Pipe Leak Repair With Expandable Grout and Carbon Fiber Wrap
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Solution Overview
Problem
Industrial facilities face significant downtime and revenue loss due to leaks in large diameter pipes, as traditional repair methods like seal tape are ineffective and require costly replacement of pipe sections, while existing solutions fail to address structural strength loss.
Innovation Solution
A method involving wrapping a flexible gasket material around the pipe with bypass valves, injecting expandable grout to seal leaks, and applying a carbon fiber reinforcement to enhance structural integrity, allowing for on-site repair of pipes of any size without full replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If seal tape is used to repair pipes, then the repair process is simple and quick, but the structural strength of the pipe is not restored and liquids can leak through over time
Solution Approach 1:
The patent applies composite materials by combining multiple materials with different properties: a flexible polymer base material for sealing, reinforcement materials (such as fiber-reinforced polymers or metal meshes) for structural strength, and potentially different polymer layers for different functions (sealing, adhesion, flexibility). This composite structure simultaneously provides ease of application and restored structural integrity, resolving the contradiction between simple repair and strength restoration.
2Reliability
If pipe sections are replaced to repair large diameter pipes, then the leak is permanently fixed and structural strength is restored, but the facility must shut down causing revenue loss
Solution Approach 1:
The repair system is applied in advance to prevent leaks before they cause major damage or require shutdowns. The flexible wrap can be installed quickly around the entire pipe, creating an immediate seal while the reinforcing materials are activated or cured, allowing the facility to resume operation much faster than traditional replacement methods.
Solution Approach 2:
The patent employs dynamic materials and methods where the flexible polymer wrap can adapt to pipe movements, thermal expansion, and pressure changes. The system transitions from a flexible installable state to a rigid reinforced state, providing both ease of application and permanent leak fixation without requiring pipe replacement or facility shutdown.
3Ease of manufacture
If seal tape is used for repair, then the repair cost is low, but the pipe must eventually be replaced and structural strength loss is not addressed
Solution Approach 1:
By combining sealing polymers with reinforcement materials in a multi-layer composite structure, the system provides both immediate leak sealing and long-term structural reinforcement. This extends the pipe's service life significantly compared to seal tape alone, while remaining more cost-effective than complete pipe replacement.
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 effectively seals leaks and reinforces the pipe's structural strength, enabling quick and cost-effective repair of large diameter pipes without shutting down facilities, maintaining or even improving the pipe's original strength.
Implementation Method 1
injecting an expandable grout into the annular cavity between the pipe and the gasket material and allowing the grout to expand upon contact with the leaking liquid to seal the leak in the pipe
Data Source
AI summary
A method for sealing a liquid leak in a pipe. The method may include wrapping a circumference of the pipe with a gasket material at a location of the leak to create an annular cavity between the gasket material and the pipe. The method may also include allowing the leaking liquid to exit from the annular cavity. The method may further include securing the gasket material to the pipe. The method may also include injecting an expandable grout into the annular cavity between the pipe and the gasket material. The method may further include allowing the grout to expand upon contact with the leaking liquid to create a seal around the leak. The method may also include adhering a reinforcement material to the gasket material and the pipe to reinforce the gasket material and the pipe at the location of the leak.