Weld-Free Vessel Insulation Ring Structure to Prevent Sagging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for insulating reactor and pressure vessels require extensive welding and subsequent post-weld heat treatment (PWHT), which increases costs, reduces material strength, and can lead to vessel distortion and insulation deterioration due to sagging and moisture exposure.
Innovation Solution
A vessel insulation system comprising a floating ring, straps, and segmented rings that circumscribe the vessel without welding, supporting insulation materials and allowing for individual segment replacement, thus eliminating the need for PWHT and enhancing insulation durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding brackets or lugs to the vessel shell is used to support insulation materials, then the insulation can be securely mounted, but post-weld heat treatment (PWHT) is required which reduces material strength and can cause vessel distortion
Solution Approach 1:
The insulation support system is divided into multiple discrete bands that wrap around the vessel circumference, with each band independently supporting portions of the insulation. This eliminates the need for welded brackets while distributing the support load across multiple non-invasive attachment points.
Solution Approach 2:
The patent uses flexible bands wrapped around the vessel to support the insulation materials. These bands can be tensioned and secured without welding, adapting to the vessel's thermal expansion and contraction while maintaining secure insulation mounting.
2Strength
If multiple banded straps are used to hold insulation via friction, then welding is avoided, but the insulation sags over time and the lifespan is shorter
Solution Approach 1:
The bands are pre-tensioned during installation to account for future thermal expansion and contraction of the vessel. This preliminary adjustment ensures the bands maintain optimal tension throughout the vessel's operational cycles, preventing insulation sag and extending service life.
Solution Approach 2:
The banding system is designed to dynamically adapt to the vessel's thermal cycles, with the bands flexing and adjusting tension as the vessel expands and contracts. This dynamic response maintains secure insulation support without causing stress concentration or material failure.
3Ease of manufacture
If friction banding without brackets is used, then installation is simpler, but moisture sealing is less effective and insulation deterioration occurs
Solution Approach 1:
The flexible bands wrap tightly around the insulation materials, creating a continuous protective envelope that seals out moisture while maintaining simple installation. The bands act as both structural support and protective barrier, eliminating the need for complex bracket systems.
Data Source
AI summary
Systems and methods for insulating vessels are disclosed. In one or more embodiments, the disclosure provides a vessel insulation system (e.g., for use with a reactor or pressure vessel), which includes a floating ring sized to circumscribe a top nozzle of a vessel; a plurality of straps connected to the floating ring, the plurality of straps extending downward from the floating ring and being positioned to run along a length of the outer shell of the vessel; and a plurality of segmented rings positioned to circumscribe the outer shell of the vessel and connected to the plurality of straps. The plurality of segmented rings is configured to support an insulation material circumscribing the outer shell of the vessel, which can provide effective securement of the insulation material around the outer shell without welding components on the vessel to secure the insulation material.