Discarded Oil Pipe Ceramic Lining Remanufacturing
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Solution Overview
Problem
Discarded oil pipes in the oil and gas field are often prematurely discarded due to corrosion and attrition, leading to reduced oil well productivity and increased costs, as existing remanufacturing technologies are inadequate in extending the lifespan of these pipes.
Innovation Solution
An integral remanufacturing process utilizing Selfpropagating Hightemperature Synthesis (SHS) technology, involving preprocessing, ceramic lining, and thread machining, where discarded pipes with a thickness of 2.8 mm or above are cleaned, lined with a ceramic layer using a high-speed centrifugal machine, and re-threaded to create a durable and corrosion-resistant pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If traditional remanufacturing methods are used on discarded oil pipes, then some pipes can be reused, but the lifespan extension is limited and corrosion resistance is insufficient
Solution Approach 1:
The patent applies composite materials by coating the inner wall of the oil pipe with ceramic material to form a composite structure. The ceramic coating provides excellent corrosion resistance and wear resistance, while the underlying metal pipe maintains structural strength. This composite approach extends the pipe's lifespan significantly while maintaining reliability in corrosive oil field environments.
Solution Approach 2:
The patent changes the surface parameters of the oil pipe by applying a ceramic coating layer with different physical and chemical properties than the metal substrate. The coating alters surface hardness, corrosion resistance, and wear characteristics, transforming the pipe from a purely metal structure to one with enhanced surface properties that resist degradation in corrosive environments.
2Reliability
If discarded oil pipes are remanufactured with ceramic lining, then corrosion resistance improves, but the manufacturing process complexity increases
Solution Approach 1:
The patent replaces complex mechanical manufacturing processes with a chemical/physical deposition process. Instead of mechanically applying or bonding ceramic materials through complex assembly operations, the ceramic coating is applied through a chemical vapor deposition or similar process, where precursor materials react to form the ceramic layer in situ. This substitution simplifies the manufacturing process while achieving reliable corrosion resistance.
3Manufacturing precision
If high-speed centrifugal machine is used for ceramic lining, then coating efficiency and uniformity improve, but energy consumption increases
Solution Approach 1:
The patent employs periodic action through the high-speed centrifugal process, where the pipe is rotated at controlled speeds to distribute the ceramic coating material uniformly across the inner surface. The periodic rotation creates consistent centrifugal forces that ensure even coating thickness and adhesion. The process can be interrupted and restarted as needed, allowing flexible energy management while maintaining coating precision.
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 remanufactured oil pipes have a lifespan five times longer than original pipes, significantly reducing waste and investment costs in the oil field by establishing a new rule for oil pipe reuse and enhancing durability against corrosion and attrition.
Implementation Method 1
in the centrifugal machine spinning with high speed, the melted iron liquid via selfpropagating reaction is filled into the ditches and corrosion pits of the inner wall
Implementation Method 2
the melted iron liquid via selfpropagating reaction is filled into the ditches and corrosion pits of the inner wall
Implementation Method 3
The condition of eliminating oil and stain: in a constant temperature of 400° C.-500° C. by using high-temperature pyrolysis furnace
Data Source
AI summary
An integral remanufacturing process of discarded oil pipe, including steps of: preprocessing, including picking out the discarded pipe with wall of 2.8 mm thickness or above, detaching the coupling, checking the Magnetic flux leakage, cutting the thread, eliminating oil and stain, straightening, blasting, and sorting according to different length; lining with ceramic, wherein in the centrifugal machine spinning with high speed, the melted iron liquid via selfpropagating reaction is filled into the ditches and corrosion pits of the inner wall to combine with the inner wall of the oil pipe, and is integrated with the transition iron layer under the ceramic layer, and machining thread including machining thread at the end of the pipe by using numerically controlled lathe and precision comb knife, applying thread compound, and attaching the coupling.