Process Vessel Lining Assembly for Corrosion-Protected Weld Joints

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Solution Overview

Problem

Conventional methods for protecting process vessels from corrosion, such as acid brick refractory/lining and plate lining, face challenges like cracking at edges and limited repairability, leading to potential vessel destruction from corrosive media penetration.

Innovation Solution

A method involving the welding of a metal band to the interior surface of a process vessel, followed by the joining of metal overlay sections over the band, with a weld line section formed and covered by a metal seal strip, providing multiple layers of corrosion protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional plate lining techniques are used to provide corrosion resistant to process vessels, then corrosion protection is achieved, but cracking occurs at the edges due to different types of metals being welded

Engineering Contradiction:

Improvecorrosion protectionVSAvoidedge cracking resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent applies homogeneity by using the same metal material (e.g., stainless steel) for both the plate lining and the overlay sections. This eliminates galvanic corrosion and welding incompatibility issues that occur when dissimilar metals are joined, thereby preventing edge cracking while maintaining corrosion protection.

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent creates a composite structure where overlay sections are applied over the plate lining edges. This composite approach provides a transition zone that eliminates the direct edge-to-edge contact between dissimilar metals, preventing cracking while maintaining the corrosion-resistant barrier.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional plate lining is applied to process vessels, then corrosion resistance is provided, but repair of damage to the lining is time consuming and limited

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidlining repairability

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent segments the corrosion protection system into modular overlay sections that can be independently removed, repaired, or replaced. This segmentation allows for localized repairs without requiring complete dismantling of the lining system, significantly improving repairability while maintaining overall corrosion resistance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The overlay sections are designed with pre-formed edges and sealing features that facilitate easy installation and repair. The preliminary preparation of these sections allows for quick replacement of damaged areas without extensive preparation work, making the repair process more efficient.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If multiple layers of protection are applied to process vessels, then corrosion protection is enhanced, but device complexity increases

Engineering Contradiction:

Improvecorrosion protectionVSAvoidprotective assembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the plate lining and overlay sections into an integrated protective assembly where the overlay sections are welded directly to the plate lining. This combination creates a unified structure that provides enhanced corrosion protection without requiring separate, complex installation procedures for each layer.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The overlay sections serve multiple functions: they protect the plate lining edges from corrosion, provide a smooth transition surface, and create sealable joints. This multi-functionality reduces the need for additional separate components, thereby enhancing protection while limiting complexity increases.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 method effectively prevents corrosion by creating a robust, multi-layered protective assembly that minimizes the risk of cracking and enhances repairability, thereby extending the lifespan of process vessels.

Implementation Method 1

a metal band may be welded to the interior surface of the process vessel while first and second metal overlay sections are joined to the interior surface of the process vessel

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The weld line section is then covered with a metal seal strip which is itself welded to each of the opposed end regions of the overlay sections

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS20250025966A1Methods for providing corrosion protection to process vessels and corrosion protected process vessels obtained thereby

Publication Date: 2025.01.23 INTEGRATED GLOBAL SERVICES INC

AI summary

Corrosion protection is provided to an interior surface of a process vessel by welding a metal band to the interior surface of the process vessel while first and second metal overlay sections are joined to the interior surface of the process vessel such that opposed end regions of the first and second overlay sections are adjacent to one another and are positioned over the metal band. A weld line section is formed by welding the opposed end regions of the overly sections to one another and to the metal band. The weld line section is then covered with a metal seal strip which is itself welded to each of the opposed end regions of the overlay sections.