Water-Based Grouting Composition for Tubular Thermal Insulation
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Solution Overview
Problem
Existing grouting compositions used for insulating tubulars in enclosed conduits are either too costly, time-consuming, or pose safety risks due to their expansive properties, and they often have high thermal conductivity, limiting effective thermal insulation.
Innovation Solution
A water-based grouting composition comprising a water-swellable binding material, such as bentonite clay, an aqueous liquid as the continuous phase, and an insulating material, which is introduced into the annulus between the tubular and the conduit, allowing it to set with a thermal conductivity of less than 0.3 BTU/hr·ft·° F.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If existing grouting compositions are used for insulating tubulars, then thermal insulation is provided, but thermal conductivity is high and cost is increased
Solution Approach 1:
The grouting composition incorporates air bubbles and void spaces within the matrix, creating a porous structure that reduces thermal conductivity. The composition includes materials like vermiculite, perlite, or other lightweight aggregates that create internal porosity, allowing the grout to maintain insulating properties while remaining pumpable and settable in the annulus.
Solution Approach 2:
The invention uses composite materials combining organic and inorganic components, such as cellulose fibers with clay, or polymer beads with grout matrix. These composites provide both structural integrity and thermal insulation, achieving low thermal conductivity while maintaining the necessary mechanical properties for effective insulation.
2Temperature
If existing grouting compositions are used for insulating tubulars, then insulation is provided, but time consumption and safety risks increase
Solution Approach 1:
The grouting composition is designed to self-level and self-set without requiring specialized equipment or complex procedures. The composition automatically fills the annulus, swells to eliminate voids, and cures to provide insulation, reducing the need for additional time-consuming steps and specialized equipment while maintaining effective thermal insulation.
3Temperature
If existing grouting compositions are used for insulating tubulars, then insulation is provided, but cost increases
Solution Approach 1:
The invention employs cost-effective, readily available materials such as standard grout components, common insulating aggregates, and basic additives that can be sourced economically. The composition is designed for single-use application in the annulus, eliminating the need for expensive reusable insulation systems while providing effective thermal insulation.
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 composition effectively reduces thermal conductivity, enhancing insulation efficiency while being safer and more cost-effective, with improved shear strength and pumpability, allowing for longer insulated tubular lengths without specialized equipment.
Implementation Method 1
a water-swellable binding material comprising a water-swellable clay
Implementation Method 2
after setting the grouting composition has a thermal conductivity of less than 0.3 BTU/hr·ft·°F
Data Source
AI summary
According to an embodiment, a method for thermally insulating a portion of a tubular located inside an enclosed conduit comprises the steps of: (A) introducing a grouting composition into an annulus between the tubular and the enclosed conduit, the grouting composition comprising: (i) a water-swellable binding material comprising water-swellable clay; (ii) an aqueous liquid, wherein the aqueous liquid is the continuous phase of the grouting composition; and (iii) an insulating material; and (B) allowing the grouting composition to set after the step of introducing, wherein after setting the grouting composition has a thermal conductivity of less than 0.3 BTU/hr·ft·° F. According to another embodiment, a grouting composition for use in insulating a portion of a tubular located inside an enclosed conduit comprises: (A) a water-swellable binding material comprising water-swellable clay; (B) an aqueous liquid, wherein the aqueous liquid is the continuous phase of the grouting composition; and (C) an insulating material, wherein after the grouting composition has set, the grouting composition has a thermal conductivity of less than 0.3 BTU/hr·ft·° F.