Pre-applied Pipe Insulation Jacketing for Corrosion Control
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Solution Overview
Problem
Current insulation methods for pipes and equipment lack a pre-applied protective jacketing that can be directly bonded to insulation materials, leading to inefficient and labor-intensive installation processes, and result in gaps that allow water intrusion and corrosion under insulation (CUI), which is costly and unpredictable to detect.
Innovation Solution
A method involving a copolymer-sodium silicate layer applied to the insulation's exterior surface and within its pores, allowing for direct adhesion of a protective jacketing, creating a composite structure that prevents water intrusion and corrosion by forming a uniform interface between the jacketing and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective jacketing is installed separately after insulation installation, then the insulation can be secured in place with tape or wires, but gaps remain between jacketing overlaps and lap joints allowing water intrusion
Solution Approach 1:
The patent combines the insulation installation and protective jacketing installation into a single integrated process. The jacketing is pre-applied to the insulation in the factory, creating a pre-jacketed insulation construction that is installed as one unit in the field, eliminating the separate jacketing installation step and ensuring continuous seal integrity.
Solution Approach 2:
The protective jacketing is applied to the insulation in advance during factory production, before the insulation is shipped to the job site. This preliminary action ensures proper alignment and sealing at overlaps and joints before field installation, preventing water intrusion pathways.
2Productivity
If protective jacketing is manually installed at the industrial site, then the installation process can be completed, but the process is slow and labor intensive
Solution Approach 1:
The protective jacketing is applied to the insulation in advance during factory production, before the insulation is shipped to the job site. This preliminary action ensures proper alignment and sealing at overlaps and joints before field installation, preventing water intrusion pathways.
Solution Approach 2:
The patent combines the insulation installation and protective jacketing installation into a single integrated process. The jacketing is pre-applied to the insulation in the factory, creating a pre-jacketed insulation construction that is installed as one unit in the field, eliminating the separate jacketing installation step and ensuring continuous seal integrity.
3Ease of manufacture
If insulation surfaces are transported and installed as-is, then the insulation materials can be delivered to site, but the dusty and fibrous surfaces prevent direct bonding of protective jacketing
Solution Approach 1:
The insulation surfaces are prepared with a bonding-promoting treatment in the factory before shipping. This preliminary surface preparation eliminates dust and fibrous characteristics that would prevent adhesion, ensuring the protective jacketing can be directly bonded to the insulation surface.
Solution Approach 2:
The patent modifies the surface properties of the insulation through chemical or physical treatment processes in the factory. This changes the surface characteristics from dusty and fibrous to smooth and adhesive-ready, enabling direct bonding of the protective jacketing without compromising the insulation material itself.
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 solution enables efficient, one-step installation of pre-jacketed insulation, reducing installation time and costs, and effectively prevents corrosion under insulation by ensuring a sealed interface, thereby minimizing operational downtime and maintenance costs.
Implementation Method 1
A copolymer-sodium silicate layer is disposed upon at least the insulation's exterior surface including within the pores
Implementation Method 2
A copolymer-sodium silicate layer is disposed upon at least the insulation's exterior surface including within the pores
Implementation Method 3
creating a composite structure that prevents water intrusion and corrosion by forming a uniform interface between the jacketing and insulation
Data Source
Figure 1A~1B
Figure 2
Figure 3~5
AI summary
A protective jacketing-insulation composite structure and method is provided for inhibiting the corrosion of a pipeline. The method includes forming a porous- insulation into an elongated-arcuate-shape, applying a sodium silicate solution layer to the insulation and at least partially within the pores thereof, permitting the sodium silicate solution layer to set to a threshold amount, adhering an outer facing to the sodium silicate solution layer after the permitting step is accomplished, installing the insulation and facing to the outer surface of a pipeline, and sealing any exposed edges or seams that may exist between multiple installed products. A structure such as made from this method can have a release layer and contact adhesive.