Thermal Welding Seal for Insulated Pipe Integrity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pipelines transporting fluids like oil and gas face challenges with thermal insulation integrity due to seawater diffusion through imperfections and delamination at high temperatures, leading to corrosion and reduced functionality, especially in offshore applications where external pressures and aggressive environments are common.
Innovation Solution
A pipe design with an inner carrier pipe and casing sealed using an electrically conductive welding means, such as a welding band or string, which integrates materials by generating heat through an electrical current, providing a strong and effective encapsulation of insulation materials and preventing seawater intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mastic is used as joining material to seal the thermal insulation layer, then sealing effectiveness is improved at limited fluid temperatures, but delamination occurs at high temperatures (up to 140°C) allowing seawater diffusion
Solution Approach 1:
The patent changes the joining method from chemical bonding (mastic) to thermal bonding (welding). The welding process melts the thermoplastic materials of the inner coating and casing, creating a strong bond that maintains sealing effectiveness across a wide temperature range including high temperatures up to 140°C, eliminating the delamination problem associated with mastic at elevated temperatures.
Solution Approach 2:
The patent replaces the mechanical/chemical joining system (mastic as glue or double-sided tape) with a thermal field system (electrically conductive welding means generating heat through electrical current). This substitution enables the sealing joint to withstand high temperatures without delamination, as the welded bond is created through melting and fusion of the thermoplastic materials rather than chemical adhesion.
2Ease of manufacture
If traditional glue methods are used to seal inner coating and casing, then manufacturing simplicity is maintained, but insulation integrity deteriorates under extreme conditions (pressures up to 20 bars and temperatures up to 140°C)
Solution Approach 1:
The patent changes the sealing mechanism from chemical adhesion to thermal fusion. The welding process creates a bond that is superior to traditional glue methods under extreme conditions of pressure (up to 20 bars) and temperature (up to 140°C), while the thermoplastic materials used in the inner coating and casing enable this high-performance bonding through their melting and integration properties.
Solution Approach 2:
The patent utilizes composite material structure where the inner coating and casing are both made of thermoplastic materials that can be welded together. This composite approach allows the sealing joint to achieve superior mechanical and thermal properties compared to traditional glue methods, maintaining insulation integrity under extreme offshore conditions while still enabling relatively simple manufacturing through the welding process.
3Ease of repair
If single insulated pipes are used instead of continuous pipelines, then repair costs are reduced and functionality is maintained under extreme conditions, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the continuous pipeline into separate, modular single insulated pipe sections. Each section has its own sealed thermal insulation layer, allowing individual replacement without affecting the entire pipeline system. This segmentation enables cost-effective repairs where only the damaged section needs to be replaced, and maintains system functionality under extreme offshore conditions through the robust sealed construction of each module.
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
The solution achieves a stronger sealing than traditional glue methods, maintaining insulation integrity at high temperatures and withstanding extreme conditions, including pressures up to 20 bars and temperatures up to 140°C, thus preventing seawater diffusion and extending pipeline lifespan and reducing repair costs.
Implementation Method 1
said melting means being an electrically conductive means with an electrical resistance having melted and thereby integrated said materials by generating heat based on a current through said means
Implementation Method 2
having melted and thereby integrated said materials by generating heat based on a current through said means
Data Source
Figure 1a~1b
Figure 1c~2
AI summary
Disclosed herein is a pipe (100) for transporting fluids such as oil or gas, said pipe comprising an inner carrier pipe (102), with an inner coating (104) on the outer surface of the inner carrier pipe (102) and a casing (108) characterised in that said inner coating and said casing are sealed by integration between the material of the inner coating and the material of the casing as a result of melting of the materials in the area which is to be integrated. Hereby a strong sealing between the casing and the inner coating is obtained, which allows for an effective encapsulation of e.g. insulation material placed in between the casing and the inner coating. The invention further relates to a method for sealing an inner coating and a casing in a pipe for transporting fluids such as oil or gas.