoxy and the combined fabric and epoxy is wrapped around the pipe to create a composite plug assembly
Data Source
AI summary
A composite plug system and a process to repair a hole in a tubular pipe. The process includes the steps of inserting a fastener through an opening in an oblong inner plate having an elongated diameter and a shorter diameter. The oblong plate is inserted into the pipe hole wherein the elongated diameter is greater than a diameter of the pipe hole and wherein the shorter diameter is less than the pipe hole diameter so that the oblong plate is within the tubular pipe beneath the hole. An initially liquid adhesive filler is applied over the oblong inner plate over the pipe hole. An outer plate having a central opening and a diameter larger than the pipe hole diameter is affixed over the pipe hole so that the central opening receives the fastener. The outer plate is secured to the oblong inner plate and the tubular pipe with the fastener until the adhesive filler solidifies. After the filler solidifies, the oblong plate and the outer plate are structurally bonded to the pipe wall through adhesion.