Rotating Pipeline Coating Applicator for Single-Pass Joint Heating
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pipeline coating technologies require multiple steps and equipment movements, leading to inefficiencies such as overheating, increased energy use, and potential de-bonding of factory-applied coatings during field joint coating processes.
Innovation Solution
A rotating applicator machine with an induction coil and coating material applicator that simultaneously heats and coats a section of pipeline, minimizing overheating and energy usage by focusing heating only on the area under the induction coil, and incorporating a design for efficient coating material application and waste collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional multi-step coating process is used with separate heating and coating equipment, then coating can be applied to pipeline sections, but the process requires multiple equipment movements and causes overheating of factory-applied coatings leading to de-bonding
Solution Approach 1:
The patent combines the heating function and coating application function into a single integrated applicator machine. The heating element and coating applicator are mounted together on the same frame, allowing both functions to be performed in one continuous operation without moving between separate equipment, thereby preventing overheating and de-bonding while maintaining productivity
Solution Approach 2:
The patent implements continuous heating and coating application in a single pass along the pipeline. The applicator machine moves continuously along the pipeline while simultaneously heating and applying coating material, eliminating interruptions and multiple equipment movements that cause thermal cycles and de-bonding
2Loss of energy
If traditional separate heating and coating equipment is used, then coating application is possible, but energy consumption increases due to repeated heating cycles
Solution Approach 1:
The patent merges multiple equipment functions into a single integrated applicator machine that performs heating, coating application, and waste collection in one unit. This reduces the number of separate equipment pieces and eliminates repeated heating cycles, thereby reducing energy consumption while managing device complexity
3Loss of substance
If traditional coating application method is used, then coating material can be applied to pipeline, but overspray increases leading to material waste
Solution Approach 1:
The patent employs a spray gun with a focused nozzle that directs coating material precisely onto the pipeline surface. The localized spray application reduces overspray and material waste while maintaining efficient coating application, as the coating material is delivered exactly where needed rather than being dispersed broadly
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 reduces cycle time, minimizes energy consumption, prevents de-bonding of factory-applied coatings, and ensures a consistent, efficient coating process with reduced overspray, thereby enhancing the quality and longevity of the pipeline coating.
Implementation Method 1
an induction coil mounted on the frame and rotatable therewith, wherein the induction coil is configured to heat a section of pipeline adjacent to the induction coil to a coating material application temperature
Implementation Method 2
the coating material applicator is arranged to spray coating material through an aperture through the induction coil
Data Source
AI summary
An applicator machine and a process for heating and coating a section of pipeline. The applicator machine includes a frame configured to rotate about a section of pipeline to be heated and coated, rotating means operable to rotate the frame, and coating material applicators induction coils and radiant heaters mounted on the frame and rotatable therewith. The induction coil is configured to heat a section of pipeline adjacent to the induction coil to a coating material application temperature. The radiant heaters are configured to heat factory-applied coatings. Each coating material applicator sprays coating material through an aperture in a respective induction coil. The applicator includes an enclosure configured to surround a section of pipeline and provision for evacuating and collecting waste coating material. The coating material applicator may be configured to spray powder coating material, such as fusion bonded epoxy powder material and/or chemically modified polypropylene powder material.