Tube-to-Tube Sheet Repair Insert for Restoring Butt-Welded Joints
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Solution Overview
Problem
Existing methods for repairing damaged tube-to-tube sheet weld joints in shell-and-tube equipment, particularly those using Internal Bore Welding (IBW) technology, fail to restore the original butt-welded joint configuration, resulting in less reliable corner or crevice welds.
Innovation Solution
A tubular connection element with a radially projecting flange and shaped recess is used to facilitate a strong, annular weld bead between the tubular connection element and the tube sheet, allowing for the restoration of the original butt-welded joint configuration through a series of machining and welding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional corner joint welding is used to repair damaged tube-to-tube sheet joints, then the repair process is simpler and easier to perform, but the joint reliability and strength are reduced compared to original butt-welded joints
Solution Approach 1:
A tubular connection element is introduced as an intermediary component between the tube and tube sheet. This element has a first connecting portion for butt-welded connection to the tube and a second connecting portion for root welding to the tube sheet, thereby restoring the reliable butt-welded joint configuration while maintaining ease of repair through standardized components
Solution Approach 2:
The connection solution is segmented into distinct functional portions: a first connecting portion for tube connection via butt-welding and a second connecting portion for tube sheet connection via root welding. This segmentation allows each portion to be optimized for its specific welding type while collectively restoring the original joint reliability
2Ease of repair
If the original tube hub is removed through cutting or machining to replace the damaged tube, then the damaged tube can be replaced, but the original butt-welded joint configuration cannot be restored and must be replaced with less reliable corner joints
Solution Approach 1:
The tubular connection element is designed in advance with pre-formed first and second connecting portions that are specifically configured for butt-welded connection to the tube and root welding to the tube sheet. This preliminary preparation allows the original butt-welded joint configuration to be restored without requiring complex on-site manufacturing operations
Solution Approach 2:
The tubular connection element serves as a mediator that bridges the gap between the replaced tube and tube sheet, restoring the original butt-welded joint configuration that would otherwise be lost when the tube hub is removed for tube replacement
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 enables the restoration of the original butt-welded joint configuration, providing a more reliable and stronger connection compared to conventional corner or crevice welds, while using conventional welding tools and maintaining the equipment's integrity.
Implementation Method 1
The tubular connection element is provided at one end thereof with at least one first connecting portion for the connection, through a butt-welded joint, to one corresponding tube of the shell-and-tube equipment
Data Source
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AI summary
A device for repairing damaged tube-to-tube sheet weld joints in a shell-and-tube equipment is disclosed. The device consists in a tubular connection element (10) oriented along a central axial direction (A) and comprising: at least one inner wall (12), designed to enclose an inner conduit for the passage, along the central axial direction (A), of at least one fluid processed by the shell-and-tube equipment, and at least one outer wall (14), which surrounds the inner wall (12). The tubular connection element (10) is provided, at one end thereof, with at least one first connecting portion (16) for the connection, through a butt-welded joint (100), to one corresponding tube of the shell-and-tube equipment and, on one side thereof, with at least one second connecting portion (18) for the connection, through at least one weld bead, of the tubular connection element (10) to at least one portion of the tube sheet (104) of the shell-and-tube equipment. The second connecting portion (18) of the outer wall (14) is provided with at least one radially projecting flange (20), designed to facilitate a root welding, through said at least one weld bead, between the tubular connection element (10) and the tube sheet (104). The radially projecting flange (20) delimits at least one shaped recess (22) on the outer wall (14) for housing at least a part of the weld bead. A method for repairing damaged tube-to-tube sheet weld joints in a shell-and-tube equipment, using at least one tubular connection element (10), is furthermore disclosed.