Vitreous Pipe Coating by Induction Heating for Corrosion Resistance

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Solution Overview

Problem

Current methods for addressing corrosion in oil and gas pipelines and downhole tubulars are expensive and inefficient, particularly at high temperatures and pressures, and lack practical solutions for joining vitreous coated pipe joints.

Innovation Solution

The use of localized induction heating to rapidly apply a vitreous coating to steel pipes, combined with induction kinetic welding for joining coated pipes, allowing for efficient and cost-effective corrosion resistance and seamless pipe connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional labor-intensive glass lining processes are used, then corrosion resistance is improved, but manufacturing cost and complexity increase significantly

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical brush application methods with electromagnetic induction heating technology. The induction heating system rapidly heats the steel substrate to melting point temperatures, allowing glass powder to melt and bond directly to the surface, eliminating labor-intensive manual brushing while achieving superior corrosion resistance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention fundamentally changes the temperature parameter of the coating process. By using induction heating to rapidly elevate the substrate temperature to extreme levels (melting point of glass), the process transforms from low-temperature manual application to high-temperature automated bonding, dramatically reducing labor costs while improving coating quality

Inventive Principle:

Principle #35Parameter changes

2Reliability

If glass lined pipes are joined with bolted flanges, then corrosion resistance is maintained, but productivity and ease of operation deteriorate

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidjoining speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent merges the pipe ends together through induction kinetic welding, creating a seamless joint that eliminates the need for separate flange components. This combining of parts into a unified structure both maintains corrosion resistance through proper coating application and dramatically improves productivity by eliminating multiple assembly steps

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention creates a composite structure where glass coating and steel substrate are bonded together through induction heating. This composite material approach allows the welded joint to maintain the corrosion-resistant properties of the glass lining while achieving the structural integrity needed for high-speed welding connections

Inventive Principle:

Principle #40Composite materials

3Productivity

If induction heating is used to apply vitreous coating, then manufacturing speed is improved, but temperature control difficulty increases

Engineering Contradiction:

Improvecoating application speedVSAvoidtemperature control

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent incorporates feedback control systems that continuously monitor the temperature during induction heating and automatically adjust power delivery to maintain optimal coating conditions. This closed-loop control manages the complexity of temperature regulation while preserving the high-speed benefits of induction heating

Inventive Principle:

Principle #23Feedback

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

This approach provides high corrosion resistance at a modest cost, suitable for extreme temperatures and pressures, and enables the practical application of glass linings in field settings, such as pipelines and well casings, while maintaining the strength properties of the steel.

Implementation Method 1

The use of localized induction heating to rapidly apply a vitreous coating to steel pipes

Methodology Applied

Scientific EffectInduction heating: Induction Heating

Implementation Method 2

combined with induction kinetic welding for joining coated pipes

Methodology Applied

Scientific EffectInduction kinetic welding: Induction Heating

Data Source

PatentUS11773495B2Vitreous coating application by induction heating and integration with induction kinetic weld joining

Publication Date: 2023.10.03 AMPCLAD COATING TECH INC

AI summary

Induction heating facilitated coating systems and processes for pipes overcome corrosion and erosion of the pipes at extreme temperatures and pressures in applications including oil and gas downhole tubulars and pipelines as well as processing facilities. Being based on vitreous fused inorganic compounds, the present invention achieves very high corrosion resistance at remarkably modest cost. Attractive economics and immunity to chlorides and moisture permeation at extreme concentrations and temperatures also make it well suited to desalination plants and potable water piping applications. Due to its extreme temperature resistance, it also is very well suited for geothermal wells. Additionally, due to its characteristic smooth durable surface, the present invention is ideally suited for applications involving the opposite of corrosion, namely scaling problems, such as fouling in sewage systems and scale buildup in heavy oil wells.