Transportable Molding System for On-Site Pipe Insulation
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Solution Overview
Problem
The high cost and logistical challenges of manufacturing and transporting long insulated pipes for subsea oil and gas exploration and extraction, as well as the impracticality of setting up permanent molding systems onsite, make existing solutions inefficient and costly.
Innovation Solution
A portable molding system composed of transportable process modules that can be shipped, assembled onsite, and easily disassembled for reconfiguration, featuring resin preparation, mold, and temperature control modules, allowing for the formation of insulation on pipes of varying lengths without the need for permanent piping or sheltered equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a permanent molding system is set up onsite, then insulation can be formed on long pipes, but the capital expenditure and effort required are impractical for end users
Solution Approach 1:
The molding system is divided into multiple independent process modules (resin preparation module, mold module, temperature control module) that can be shipped separately and assembled onsite. Each module performs a specific function in the insulation formation process, allowing the system to be configured for different pipe lengths and requirements without requiring a complete permanent installation.
Solution Approach 2:
The system transitions from a static permanent installation to a dynamic portable configuration. The modules can be easily assembled, disassembled, and repositioned based on project needs, enabling flexibility in deployment without the commitment of permanent infrastructure.
2Productivity
If long insulated pipes are manufactured remotely and shipped to the field, then insulation can be applied, but the cost and logistical challenges increase
Solution Approach 1:
The process modules are pre-configured and pre-tested in a controlled manufacturing environment before shipment. This preliminary preparation ensures that when the modules are assembled onsite, the insulation formation process can begin immediately without requiring extensive setup time, thereby reducing logistical delays.
Solution Approach 2:
The portable modules serve as an intermediary solution between remote manufacturing and field deployment. They can be shipped to the field site and quickly assembled to create an on-site insulation production capability, eliminating the need for either fully remote manufacturing or permanent onsite installations.
3Adaptability or versatility
If a portable molding system with multiple process modules is used, then on-site production is enabled, but the complexity of assembling and connecting modules increases
Solution Approach 1:
The process modules are designed with universal connection interfaces and standardized mounting configurations that allow them to be assembled in various arrangements depending on the pipe length and project requirements. The modules can be connected through standardized coupling mechanisms that simplify assembly while maintaining full process functionality.
Solution Approach 2:
The modules incorporate self-aligning features and tool-free connection mechanisms that enable operators to assemble and disassemble the system with minimal equipment and expertise. This self-service capability reduces the complexity of module connection while maintaining adaptability for different application scenarios.
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
Enables efficient and cost-effective on-site production of long insulated pipes by allowing modular, portable, and adaptable insulation application, reducing capital expenditures and logistical complexities.
Implementation Method 1
The transportable process modules are used to condition the resin, mix the conditioned resin with catalyst
Implementation Method 2
The resin is cured in the mold cavity to form an insulated pipe at the molding site
Data Source
AI summary
A portable molding system is configured for forming insulation on pipes. A set of transportable process modules are configured to be shipped to a molding site, operatively connected together at the molding site to form a site-installed molding system, and subsequently disconnected for transport to another site. The set of transportable process modules includes one or more resin preparation modules configured to prepare resin for being formed into insulation on the pipes. One or more mold modules are configured to define a mold cavity. The one or more mold modules are configured to hold a pipe in the mold cavity, to receive resin prepared by the one or more resin preparation modules in the mold cavity around the pipe, and to form said resin received in the mold cavity into insulation on the pipe.