Segmented Pipeline Compensator for External Repair Installation
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Solution Overview
Problem
Existing industrial pipeline compensators are difficult to repair and replace quickly, leading to costly downtime when damaged, as they often require complete removal and replacement, especially in extreme conditions like high-temperature flue gas pipelines.
Innovation Solution
A multi-layer compensator design that can be installed externally, with layers such as metallic wire mesh, insulation, and fluid-tight fabric, allowing for connection to existing pipe ends without dismantling, using screw connections and welded connections for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a traditional sleeve-shaped expansion joint is used, then the pipeline can compensate for thermal expansion and contraction, but when damaged it must be completely removed and replaced, requiring plant shutdown and causing high costs and long downtime
Solution Approach 1:
The compensator is divided into multiple segments along its longitudinal axis, with each segment being independently replaceable. The compensation bore is divided into first, second, and third segments that can be removed and replaced individually without replacing the entire compensator structure.
Solution Approach 2:
The segmented compensator segments are designed to be nested within each other, with the compensation bore segments fitting within the housing structure. This nested design allows for easy insertion and removal of individual damaged segments while maintaining the overall compensator assembly.
2Ease of operation
If a traditional sleeve-shaped expansion joint is used, then the pipeline can compensate for thermal expansion, but replacement requires complete removal and installation of new joint, necessitating plant shutdown
Solution Approach 1:
The compensator is divided into multiple segments along its longitudinal axis, with each segment being independently replaceable. The compensation bore is divided into first, second, and third segments that can be removed and replaced individually without replacing the entire compensator structure.
Solution Approach 2:
The compensator segments are pre-assembled with connection mechanisms that facilitate quick attachment to the pipeline. The housing and bore segments are prepared in advance with matching interfaces, allowing for rapid installation without extensive on-site assembly work.
3Ease of repair
If a multi-layer divided compensator is used, then quick repair is enabled by external installation over existing pipeline, but the structure becomes more complex with multiple layers and division joints
Solution Approach 1:
The compensator is divided into multiple segments along its longitudinal axis, with each segment being independently replaceable. The compensation bore is divided into first, second, and third segments that can be removed and replaced individually without replacing the entire compensator structure.
Solution Approach 2:
Multiple functional layers (housing, compensation bore, insulation, fabric layer) are combined into a single integrated multi-layer structure that functions as one compensator unit. The division joints connect these layers together to form the complete sleeve-shaped compensator when assembled.
Data Source
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AI summary
The invention relates to a multi-layered compensator for an industrial pipeline, divided longitudinally (XX), designed to connect a first pipe end (101) with a second pipe end (102), comprising a metallic wire mesh (2) which forms an inner layer of the compensator and has at least one separation in the axial direction (XX), a multi-part insulating material (3) which surrounds the wire mesh on an outer side and forms a middle layer of the compensator, a first multi-part metal ring disc (4) and a second multi-part metal ring disc (5), wherein the first metal ring disc (4) is arranged at a first longitudinal end (11) of the compensator and the second metal ring disc (5) is arranged at a second longitudinal end (12) of the compensator, and a fluid-tight fabric layer (6) which is arranged on the outer side of the insulating material (3) and forms an outer layer of the compensator.and has at least one separation in the axial direction (XX), wherein the fabric layer (6) is fluid-tightly connected to the first metal ring disc (4) and the second metal ring disc (5).