Offshore Tubular Repair Shell with Threaded Fasteners

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Solution Overview

Problem

Existing methods for repairing tubular members in offshore marine environments, such as those damaged by hurricanes, often require lengthy and costly processes like post-tensioned cementitious grouted clamps or wet welding, which are inefficient and pose hazards in marine settings.

Innovation Solution

A method and apparatus utilizing a specially configured shell with threaded fasteners and inflatable seals to enhance the shear bond strength of epoxy/polymer grout, allowing for rapid and cost-effective repair by clamping the shell to the tubular member and filling the annulus with grout, which cures to improve load capacity and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If post-tensioned cementitious grouted clamps or wet welding are used to repair tubular members, then structural integrity can be restored, but the repair process becomes lengthy and costly

Engineering Contradiction:

Improvestructural integrityVSAvoidrepair time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The repair system is divided into modular components: a clamp assembly with separate jaw members that can be independently positioned and secured, allowing for staged installation and repair operations without requiring complete disassembly or lengthy continuous processes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamp assembly is pre-configured with bonding surfaces and positioning features before installation. The grout material is prepared and positioned in advance within the clamp structure, enabling immediate bonding upon clamping without requiring extended preparation time during the repair operation

Inventive Principle:

Principle #10Preliminary action

2Reliability

If post-tensioned cementitious grouted clamps or wet welding are used to repair tubular members, then structural integrity can be restored, but the process becomes costly

Engineering Contradiction:

Improvestructural integrityVSAvoidrepair cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The clamp assembly is designed as a relatively simple mechanical device that can be manufactured at lower cost compared to complex post-tensioning systems or welding equipment. The clamp serves its primary function of holding and bonding, then can be removed and reused, avoiding the need for expensive permanent modifications or specialized welding operations

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The system transitions from using expensive cementitious grouts requiring complex post-tensioning to a polymer-based grout system that cures faster and requires simpler application equipment. This material parameter change reduces both material costs and equipment investment while maintaining bonding strength

Inventive Principle:

Principle #35Parameter changes

3Ease of repair

If traditional repair methods are used in offshore marine environments, then repairs can be performed, but hazards are posed to safe operation

Engineering Contradiction:

Improverepair capabilityVSAvoidoperational hazards

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

The system replaces wet welding operations with a mechanical clamping and chemical bonding process. This substitution eliminates the hazards associated with welding in marine environments (sparks, heat, fumes) while maintaining effective structural repair capability through the combination of mechanical compression and polymer grout bonding

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If the annulus between the damaged section and shell is filled with grout, then shear bond strength is enhanced, but the complexity of the repair apparatus increases

Engineering Contradiction:

Improveshear bond strengthVSAvoidapparatus complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The clamp assembly integrates multiple functions into a single structure: it provides mechanical compression, contains the grout material, positions the bonding surfaces, and transfers loads. This merging of functions into one unified device achieves high shear bond strength without requiring separate complex systems for each function, thereby limiting the increase in overall apparatus complexity

Inventive Principle:

Principle #5Merging (Combining)

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 method significantly reduces installation time and cost compared to traditional methods, enhancing the structural integrity and load capacity of repaired tubular members while ensuring safe and efficient operations in offshore environments.

Implementation Method 1

a polymer/grout is placed in an annulus between the member and a clamp assembly of improved configuration... the shear bond strength of the epoxy/polymer grout between the clamp and the member

Methodology Applied

Scientific EffectPolymer curing: Chemical Bonding

Data Source

PatentUS8628275B1Structural bonded repair method for repairing tubular members in an offshore marine environment

Publication Date: 2014.01.14 MADCON CORP

AI summary

A method and apparatus for repairing a tubular member in an offshore marine environment provides a specially configured shell having shell halves, longitudinal seals, and optionally upper and lower seals. Additionally, the shell halves are each provided with a plurality of threaded fasteners that will help with shell alignment, holding the shell rigidly to the tubular member prior to grouting operations.