FIELD OF INVENTION:

The present invention relates to an injection system for the injection of sealant or a lubricant into an injection site. More particularly the present invention relates to the injection system to inject pressurized sealant or a lubricant into the injection site.

BACKGROUND OF THE INVENTION:

Sealant is a semi solid compound which is periodically injected into lubricated valves in order to provide proper sealing, facilitate smoother operation and extending their service life. This sealant, on injection into the valve, occupies all undesired voids inside the valve body from where leakage could occur and also forms a fine lubricating film between moving parts of the valve. Thus the operating life of even an aging valve can be increased manifold.

Presently, injection of sealant or lubricant is done manually with the help of a injecting gun. However, the main drawback of manual sealant or lubricant injection is that it is both laborious and time consuming. For instance, to inject sealant or lubricant into a 10" valve under pressurised condition, two operators are required to work simultaneously for 6 hours continuously. Thus maintaining all the valves of a production platform/plant in
healthy operating condition is an enormous task.

There are two limitations in operating a conventional pump to inject sealant or lubricant.

1. A conventional pump cannot suck sealant during its suction stroke unless sufficient positive pressure is applied because of the semisolid viscous nature of the sealant.

2. The pump has much a faster stroke, so the frequency of the Check valve's open and close sequence is also so much faster that it again cannot handle the thickness and consistency of the sealant or lubricant in discharging the sealant or lubricant.
These two factors combine to make it impossible to operate a conventional pump for the purpose of injecting sealant or lubricant.

To overcome the above limitations this particular invention, the injection system has been designed and developed.

OBJECT OF THE INVENTION:

To overcome the shortcomings of the prior art, the object of the present invention is to provide an injection system with a plurality of pressure inducing means for slowly delivering the sealant or the lubricant into the injection site with high pressure in a controlled manner.

Another object of the present invention is to provide a two stage pumping design with first stage pressure inducing means and second stage pressure inducing means for online injection of sealant or lubricant.

Yet another object of the present invention is to provide an injection system for online injection of sealant to arrest leakage of high pressure valves, prevent mechanical failure and ensure operational viability in the injection site

Further object of the present invention is to provide a injection system for online injection of lubricant to reduce the friction, improve efficiency, dissolve foreign particles, transport foreign particle , distribute heat, reduce wear and also provides a coating on the dried sealant surface.

SUMMARY OF THE INVENTION:

The invention relates to an injection system for injecting a sealant and/or lubricant into the injection site. The injection system is designed to deliver sealant and/or lubricant into the injection site by slow stoke at a high pressure. The injection system of the present invention comprises of a first conveying means, second conveying means, third conveying means, a first storage means with first pressure inducing means arrangement and second storage means with second pressure inducing means arrangement. The invention features a two stage pumping design i.e. it uses a first storage means with first pressure inducing means in the first stage and a second storage means with second pressure inducing means in the second stage. The sealant and/or lubricant is filled into the first storage means and then transferred to the second storage means then it is slowly injected into the injection site with high pressure. The purpose of sealant injection is arresting leakage of high pressure valves, prevent mechanical failure and ensure operational viability and the purpose of lubricant injection is to reduce the friction, improve efficiency, dissolve foreign particles, transport foreign particle, distribute heat, reduce wear and also provides a coating on the dried sealant surface.

BRIEF DESCRIPTION OF THE DRAWINGS:

Figure-1 illustrates schematic cross sectional view of the first storage means , which is generally referred to as pneumatic feeder in the trade.

Figure-2 illustrates schematic cross sectional view of the second storage means, which is generally referred to as pressure intensifier in the trade.

Figure-3 illustrates first pressure inducing means for first storage means suction stroke.

Figure-4 illustrates schematic front view of the injection system during first storage means suction stroke.

Figure-5 illustrates schematic rear view of the injection system during first storage means suction stroke.

Figure-6 illustrates schematic view of control panel during first storage means suction stroke.

Figure-7 illustrates first pressure inducing means for first storage means discharge stroke.

Figure-8 illustrates schematic front view of the injection system during first storage means discharge stroke.

Figure-9 illustrates schematic rear view of the injection system during first storage means discharge stroke.

Figure-10 illustrates schematic view of control panel during first storage means discharge stroke.

Figure-11 illustrates first pressure inducing means and second pressure inducing means for second storage means suction stroke.

Figure-12 illustrates schematic front view of the injection system during second storage means suction stroke.

Figure-13 illustrates schematic rear view of the injection system during second storage means suction stroke.

Figure-14 illustrates schematic view of control panel during second storage means suction stroke

Figure-15 illustrates first pressure inducing means and second pressure inducing means for second storage means discharge stroke.

Figure-16 illustrates schematic front view of the injection system with injection hose, three way selector valves and injection valve during second storage means discharge
stroke.

Figure-17 illustrates schematic top view of the injection system with injection hose, three way selector valves and injection valve during second storage means discharge stroke.

Figure-18 illustrates schematic view of control panel during second storage means discharge stroke

Figure-19 illustrates first pressure inducing means and second pressure inducing means for nipple flushing.

Figure-20 illustrates schematic front view of the injection system with hydraulic oil and injection hose, three way selector valves and injection valve during nipple flushing.

Figure-21 illustrates schematic top view of the injection system with hydraulic oil and injection hose, three way selector valves and injection valve during nipple flushing.

Figure-22 illustrates schematic view of control panel during nipple flushing Figure-23 illustrates schematic view of injection system from input side. Figure-24 illustrates schematic view of injection system from tool box side. Figure-25 illustrates schematic front view of injection system structural support with impact resistance rubber padding.

Figure-26 illustrates schematic top view of injection system with top cover plates. Figure-27 illustrates schematic front view of injection system with front cover plates. Figure-28 illustrates schematic rear view of injection system with rear cover plates. Figure-29 illustrates schematic view of injection system from first storage means input side during operation.

Figure-30 illustrates schematic view of injection system from tool box side during operation. Figure-31 illustrates schematic top view of injection system during operation.

Figure-32 illustrates schematic front view of injection system during operation. Figure-33 illustrates schematic rear view of injection system during operation.

Figure-34 illustrates schematic top view of injection system for onshore application.

Figure-35 illustrates schematic front view of injection system for onshore application.
Figure-36 illustrates schematic rear view of injection system for onshore application.

DETAILED DESCRIPTION:

The invention relates to an injection system for slowly injecting a sealant or lubricant into the injection site with high pressure. The injection system comprising of a plurality of pressure inducing means for controlling the delivery of the sealant or lubricant into the injection site.

The invention features a two stage pumping design i.e. it uses first pressure inducing means with first storage means in the first stage and a a second pressure inducing means with second storage means in the second stage for online injection of sealant or lubricant.

The Sealant or lubricant is filled into the first storage means manually by disengaging the cam locks. To feed the sealant or lubricant into the second pressure inducing means , the cam locks are brought into engagement. Safety interlock is provided to prevent air entry into the first storage means sealant or lubricant chamber and to prevent the formation of explosive mixture inside the chamber. Pressure regulator and Limit switch provided at the air inlet to the first storage means sealant or lubricant chamber provides end position cushioning to the first storage means piston. Quantity of sealant or lubricant inside the sealant or lubricant chamber of the first storage means and the swept volume can be measured by the movement of a pointer, attached to first storage means piston rod, over a calibrated scale. The injected sealant or lubricant can be accurately measured by indirectly measuring the flow of hydraulic oil through second storage means by a hydraulic oil flow meter. Using hydraulic oil from the injection system, valves and injection nipple can be flushed. Safety Logic circuit with triple safety system comprising of a pneumatic horn, hydraulic circuit pressure switch, hydraulic circuit pressure safety valve, hydraulic pump pressure safety valve, and second storage means pressure safety valve are also featured in this design. An economically designed control panel with necessary valves, pressure regulators, status switch and an array of pressure gauges and also a simple schematic circuit diagram etched on it has been mounted on the machine for ease of operation by the operator. A tool box is provided for keeping necessary tools and fittings. All the sensitive components are mounted over oil resistant rubber padding for impact resistance. The injection system, is mounted over two fixed wheel and two swivel wheel and a tow bar is provided for short distance movement. Lifting lug is provided for shipment and transportation. A dedicated lubrication line with isolation valve is provided from storage means for lubricating thrust bearing of the swivel front wheel axle. Weather proof covering is provided at all the four side of the injection system,

The first embodiments of the invention includes an injection system for injecting a sealant into an injection site. The injection system comprising a plurality of pressurizing chambers interconnected in series with plurality of conveying means. The injection system includes a first storage means having an enclosed volume, an input port for receiving sealant, an output port and a first pressure inducing means is disposed in the first storage means. A first conveying means terminating at an external source containing sealant at its one end and terminating at the input port of the first storage means at its other end, thereby conveying the sealant from source to first storage means, corresponding to the pressure induced by first pressure inducing means. A second storage means having an enclosed volume, an input port for receiving sealant, an output port and a second pressure inducing means disposed there within, a second conveying means terminating at the output port of first storage means at its one end and terminating at the input port of the second storage means at its other end, thereby conveying the sealant from first storage means to second storage means, corresponding to the pressure induced by first pressure inducing means, pressure corresponding to second pressure inducing means or both. A third conveying means extending from the output port of second storage means to deliver the sealant from the second storage means to the injection site, corresponding to the pressure induced by second pressure inducing means. The conveying means may be a combination of single conveying line with cam lock arrangement or plurality of conveying lines with cam lock arrangement. The first pressurizing means is preferably pneumatic or it may be pneumatic, hydraulic or combination thereof. The second pressurizing means is pneumatic actuated hydraulic pressure inducing means or it may be pneumatic, hydraulic or combination thereof. The first pressure inducing means, disposed within the first storage means comprises of a moveable piston dividing the storage means into a sealant or lubricant chamber and a pressure chamber. The pressure inducing means is disposed within the second storage means which comprises of a moveable piston and divides the storage means into a sealant chamber, a first pressure chamber and a second pressure chamber. The first and second chamber may be an air pressure chamber or hydraulic pressure chamber. The first pressure inducing and the second pressure inducing means may include plurality of control valves for controlling the pressure of pressure inducing means and flow of sealant in the conveying means. The injection system further comprises of a control panel includes plurality pressure regulators, plurality of valves, plurality of switches, plurality of pressure gauges, plurality of schematic circuits along with displaying and monitoring means for controlling the first storage means, second storage means, first conveying means, second conveying means and third conveying means. The injection system is mounted on a plurality of wheel means for mobility. The system is further provided with lifting lugs means for shipment and transportation.

The second embodiment of the invention includes an injection system for injecting a lubricant into an injection site. The injection system comprising a plurality of pressurizing chambers interconnected in series with plurality of conveying means

The injection system includes a first storage means having an enclosed volume, an input port for receiving lubricant , an output port and a first pressure inducing means is disposed in the first storage means. A first conveying means terminating at an external source containing lubricant at its one end and terminating at the input port of the first storage means at its other end, thereby conveying the lubricant from source to first storage means, corresponding to the pressure induced by first pressure inducing means. A second storage means having an enclosed volume, an input port for receiving lubricant, an output port and a second pressure inducing means disposed there within, a second conveying means terminating at the output port of first storage means at its one end and terminating at the input port of the second storage means at its other end, thereby conveying the lubricant from first storage means to second storage means, corresponding to the pressure induced by first pressure inducing means, pressure corresponding to second pressure inducing means or both. A third conveying means extending from the output port of second storage means to deliver the lubricant from the second storage means to the injection site, corresponding to the pressure induced by second pressure inducing means. The conveying means may be a combination of single conveying line with cam lock arrangement or plurality of conveying lines with cam lock arrangement. The first pressurizing means is preferably pneumatic or it may be pneumatic, hydraulic or combination thereof. The second pressurizing means is pneumatic actuated hydraulic pressure inducing means or it may be pneumatic, hydraulic or combination thereof. The first pressure inducing means disposed within the first storage means comprises of a moveable piston dividing the storage means into a lubricant chamber and a pressure chamber. The pressure inducing means is disposed within the second storage means which comprises of a moveable piston and divides the storage means into a lubricant chamber, a first pressure chamber and a second pressure chamber. The first and second chamber may be an air pressure chamber or hydraulic pressure chamber. The first pressure inducing and the second pressure inducing means may include plurality of control valves for controlling the pressure of pressure inducing means and flow of lubricant in the conveying means. The injection system further comprises of a control panel includes plurality pressure regulators, plurality of valves, plurality of switches, plurality of pressure gauges, plurality of schematic circuits along with displaying and monitoring means for controlling the first storage means, second storage means, first conveying means, second conveying means and third conveying means. The injection system is mounted on a plurality of wheel means for mobility. The system is further provided with lifting lugs means for shipment and transportation.

The third embodiment of the invention shall disclose a method of injecting sealant into an injection site. The method comprises the steps of, conveying a sealant contained in an external source into a first storage means through a first conveying means by inducing pressure in the first storage means with a first pressure inducing means disposed there within; conveying the sealant further from the first storage means into a second storage means through a second conveying means by inducing pressure in the second storage means with a pressure inducing means disposed there within, or inducing pressure in the first storage means with the pressure inducing means disposed there within or both; and conveying the sealant from the second storage means outwardly out of the second storage means through a third conveying means by inducing pressure in the second storage means with the second pressure inducing means disposed therein within. The method includes first pressure inducing means and second pressure inducing means. The first pressure inducing as described above may be actuated by pneumatic pressure, hydraulic pressure or combination thereof. The second pressure inducing as described above may be actuated by hydraulic pressure with pneumatic actuation. The pressure inducing means disposed within the first storage means as described in the above method, the first storage means comprises of a moveable piston which divides the storage means into a sealant chamber and a pressure chamber. The pressure chamber as air chamber or hydraulic chamber. The pressure inducing means disposed within the second storage means as described in the above method, the second storage means comprises of a movable piston which divides the second storage means into a sealant chamber, a first pressure chamber and a second pressure chamber. The pressure chambers as air chambers, hydraulic chambers or combination thereof. The method includes the first pressure inducing means and second pressure inducing means, each having plurality of control valves to control the pressure and flow of sealant. The above described method comprises of a first conveying means, second conveying means and third conveying means, each conveying means may include a single or plurality of conveying lines with cam lock arrangement. The above described method comprises of a wheels means for moving the system and lifting lugs means for transportation. The method further includes providing a control panel for controlling first storage means, second storage means, first conveying means, second conveying means and third conveying means.

The fourth embodiment of the invention shall disclose a method of injecting lubricant into an injection site. The method comprises the steps of, conveying a lubricant contained in an external source into a first storage means through a first conveying means by inducing pressure in the first storage means with a first pressure inducing means disposed there within; conveying the lubricant further from the first storage means into a second storage means through a second conveying means by inducing pressure in the second storage means with a pressure inducing means disposed there within, or inducing pressure in the first storage means with the pressure inducing means disposed there within or both; and conveying the lubricant from the second storage means outwardly out of the second storage means through a third conveying means by inducing pressure in the second storage means with the second pressure inducing means disposed therein within. The method includes first pressure inducing means and second pressure inducing means. The first pressure inducing as described above may be actuated by pneumatic pressure, hydraulic pressure or combination thereof. The second pressure inducing as described above may be actuated by hydraulic pressure with pneumatic actuation. The pressure inducing means disposed within the first storage means as described in the above method, the first storage means comprises of a moveable piston which divides the storage means into a lubricant chamber and a pressure chamber. The pressure chamber as air chamber or hydraulic chamber. The pressure inducing means disposed within the second storage means as described in the above method, the second storage means comprises of a movable piston which divides the second storage means into a lubricant chamber, a first pressure chamber and a second pressure chamber. The pressure chambers as air chambers, hydraulic chambers or combination thereof. The method includes the first pressure inducing means and second pressure inducing means, each having plurality of control valves to control the pressure and flow of lubricant . The above described method comprises of a first conveying means, second conveying means and third conveying means, each conveying means may include a single or plurality of conveying lines with cam lock arrangement. The above described method comprises of a wheels means for moving the system and lifting lugs means for transportation. The method further includes providing a control panel for controlling first storage means, second storage means, first conveying means, second conveying means and third conveying means.

The invention is illustrated in the accompanying drawings, throughout which, like reference numerals indicate corresponding parts in various figures.

Referring to Figure-1 the first storage means 1 piston 2 can be brought to bottom dead centre for filling sealant or lubricant into the chamber 3 after ensuring all the valves in outlet line/second conveying means 4 and the vent and lubrication line 5 and 6" camlock 6 is closed and by letting pneumatic pressure through air inlet port 7 of sealant or lubricant chamber 3 and venting air inside the air chamber 8 through the air outlet port 9 of first storage means air chamber 8. By venting the air inside the sealant or lubricant chamber 3 through sealant or lubricant chamber vent port 5 and by opening 6" camlock 6, sealant or lubricant can be filled inside the chamber 3. A pointer 10 attached to the piston rod 11 which, slides over calibrated scale 12 indicates the position of the piston 2 inside the first storage means 1, thus indicating volume of the sealant or lubricant chamber 3. The piston rod 11 is sealed and guided by two split type brass bushes 13 &14, one 13 is screwed inside the air chamber 8 and the other 14 with groove for 'O' 15 ring is screwed outside the first storage means air chamber 8. The brass bush 14 which is screwed outside the pneumatic chamber 8 enables the replacement of worn out sealing rings 15.

Referring to Figure-2 the second storage means 16 piston 17 can be brought to the bottom dead centre for filling sealant into second storage means sealant or lubricant chamber 18 by letting pressurised hydraulic fluid into upper part of the hydraulic chamber 19 through the upper port 20 and bleeding hydraulic pressure from lower part of the hydraulic chamber 21 through the lower port 22. The sealant or lubricant inside the chamber 18 can be pressurised and discharged to third conveying means / second storage means discharge line 23 by letting pressurised hydraulic fluid into the lower part of the hydraulic chamber 21 through lower port 22 and bleeding upper part of hydraulic chamber 19 through upper port 20.

OPERATIONAL DETAILS:

Sealant or lubricant can be injected into the high pressure valve through the following procedures.

Referring to Figure-3 to 6, sealant or lubricant can be filled into the sealant chamber of first storage means by the following procedures:- Pneumatic source line-up:-

Connect external pneumatic power source to quick joint (Figure-3 to 5 No.24)

■ Drain the moisture in the moisture trap (Figure-3 to 5 No. 25) to atmosphere by opening the drain valve (Figure-3 to 5 No. 26).

■ Keep the panel (Figure-6, No.27) mounted three way selector valve knob for first storage means (Figure-3&6 No.28) in vertical position.

■ Open panel (Figure-6, No.27) mounted air supply isolation ball valve (Figure-3&6 No.29), pneumatic pressure can be supplied to the injection system which can be read from the panel mounted pressure gauge (Figure-3&6 No.30).

■ Pull and rotate the panel mounted pressure regulator (Figure-3&6 No.31) in clockwise direction for few turns to obtain the required pressure for first storage means. Regulated pressure can be read from the panel mounted pressure gauge (Figure-3&6 No.32).

First storage means Suction stroke:-

■ Ensure that the second storage means 1/2" inlet isolation ball valves (Figure-3&4 No.33&34) and 1/2" outlet isolation ball valve (Figure-3 to 5 No.35) are in closed condition and second storage means sealant or lubricant chamber (Figure-3 No. 18) is depressurised by checking the panel mounted pressure gauge (Figure-3&6 No.36)

■ Ensure that 1/2" ball valve (Figure-3&4 No.37), 1/4" ball valve (Figure-3&4 No.38) in first storage means sealant or lubricant chamber vent line and lubricant injection line (Figure-3 No.5), 6" camlock (Figure-3 to 5 No.6), male (Figure-3 to 5 No.39) and female (Figure-3 to 5 No.40) camlock in first storage means outlet line/second conveying means (Figure-3 to 5 No.4) are in closed position.

■ Turn the panel mounted three way selector valve(Figure-3&6 No.28) knob for first storage means towards left, pneumatic pressure is supplied to a pressure regulator (Figure-3&5 No.41), the regulated pressure, which is of about lkg/cm2, sufficient enough to bring down the piston (Figure-3 No.2), is fed to a pressure switch (Figure- 3&5 No.42), from the pressure switch (Figure-3&5 No.42) regulated air is fed to limit switch (Figure-3 to 5 No.43). From limit switch through a check valve (Figure-3&5 No.44) regulated pneumatic pressures is fed to first storage means sealant or lubricant chamber (Figure-3 No.3). The pressure inside the first storage means sealant chamber (Figure-3 No.3) can be read from the panel mounted pressure gauge (Figure-3&6 No.45).

■ Open the panel mounted ball valve (Figure-3&6 No.46) and vent the pressure inside the first storage means to bring down the first storage means piston (Figure-3 No.2) to the desired position by observing the pointer (Figure-4 No.10) over the calibrated scale (Figure-4 No.12). Limit switch (Figure-3 to 5 No.43) fixed at the bottom of the first storage means cut off the air to sealant chamber (Figure-3 No.3) when the piston (Figure-3 No.2) approaches the bottom dead centre, thus effecting cushioning to the first storage means piston (Figure-3 No.2) when it approaches the bottom dead centre.

Sealant filling into first storage means:-

■ Select panel mounted three way selector valve knob for first storage means (Figure- 3&6 No.28) to vertical position

■ Vent the pressure inside the first storage means sealant chamber (Figure-3 No.3) by opening the ball valve (Figure-3&4 No.37) on first storage means sealant or lubricant chamber vent line (Figure-3 No.5).

■ Ensure that the first storage means sealant or lubricant chamber (Figure-3 No.3) is depressurised from the panel mounted pressure gauge (Figure-3&6 No.45).
" Open 3/4" female (Figure-3 to 5 No.40) camlock and 6" female camlock (Figure-3 to 5 No.6) and remove the first storage means discharge pipe spool (Figure-3 to 5 No.4).

■ Fill sealant or lubricant into the first storage means chamber 3 through 6" camlock opening (Figure-3 to 5 No.6).

Referring to Figure-7 to 10, after filling required sealant or lubricant into the chamber 3 of first storage means, the sealant or lubricant can be pressurised and fed to the second storage means by the following procedures

First storage means discharge stroke:-

■ Close the panel mounted ball valve (Figure-7&10 No.46).

■ Turn the panel mounted three way selector valve(Figure-7&10 No.28) knob for first storage means toward right. First storage means piston (Figure-7 No.2) starts moving up and brings the sealant to the top of the 6" camlock opening (Figure-7 to 9 No.6).

■ Bring back the panel mounted three way selector valve(Figure-78il0 No.28) knob for first storage means to vertical position. Online lubricator (Figure-7 to 9 No.47) connected to the pneumatic input line lubricates the moving parts inside the first storage means.

■ Latch 6" female camlock (Figure-7 to 9 No.6).

■ Once again slowly turn the three way selector valve (Figure-7&10 No.28) toward right, sealant or lubricant start coming out of the 3/4" male camlock (Figure-7 to 9 No.39). Bring back the three way selector valve (Figure-7&10 No.28) to vertical position.
■ Latch 3/4 male (Figure-7 to 9 No.39) and female (Figure-7 to 9 No.40) camlock.

■ Close 1/4" vent valve (Figure-7&8 No.37) on the vent line.

■ Turn the panel mounted three way selector valve knob for first storage means (Figure-7&10 No.28) toward right. First storage means pneumatic chamber (Figure-7 No.8) get pressurised by pneumatic pressure, correspondingly first storage means sealant chamber (Figure-7 No.3) get pressurised.

■ To get the maximum output pressure of sealant or lubricant from first storage means pull and rotate panel mounted pressure regulator (Figure-7&10 No.31) in clockwise direction. The regulated pressure can be read from panel mounted pressure gauge (Figure-7&10 No.32). The output pressure can be read from panel mounted first storage means output pressure gauge (Figure-7&10 No.45). Check valve (Figure-7&9 No.44) connected to the air input to sealant or lubricant chamber prevents the backflow of sealant into the pneumatic component during discharge stroke.

Safety interlock:- To prevent air entry into the first storage means sealant chamber (Figure-7 No.3) during first storage means discharge stroke a safety interlock is provided.

A signal line from first storage means pneumatic chamber (Figure-7 No.8) is fed to the pressure switch (Figure-7&9 No.42) through a pressure regulator (Figure-7&9 No.48). Once the first storage means pneumatic chamber (Figure-7 No.8) is pressurised, the pressure switch (Figure-7&9 No.42) actuates and cut off air inlet to first storage means sealant or lubricant chamber (Figure-7 No.3). When the operator by mistake turns the panel mounted three way selector valve (Figure-7&10 No.28) towards left that is towards sealant or lubricant chamber (Figure- 7 No.3) the pressure switch (Figure-7&9 No.42), which is in actuated condition, cut off air inlet to sealant or lubricant chamber (Figure-7 No.3) and divert air through a bypass valve (Figure-7&10 No.49) to a pneumatic horn (Figure-7&9 No.50) thus alerting the operator. By turning the panel mounted bypass valve (Figure-7&10 No.49) for pneumatic horn towards left, air to the pneumatic horn (Figure-7&9 No.50) can be diverted to vent or silenced. Once the pneumatic chamber (Figure-7 No.8) is depressurised, the pressure switch (Figure-7&9 No.42) resets and allows the air to pass through it for first storage means suction stroke. This safety interlock prevents air entry into the first storage means sealant chamber (Figure- 7 No.3) during first storage means discharge stroke, thus preventing the formation of explosive mixture inside the sealant or lubricant chamber(Figure 7 No:3) of the first storage means
Lubricant Injection - Lubricant can be fed to second storage means through a flexible hose (Figure-7 No.51) by latching 3/4" male camlock (Figure-7 No.39) with 3/4" female camlock (Figure-7 to 9 No.52) through an isolation ball valve (Figure-7 to 9 No.34) and a check valve (Figure-7&8 No.53). The check valve (Figure-7&8 No.53) prevents the back flow of sealant or lubricant from second storage means chamber (Figure-7 No.18) to the First storage means (Figure-7 No.3) during second storage means (Figure-7 to 9 No.16) discharge stroke. During injection the isolation ball valve (Figure-7 to 9 No.34) can be kept open during second storage means (Figure-7 to 9 No.16) suction and discharge stroke.

Referring Figure-11 to 14 the pressurised sealant from first storage means can be fed to the second storage means by making second storage means suction stroke. This can be achieved through following stages

First pressure inducing means for hydraulic pump:- External pneumatic power source through quick joint (Figure-11 to 13 No.24), moisture trap (Figure-11 to 13 No.25) and panel mounted 1/2" isolation ball valve (Figure-11 & 14 No.29) is fed to a pressure regulator (Figure- 11 & 13 No.54) and the regulated pressure of about 1.5 kg/cm2 which can be read from the pressure gauge (Figure-11 & 13 No.55) is fed to the pressure switch high (Figure-11 to 13 No.56) of Second storage means (Figure-11 to 13 No.16). The hydraulic pump discharge pressure can be read from the panel mounted pressure gauge (Figure-11 & 14 No.58) and the status of the pressure switch can be read from panel mounted status switch (Figure-11 & 14 No.59).

Air driven hydraulic pump:- The air driven hydraulic pump (Figure-11 to 13 No.57), which circulates hydraulic oil through second storage means, can be operated by a panel mounted pressure regulator (Figure-11 & 14 No.60) or can be operated by a panel mounted pressure regulator (Figure-11 & 14 No.62) and a needle valve (Figure-11 & 14 No.63) and through a panel mounted manually operated spring return pilot valve (Figure-11 & 14 No. 61). The signal pressure for the manually operated spring return pilot valve (Figure-11 & 14 No. 61) is from pressure switch high (Figure-11 to 13 No.56). An online lubricator (Figure-11 to 13 No.64) provided at the upstream of air driven hydraulic pump (Figure-11 to 13 No.57) provides lubrication to the moving parts inside the hydraulic pump.

Hydraulic oil reservoir:- Clean hydraulic fluid to hydraulic pump {Figure-11 to 13 No.57) is obtained from the hydraulic oil reservoir (Figure-11 to 13 No.65) with the following components. A baffle plate (Figure-11 No.66) which extends lengthways through the centre of the tank; it is about 2/3rd the height of the oil level and is used to separate the pump inlet from the return line so that the same fluid cannot re circulate continuously, but must take a circuitous route through the tank. To safeguard the reservoir from over pressure due to sudden oil surge at the time of hydraulic pressure bleed off, one breather filler (Figure-11 No.67) is provided. Breather (Figure-11 No.67) can be easily removed for hydraulic oil topping up. Below the breather filler a strainer (Figure-11 No.68) is provided for removing the solid particle from the toping up hydraulic oil. The level of the hydraulic oil inside the tank can be monitored from the level gauge (Figure-11 No.69). To monitor the condition of the hydraulic oil a sight glass (Figure-11 No.70) is provided. To monitor the pressure of the reservoir a low range pressure gauge (Figure-11 No.71) is mounted over the cover plate of the reservoir. The hydraulic oil reservoir is dished towards the drain line with a 1/2" isolation valve (Figure-ll&13 No.72) to drain the separated and accumulated water and debris from the hydraulic oil reservoir. A 1/2" isolation (Figure-ll&13 No.73) valve is provided at the hydraulic oil outlet from hydraulic oil reservoir (Figure-11 to 13 No.65) to air driven hydraulic pump (Figure-11 to 13 No.57). By opening 1/2" isolation valve (Figure-ll&13 No.73), hydraulic oil from reservoir (Figure-11 to 13 No. 65) is fed to the hydraulic pump.

The discharge pressure of the hydraulic pump through a check valve (Figure-11 No.74) is fed to a nitrogen filled bladder type accumulator (Figure-ll&12 No.75), pump discharge pressure safety valve (Figure-11 to 13 No.76), panel mounted hydraulic pump loading and dump needle valve (Figure-ll&14 No.77), panel mounted hydraulic pump outlet three way selector valve (Figure-ll&14 No.78), pressure switch (Figure-11 to 13 No.56) and panel mounted pressure gauge (Figure-ll&14 No.58).

Nitrogen has to be charged in the bladder type accumulator (Figure-ll&12 No.75) up to 2/3rd of the operating hydraulic pressure.

Before lining up the hydraulic pump (Figure-11 to 13 No.57) discharge to second storage means (Figure-11 to 13 No.16), hydraulic pump pressure safety valve (Figure-11 to 13 No.76), second pressure inducing means pressure safety valve (Figure-11 to 13 No.79) and Second storage means pressure switch high (Figure-11 to 13 No.56) have to be calibrated.

Hydraulic pump pressure safety valve (Figure-11 to 14 No.76) setting.

■ Put panel mounted hydraulic pump outlet three way selector valve knob (Figure- 11&14 No.78) in vertical position, and close panel mounted hydraulic pump loading and dump needle valve (Figure-ll&14 No.77).

■ Tighten the pressure switch knob to full extent to obtain maximum pressure (Figure- 11 to 13 No.56).

■ Operate the hydraulic pump (Figure-11 to 13 No.57) by closing and opening panel mounted pressure regulator (Figure-ll&14 No.62), needle valve (Figure-ll&14 No.63) respectively and pulling manually operated spring return pilot valve (Figure- 11&14 No.61).

■ Set the pressure by turning pressure safety valve knob (Figure-11 to 13 No.76) towards clockwise or anticlockwise using align key for increasing and decreasing respectively. The set pressure can be read from panel mounted hydraulic pump discharge pressure gauge (Figure-ll&14 No.58).

■ The pressure can be bleed off through a check valve (Figure-11 No.80) and a filter (Figure-ll&12 No.81) to the hydraulic oil reservoir (Figure-11 to 13 No.65) by opening panel mounted hydraulic pump loading and dump needle valve (Figure- 11&14 No.77). Check valve (Figure-11 No.80) absorbs the pressure shock wave due to sudden surge of hydraulic oil to the hydraulic oil reservoir (Figure-11 to 13 No.65). Return line filter (Figure-ll&12 No.81) filters the fine particle from the circulating hydraulic oil.

Second pressure inducing means pressure safety valve (Figure-11 to 13 No.79) setting.

■ Select panel mounted hydraulic pump outlet three way selector valve knob (Figure- 11&14 No.78) towards right, that is, in circulation mode.

■ Put panel mounted second storage means hydraulic oil inlet three way selector valve (Figure-ll&14 No.82) knob in vertical position and close panel mounted hydraulic pump loading and dump needle valve (Figure-ll&14 No.77).

■ Operate the hydraulic pump (Figure-11 to 13 No.57) by closing and opening panel mounted pressure regulator (Figure-ll&14 No.62), needle valve (Figure-ll&14 No.63) respectively and pulling manually operated spring return pilot valve (Figure- 11&14 No.61).

■ Set the pressure by turning second pressure inducing means pressure safety valve (Figure-11 to 13 No.79) knob towards clockwise or anticlockwise using align key for increasing and decreasing respectively. The set pressure can be read from panel mounted hydraulic pump discharge pressure gauge (Figure-ll&14 No.58).

■ The pressure can be bleed off to the hydraulic oil reservoir (Figure-11 to 13 No.65) by opening panel mounted hydraulic pump loading and dump needle valve (Figure- 11&14 No.77).

Second storage means pressure switch high (Figure-11 to 13 No.56) setting.

■ Put pneumatic horn (Figure-ll&13 No.50) in bypass mode by turning panel mounted bypass valve knob (Figure-ll&14 No.49) towards left.

■ Select panel mounted hydraulic pump outlet three way selector valve knob (Figure- 11&14 No.78) towards right, that is, in circulation mode.

■ Put panel mounted second storage means hydraulic oil inlet three way selector valve knob (Figure-ll&14 No.82) in vertical position and close panel mounted hydraulic pump loading and dump needle valve (Figure-ll&14 No.77).

■ Loosen the pressure switch knob to obtain minimum pressure (Figure-11 to 13 No.56).

■ Operate the hydraulic pump (Figure-11 to 13 No.57) by closing panel mounted pressure regulator (Figure-ll&14 No.60) and pulling manually operated spring return pilot valve (Figure-ll&14 No.61).

■ On pressure switch high (Figure-11 to 13 No.56) actuation, hydraulic pump (Figure- 11 to 13 No.57) stops and panel mounted status switch (Figure-ll&14 No.59) status changes to red.

■ Set the pressure by turning the pressure switch high (Figure-11 to 13 No.56) knob towards clockwise or anticlockwise for increasing and decreasing respectively. The set pressure can be read from panel mounted hydraulic pump discharge pressure gauge (Figure-ll&14 No.58).

* The pressure can be bleed off to the hydraulic oil reservoir (Figure-11 to 13 No.65) by opening panel mounted hydraulic pump loading and dump needle valve (Figure- 11&14 No.77).

After setting hydraulic pump pressure safety valve (Figure-11 to 13 No.76), second pressure inducing means pressure safety valve (Figure-11 to 13 No.79) and Second storage means pressure switch high (Figure-11 to 13 No.56) pressure, pressurised sealant from first storage means sealant chamber (Figure-11 No.3) can be filled into second storage means sealant chamber (Figure-11 No.18) by bringing down the second storage means piston (Figure-11 No.17) to bottom dead centre by pressurised circulating hydraulic fluid through second storage means suction stroke

Second storage means suction stroke:-

■ Put pneumatic horn (Figure-ll&13 No.50) in service mode by selecting the panel mounted bypass valve knob (Figure-ll&14 No.49) towards right.

■ Ensure that the panel mounted hydraulic pump outlet three way selector valve knob (Figure-ll&14 No.78) is selected towards right, that is, in circulation mode.

■ Turn both panel mounted three way selector valve for second storage means hydraulic oil inlet (Figure-ll&14 No.82) and outlet (Figure-ll&14 No.83) towards left.

■ Ensure that the second storage means outlet isolation ball valve (Figure-11 to 13 No.35) and panel mounted hydraulic pump loading and dump needle valves (Figure- 11&14 No.77) are closed.

■ Operate hydraulic pump (Figure-11 to 13 No.57) for few stroke by closing panel mounted pressure regulator (Figure-ll&14 No.60) and pulling manually operated
spring return pilot valve (Figure-ll&14 No.61).

■ Ensue that the first storage means sealant chamber (Figure-11 No.3) is pressurised and second storage means sealant chamber (Figure-11 No.18) is depressurised from panel mounted pressure gauges (Figure-ll&14 No.45&36).

■ Open second storage means inlet isolation ball valve (Figure-11 to 13 No.33).

■ Operate the hydraulic pump (Figure-11 to 14 No.57) by closing panel mounted pressure regulator (Figure-ll&14 No.60) and pulling manually operated spring return pilot valve (Figure-11 & 14 No.61) knob on air inlet to hydraulic pump.

The hydraulic pump (Figure-11 to 13 No.57) gets hydraulic fluid from hydraulic oil reservoir (Figure-11 to 13 No.65) through isolation valve (Figure-ll&13 No.73) which is kept open and pumps hydraulic oil through check valve (Figure-11 No.74), hydraulic pump outlet three way selector valve (Figure-ll&14 No.78), second storage means inlet three way selector valve (Figure-ll&14 No.82) and upper part of the second storage means hydraulic chamber (Figure-11 No. 19) pushing the second storage means piston (Figure-11 No. 17) towards bottom dead centre. The return fluid from lower part of the hydraulic chamber (Figure-11 No.21) flows through by pass line of hydraulic oil flow meter (Figure-11 No.84) through check valve (Figure-11 No.85), second storage means outlet three way selector valve (Figure-ll&14 No.83), return line check valve (Figure-11 No.80) and return line filter (Figure-ll&13 No.81) to hydraulic oil reservoir (Figure-11 to 13 No.65). Direction of check valve (Figure-11 No.86) on the flow meter line prevents the flow of hydraulic oil through flow meter (Figure-11 No.84) during second storage means suction stroke.

The direction of check valve (Figure-11 No.87) on the second storage means outlet line / third conveying means (Figure-11 No.23) prevents the back flow of sealant from the outlet line in to the second storage means sealant chamber during second storage means suction stroke.

Flow of sealant or lubricant from first storage means sealant or lubricant chamber (Figure- 11 No.3) to second storage means sealant or lubricant chamber (Figure-11 No.18) can be confirmed by the upward movement of pointer (Figure-12 No.10) attached to the piston-rod (Figure-11 to 13 No.11) of first storage means over the calibrated scale (Figure-12 No.12).

■ At the end of the suction stroke pressure builds up at the upper part of the second storage means hydraulic chamber (Figure-11 No.19), the hydraulic pump (Figure-11 & 13 No.57) stops.

■ Push manually operated spring return pilot valve (Figure-11 & 14 No.61) knob on air inlet to hydraulic pump and bleed hydraulic pressure by opening panel mounted hydraulic pump loading and dump needle valve (Figure-ll&14 No.77).

Referring figure 15 to 18, sealant from second storage means can be injected to high pressure leaking valve by making second storage means discharge stroke. This can be achieved through following stages.

Before making second storage means discharge stroke second storage means safety valve (Figure- 15tol7 No.88) pressure has to be set.

Second storage means safety valve (Figure-15 to 17 No.88) setting:-

■ Select all the three panel mounted three way selector valves knobs for hydraulic pump outlet (Figure-15&18 No.77), second storage means inlet (Figure-15&18 No.82) and outlet (Figure-15&18 No.83) toward right.

■ Close panel mounted hydraulic pump loading and dump needle valves (Figure-15&18 No.77)

■ Ensure that the second storage means inlet isolation ball valves (Figure-15 to 17 No.33&34) are closed.

■ Ensure second storage means output isolation ball valve (Figure-15 to 17 No.89) is closed.

■ Open second storage means sealant chamber outlet isolation ball valve (Figure-15 to 17 No.35).

■ Check second storage means output pressure from panel mounted pressure gauge (Figure-15&18 No.90), if there is any pressure, bleed off pressure by opening second storage means bleed off needle valve (Figure-15 to 17 No.91) and close it after pressure bleed off.

■ Tighten the pressure switch knob (Figure-15 to 17 No.56) to obtain maximum pressure

■ Operate the hydraulic pump (Figure-15 to 17 No.57) by closing panel mounted pressure regulator (Figure-15&18 No.62), opening needle valve (Figure-15 & 18 No.63) and pulling manually operated spring return pilot valve(Figure-15 & 18 No.61), thus increasing second storage means sealant or lubricant chamber pressure (Figure-15&18 No.36) and second storage means output pressure (Figure-15&18 No.90). Check for second storage means pressure safety valve (Figure-15 to 17 No.88) actuation. On pressure safety valve actuation, second storage means sealant or lubricant chamber (Figure-15 No.18) pressure (Figure-15&18 No.36) and the second storage means outlet line/third conveying means (Figure-15 No.23) pressure (Figure-15&18 No.90) remains at the actuated pressure as the check valve (Figure-15 No.87) prevents the back flow of sealant or lubricant from outlet line/third conveying means (Figure-15 No.23) into second storage means sealant or lubricant chamber (Figure-15 No.18).

■ Stop hydraulic pump (Figure-15 No.57) by pushing manually operated spring return pilot valve (Figure-15 & 18 No.61).

■ Bleed off second storage means outlet pressure (Figure-15&18 No.90) into first storage means (Figure-15 No.1) by opening second storage means bleed off needle valve (Figure-15 to 17 No.91) and by opening the panel mounted hydraulic pump loading and dumping valve (Figure-15&18 No.77). Check valve (Figure-15&16 No.92) provided at the downstream of second storage means pressure safety valve (Figure- 15 to 17 No.88) absorbs the pressure shock wave due to sudden release of high pressure sealant from second storage means (Figure-15 No.16) to low pressure first storage means (Figure-15 No.1).

■ Open the hexagonal nut of the second storage means outlet safety valve (Figure-15 to 17 No.88). Loosen or tighten the spring tension bolt for decreasing or increasing the set pressure respectively.
After setting second storage means pressure safety valve (Figure-15 to 17 No.88) once again set the second storage means pressure switch (Figure-15 to 16 No.56).

Second storage means discharge stroke:-

■ Ensure that the second storage means inlet (Figure-15 to 17 No.33&34) and outlet (Figure-15 to 17 No.35&89) valves are closed and equalisation needle valve (Figure- 15 to 17 No.91) is closed.

■ Put pneumatic horn (Figure-15 No.50) in service mode.

■ Select all the three panel mounted three way selector valves knobs for hydraulic pump outlet (Figure-15&18 No.78), second storage means inlet (Figure-15&18 No.82) and outlet (Figure-15&18 No.83) toward right.

■ Pull panel mounted manually operated spring return pilot valve knob (Figure-15&18 No.61) to start hydraulic pump (Figure-15 No.57).

■ Obtain the desired output pressure for sealant or lubricant injection by pulling and rotating panel mounted pressure regulator knob (Figure-15&18 No.60) at air inlet to the hydraulic pump (Figure-15 No.57) in clockwise direction.

■ Connect sealant filling hose (Figure-15 to 17 No.93) between sealant outlet quick joint (Figure-15 to 17 No.94) and three way selector valve for hose selection (Figure- 15 to 17 No.95). Connect three way selector valve for hose selection (Figure-15 to 17 No.95) to three way selector valve for nipple adapter (Figure-15 to 17 No.96). Connect three way selector valve for nipple adapter (Figure-15 to 17 No.96) to nipple adapter (Figure-15 to 17 No.97). Connect nipple adapter (Figure-15 to 17 No.97) to injection nipple (Figure-15 to 17 No.98).

■ Select three way selector valve for hose (Figure-15 to 17 No.95) toward sealant hose (Figure-15 to 17 No.93) and select three way selector valve for sealant nipple and venting (Figure-15 to 17 No.96) towards three way selector valve for hose (Figure-15 to 17 No.95).

■ Open second storage means outlet valves (Figure-15 to 17 No.35&89). Second storage means sealant or lubricant chamber pressure (Figure-15&18 No.36&90) drops due to flow of sealant or lubricant from high pressure sealant or lubricant chamber (Figure-15 No.18) to the leaking valve (Figure-15 to 17 No.99) through injection hose (Figure-15 to 17 No.93), three way selector valves (Figure-15 to 17 No.95&96), injection nipple adapter (Figure-15 to 17 No.97) and injection nipple (Figure-15 to 17 No.98).

Once the chamber pressure (Figure-15&18 No.36&90) drops correspondingly second pressure inducing means pressure (Figure-15&18 No.58) drops. Since panel mounted manually operated spring return pilot valve knob (Figure-15&18 No. 61) is kept in pulled position hydraulic pump (Figure-15&16 No.57) starts to maintain the second pressure inducing means pressure (Figure-15&18 No.58). The hydraulic pump (Figure-15&16 No.57) gets hydraulic fluid from hydraulic oil reservoir (Figure-15&16 No.65) through isolation valve (Figure-15 No.73) and pumps hydraulic oil through check valve (Figure-15 No.74) hydraulic pump output three way selector valve (Figure-15&18 No.78), second storage means inlet three way selector valve (Figure-15&18 No.82), flow meter line check valve (Figure-15 No.86), flow meter (Figure-15 No.84) to lower part of the second storage means hydraulic chamber (Figure-15 No.21). The hydraulic fluid at the lower part of second storage means hydraulic chamber (Figure-15 No.21) displaces second storage means piston (Figure-15 No.17) to move upward, making discharge stroke. The hydraulic fluid from upper part of second storage means hydraulic chamber (Figure-15 No.19) flow through second storage means outlet three way selector valve (Figure-15&18 No.83), check valve (Figure-15 No.80) and filter (Figure-15&16 No.81) to hydraulic oil reservoir (Figure-15&16 No.65) thus completing a closed second pressure inducing means.

■ Once the sealant or lubricant at the second storage means sealant or lubricant chamber (Figure-15 No.18) is consumed second storage means sealant or lubricant chamber pressure decreases (Figure-15&18 No.36) and the hydraulic pressure remains constant and the pump stops. Repeat the second storage means suction stroke and fill sealant or lubricant into the second storage means sealant or lubricant chamber (Figure-15 No.18) and then repeat above procedure for injection of sealant or lubricant into the injection site.

■ Once the leakage stops from the leaking valve (Figure-15 to 17 No.99), stop hydraulic pump (Figure-15 to 17 No.57) by pushing panel mounted manually operated spring return pilot valve knob (Figure-15&18 No 61).

■ Once the sealant or lubricant inside the first storage means sealant chamber (Figure- 15 No.3) is consumed, first storage means sealant chamber pressure decreases (Figure-15&18 No.45) but the first storage means pneumatic chamber pressure (Figure-18 No.32) remains the same. Fill sealant or lubricant into the first storage means (Figure-15 No.1) by sealant or lubricant filling procedures and pressurise the sealant chamber (Figure-15 No.3) by first storage means discharge stroke.

Referring figure 19 to 22 hydraulic oil needs to be injected into the valve for two main purposes. One is for de-freezing the jammed valve and other is for injection nipple flushing immediately after sealant or lubricant injection. For de-freezing the valve and for removing scaling and old lubricant or sealant inside the valve hydraulic oil flushing is required before lubricating a valve. When the valve is jammed, hydraulic oil is pumped inside the valve and kept for few hours till the valve internals are fully soaked with hydraulic oil. The hydraulic oil inside the valve is flushed with fresh oil till the valve is free to rotate. Now lubricant can be injected into the valve for trouble free operation. The quantity of hydraulic oil used in this operation is more; hence hydraulic oil can be filled into the first storage means and then pumped to second storage means through male and female camlock (Figure-19&20 No.39&52) flexible hose (Figure-19&20 No.51) isolation ball valve (Figure-19&20 No.34) and check valve (Figure-19&20 No.53). From second storage means hydraulic oil can be pumped to the valve.

Injection nipple is an integral part of the valve and is thread connected. This injection nipple has an inbuilt check valve which is of either ball type or plate type. During sealant or lubricant injection the spring inside the nipple may get clogged with sealant or lubricant and reducing the performance of the spring, due to this the spring may not reset the plate or ball over its seat resulting in back flow of sealant or gas from the valve. To overcome this, after injection, nipple has to be flushed with hydraulic oil and the spring will reseat the plate or ball inside the injection nipple.

Injection nipple flushing using hydraulic oil:-

■ Ensure sealant or lubricant filling is completed inside the leaking valve (Figure-19 to 21 No.99).

■ Ensure hydraulic oil outlet needle valve (Figure-19&21 No.100) is closed.
" Connect hydraulic oil filling hose (Figure-19 to 21 No.101) with hydraulic oil outlet quick joint (Figure-19 to 21 No.102) and three way selector for hose selection (Figure-19 to 21 No.95).

■ Select three way selector valve for sealant nipple adapter (Figure-19 to 21 No.96) toward vent line (Figure-19 to 21 No. 103) if sealant comes from the vent line put back the three way selector valve for sealant nipple adapter (Figure-19 to 21 No.96) towards three way selector valve for hose (Figure-19 to 21 No.95).

■ Select panel mounted hydraulic pump outlet three way selector valve knob (Figure- 19&22 No.78) towards left, that is, hydraulic oil injection mode.

■ Obtain second pressure inducing means pressure (Figure-19&22 No.58) of about 5 to 10 kg/cm2 above the valve operating pressure by closing panel mounted pressure regulator (Figure-19&22 No.62) opening needle valve (Figure-19&22 No.63) and pulling manually operated spring return pilot valve (Figure-19&22 No.61).

■ Open hydraulic oil outlet needle valve (Figure-19&21 No.100).

■ Select three way selector for hose (Figure-19 to 21 No.95) toward hydraulic oil injection hose (Figure-19 to 21 No.101).

■ Select three way selector valve for nipple adapter (Figure-19 to 21 No.96) towards three way selector valve for hose (Figure-19 to 21 No.95).

■ After few stroke of hydraulic pump, select three way selector valve for nipple adapter (Figure-19 to 21 No.96) toward vent line (Figure-19 to 21 No.103) if sealant or lubricant comes from the vent line put back the three way selector valve (Figure- 19 to 21 No.96) towards three way selector valve for hose (Figure-19 to 21 No.95).

■ Repeat above procedures till the check valve inside the injection nipple (Figure-19 to 21 No.98) resets. The check valve (Figure-19 & 21 No.104) provided at the upstream of hydraulic oil flushing line isolation needle valve (Figure-19 to 21 No.100) prevents the entry of gas or sealant into the hydraulic oil circulation system.

■ Monitor the hydraulic oil level (Figure-19 No.69) and pressure (Figure-19&20 No.71) inside the hydraulic oil reservoir. If the level drops top up hydraulic oil by opening breather filler (Figure-19 No.67).

ADDITIONAL FEATURES:

End-position cushioning for first storage means

Referring figure-1, 7&9 Cushioning or end position cushioning refers to breaking and
deceleration of the final stroke portion until stand still occurs. Cushioning becomes
essential above a certain stroke speed. End position cushioning must be applied where piston speed exceeds 0.1m/sec. During first storage means discharge stroke the speed of the piston (Figure-7 No.2) is very less as the piston moves against sealant pressure (Figure-7 No.45). During suction stroke the piston (Figure-7 No.2) moves against atmospheric pressure and the velocity of the piston (Figure-7 No.2) is high. If cushioning is not provided, then the kinetic energy released at the end will cause damage to the guide bush (Figure-1 No.13) resulting in early failure of the system. To regulate the speed of the piston (Figure- 1&7 No.2), air supply to first storage means during suction stroke is through a pressure regulator (Figure-7&9 No.41) and a pneumatic limit switch (Figure-7&9 No.43) fixed at the bottom of the first storage means, well above the end position of the first storage means piston rod (Figure-7&9 No.11). Regulated minimum air supply to the piston ensures smooth movement of the piston (Figure-7 No.2). When the piston (Figure-7 No.2) approaches the bottom dead centre during suction stroke, piston rod (Figure-7&9 No.11) actuates the pneumatic limit switch lever (Figure-7&9 No.43) and cut off the air supply to the pneumatic cylinder sealant chamber (Figure-7 No.3) and the piston (Figure-7 No.2) decelerate and stop smoothly at the bottom dead centre.

Prevention of Sealant Entry into the Pneumatic Line

Referring figure-7:- A check valve 44 provided in the air input line 7 to the sealant chamber 3 of the first storage means 1 prevents sealant entry into pneumatic line 7 during first storage means discharge stroke.

Safety interlock

Referring figure-7&9:- To prevent air entry into the first storage means sealant chamber (Figure-7 No.3) during first storage means discharge stroke a safety interlock is provided. A signal line from first storage means pneumatic chamber (Figure-7 No.8) is fed to the pressure switch (Figure-7&9 No.42) through a pressure regulator (Figure-7&9 No.48). Once the first storage means pneumatic chamber (Figure-7 No.8) is pressurised, the pressure switch (Figure-7&9 No.42) actuates and cut off air supply to first storage means sealant chamber (Figure-7 No.3). When the operator by mistake turns the panel mounted three way selector valve knob for first storage means (Figure-7&10 No.28) towards left that is towards sealant chamber (Figure-7 No.3) the pressure switch (Figure-7&9 No.42), which is in actuated condition, cut off air inlet to sealant chamber (Figure-7 No.3) and divert air through a bypass valve (Figure-7 No.49) to a pneumatic horn (Figure-7&9 No.50) thus alerting the operator. By turning the panel mounted bypass valve (Figure-7&10 No.49) for pneumatic horn towards left, air to the pneumatic horn (Figure-7&9 No.50) can be vented or silenced. Once the pneumatic chamber (Figure-7 No.8) is depressurised, the pressure switch (Figure-7&9 No.42) resets and allows the air to pass through it for first storage means suction stroke. This safety interlock prevents air entry into the first storage means sealant or lubricant chamber (Figure-7 No.3) during first storage means discharge stroke, thus preventing the formation of explosive mixture inside the first storage means sealant chamber (Figure-7 No.3).

First storage means Output Volume Measurement

Referring figure-1,4&11:- To measure the volume of sealant chamber (Figure-1 No.3) and swept volume of the first storage means (Figure-1&4 No.1) a pointer (Figure-1&4 No.10) is attached to the protruding first storage means piston rod (Figure-1&4 No.11). The pointer (Figure-1&4 No.10) indicates the volume of the sealant or lubricant chamber (Figure-1 No.3) of the first storage means by pointing the reading on a calibrated scale (Figure-1&4 No.12) in volume measurement fixed at the support structure. By measuring the displacement of the pointer (Figure-1&4 No.10) over the calibrated scale (Figure-1&4 No.12), the swept volume of the first storage means (Figure-1&4 No.1) can be measured. This swept volume is fed to the second storage means sealant chamber (Figure-11 No.18) during second storage means suction stroke.

Second storage means Output Volume Measurement

Referring figure-ll&15:- A valve needs replacement when the clearance between the moving parts increase beyond the permissible limits. By knowing the precise volume of injected sealant into a valve, the condition of the valve can be assessed. Since sealant is a semisolid compound and injected volumes are very minute, it is not possible to measure the injected sealant by using a flow measurement device on the sealant line. Hence an indirect method of flow measurement has been adopted.

The direction of check valve (Figure-11 No.85) on the flow meter (Figure-11 No.84) bypass line is such that it allows the hydraulic fluid to flow through it only during suction stroke of second storage means and prevent the hydraulic oil to pass through it during discharge stroke of second storage means.

The direction of check valve (Figure-15 No.86) on the flow meter (Figure-15 No.84) line is such that it allows the hydraulic fluid to flow through it for flow measurement only during discharge stroke of second storage means and prevent the hydraulic oil to pass through it during suction stroke of second storage means.

By the combination of these check valves (Figure-ll&15 No.85&86) Flow meter (Figure- 11&15 No.84) measures the volume of hydraulic fluid passing through it only during second storage means discharge stroke, thus measuring only injected sealant or lubricant from the second storage means. Since the flow to be measured is hydraulic fluid, turbine type flow meter can be used. The second storage means develops a pressure ratio of 1:5; the volume of hydraulic fluid being pumped through the second storage means during discharge stroke is 5 times than the volume of sealant injected. By measuring the volume of hydraulic fluid through flow meter (Figure-15 No.84) during discharge stroke of the second storage means, even small quantity of sealant or lubricant injected can be precisely measured.

Control Panel

Referring to figure-22:- An economically designed, user friendly control panel 27 of the injection system with schematic circuit diagram etched over it makes it easy to operate even by unskilled worker. All the necessary valves, inlet air supply isolation ball valve 29, first storage means venting and isolation ball valve 46, three way selector valves for first storage means 28, pump outlet 78, second storage means inlet 82 and outlet 83, bypass selector valve for pneumatic horn 49, pressure regulator for first storage means 1 and for air supply to hydraulic pump, manually operated spring return pilot valve 61, air inlet to hydraulic pump isolation needle valve 63 and hydraulic pressure loading and dumping needle valve 77, status switch 59 and pressure gauges for inlet air pressure 30, first storage means input pressure 32, first storage means output pressure 45, hydraulic pump discharge pressure 58, second storage means sealant chamber pressure 36 and second storage means output pressure 90 are mounted for necessary operation and monitoring.

The control panel is inclined at 30° to vertical (Figure-23 No.27) for easy viewing and operation.

All the pressure gauges tubing which sense the pressure of sealant or lubricant, that is, first storage means sealant or lubricant chamber (Figure-22 No.45), second storage means sealant or lubricant chamber (Figure-22 No.36) and second storage means output (Figure- 22 No.90) are filled with hydraulic oil for better communication of pressure and the tubing ends are sealed with grease to prevent the loss of hydraulic oil from the tubing.

Mounting Wheels

Referring figure-23:- Two swivel wheels at the front end 105 and two fixed wheel at the rear end 106 are provided for short distance movement of the injection system. Each wheel 105 &106 are fitted with two nos. tapered roller bearings 107 to withstand misalignment and impact load during transportation of the injection system . A grease cup 108 is provided at the front wheels to hold grease. Tow bar for Steering

Referring figure-23 the front wheel axis 109 which is made up of stainless steel is attached to a tow bar 110 which can be used for short distance manoeuvring. The tow bar can be latched at the front side by a locking pin 111. Lifting Lugs

Referring figure-23 Long distance transportation of the injection system is easily facilitated with the help of 4 nos. lifting lugs 112 mounted on the top of the module which is inclined with 30° angles for better load transfer to the lifting equipment.

Lubrication for thrust bearing

Lubrication for thrust bearing (Figure-23 No. 113) is provided from first storage means (Figure-4 No.1) through a dedicated line (Figure-23 No. 114) with isolation valve (Figure-4 No.38). Whenever the first storage means (Figure-4 No.1) is pressurised with lubricant, the %" isolation valve (Figure-4 No.38) is opened to lubricate the thrust bearing (Figure-23 No. 113).

Tool Box

Referring to figure-24 the rear wheel axis 115 which is made up of stainless steel rod is fixed to the structure. A tool box 116 with a hinged door 117 is provided at the rear end of the injection system where necessary tools and fittings can be kept.

Impact resistance

Referring to Figure-25 which shows the schematic view of structural support with impact resistance rubber padding for first storage means base 118, and top support 119, limit switch support 120, second storage means base horizontal 121 and base vertical 122 and top horizontal 123, control panel 124, pneumatic horn 125, hydraulic pressure switch and pressure safety valves 126, hydraulic pump 127, hydraulic oil reservoir 128, accumulator 129, tool box 130 and outlet manifold 131. The oil resistance rubber padding absorbs the shock due to impact during transportation from one platform to another platform or rig or during shifting within platform or rig. All the components can be removed easily from the injection system . Control panel is mounted over a detachable structure so that all the components attached to the control panel can be easily removed and serviced.

Weather proof covering

The injection system" is covered on four sides that is front, rear, top and pneumatic power input side.

Referring to Figure-26, the top of the control panel is covered by a 3mm stainless steel plate 132 with hinge joint 133 &134. The hinge joint 134 is positioned such that the cover plate 132 can be rotated to an angle of 270° and can be kept behind the control panel. The cover plate can be removed by sliding out the welded hinge 133 attached to the cover plate 132 from the bore of the hinge 134 welded to the injection system . The top side of first storage means, second storage means, tool box and outlet manifold are covered by a twofold cover plates 135, 136&137 with hinge joint 138. The cover plates 135, 136&137 are made up of fiber reinforced plastic which is kept in place by the guide plate 139 and can be easily removed from the guide plate 139 by folding and sliding it out.

Referring to Figure-27, control panel front side is covered by a 3mm stainless steel plate 140 with hinge joint 141&142. The hinge joint 142 is positioned such that the control panel front cover plate 140 can be rotated to an angle of 270 and can be latched at the pneumatic power input side. The control panel front cover plate 140 can be removed by sliding out the hinge joint 141 which is welded to the cover plate 140 from the bore of the hinge 142 welded to the injection system . During shipment the control panel front cover plate 140 is kept in position by the overlapping plate of the control panel top cover plate 132. Hydraulic components front side is covered by a 3mm stainless steel cover plate 143 which is of sliding type. This plate 143 is kept in place by the vertical 144, horizontal 145 guide plates and by the overlapping control panel front cover plate 140. First storage means and second storage means front sides are covered by cover plate 146&147 which are of sliding type and made up of fiber reinforced plastic and the cover plates 146&147 are kept in place by lower 145 and upper horizontal 148 guide plates.

Referring to Figure-28, control panel, hydraulic components, first storage means and second storage means rear sides are covered by two sliding type cover plates 149&150 which are made up of fibre reinforced plastic and the cover plates 149&150 are kept in place by lower 151 and upper 152 horizontal guide plates.

Referring to Figure-29, pneumatic power input side is covered by a 3mm stainless steel cover plate 153 which is of sliding type. This 153 plate is kept in place by the lower 154 and upper 155 horizontal guide plates, pneumatic input quick joint 24 and tow bar locking pin 111. During operation the control panel front door 140 can be rotated towards first storage means input side and can be latched using tow bar 110 and locking pin 111. The two fold top cover plates 135&136 of first storage means and second storage means can be folded using the hinge joint 138 for easy access to first storage means and second storage means from the top side.

Referring to Figure-30, tool box 116 side is not covered by cover plate for easy access to second storage means sealant or lubricant chamber outlet isolation valve 35, second storage means outlet isolation valve 89, second storage means outlet quick joint 94, hydraulic oil outlet isolation needle valve100, hydraulic oil outlet quick joint 102, second storage means bleed off needle valve 91 and tool box 116.

Referring to Figure-31 which shows the schematic top view of the injection system during operation, the control panel top side is covered by control panel top cover plate 132 and the first storage means and second storage means top cover plates 135 and 136 are folded for easy access to first storage means and second storage means valves and cam lock.

Referring to Figure-32 which shows the schematic front view of the injection system during operation, the control panel front side is kept open, the hydraulic components front side is covered by its cover plate 143, first storage means and second storage means doors 146 are folded for easy access to first storage means and second storage means valves.

Referring to Figure-33 which shows the schematic rear view of the injection system during operation, the rear cover plate for second storage means 149 can be slid behind first storage means cover plate 150 and the first storage means and second storage means top cover plates 135 and 136 are folded. In between the gap of folded top cover plates 135 and 136 tools can be kept during operation. injection system for onshore application.

Referring to Figure-34 to 36 which show the schematic top, front and rear view of the injection system respectively for onshore application. Unlike offshore where there is a space limitation, at onshore there is no space constraints hence the first storage means 1 and second storage means 16 are placed in parallel to each other which gives better stability during short distance manoeuvring. The control panel 27, hydraulic pump 57, hydraulic oil reservoir 65 and other components are spread out for stability. The tool box 116 is kept at the extreme end.

The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

WE CLAIM:

1. An injection system for injecting a sealant into an injection site, characterized in comprising a plurality of sealant pressurizing chambers interconnected in series with plurality of conveying means such that it comprises of :-

a. a first storage means having an enclosed volume, an input port for receiving sealant, an output port and a first pressure inducing means disposed there within,

b. a first conveying means terminating at an external source containing sealant at its one end and terminating at the input port of the first storage means at its other end, thereby conveying the sealant from source to first storage means, corresponding to the pressure induced by first pressure inducing means,

c. a second storage means having an enclosed volume, an input port for receiving sealant, an output port and a second pressure inducing means disposed there within,

d. a second conveying means terminating at the output port of first storage means at its one end and terminating at the input port of the second storage means at its other end, thereby conveying the sealant from first storage means to second storage means, corresponding to the pressure induced by first pressure inducing means, pressure corresponding to second pressure inducing means or both, and

e. a third conveying means extending from the output port of second storage means to deliver the sealant from the second storage means to the injection site, corresponding to the pressure induced by second pressure inducing means.

2. The injection system as claimed in claim 1, wherein the first pressurizing means is preferably pneumatic.

3. The injection system as claimed in claim 1, wherein the first pressurizing means may be pneumatic, hydraulic or combination thereof.

4. The injection system as claimed in claim 1, wherein second pressurizing means is pneumatic actuated hydraulic pressure inducing means.

5. The injection system as claimed in claim 1, wherein the second pressurizing means may be pneumatic, hydraulic or combination thereof.

18. The injection system as claimed in claim 1, wherein the said sealant may be a lubricant.

19. A method of injecting a sealant into an injection site, characterized in pressurizing the sealant in plurality of sealant pressurizing chambers formed in plurality of storage means and interconnecting the plurality of sealant pressurizing chambers in series such that, the method comprises of steps:-

a. conveying a sealant contained in an external source into a first storage means through a first conveying means by inducing pressure in the first storage means with a first pressure inducing means disposed there within;

b. conveying the sealant further from the first storage means into a second storage means through a second conveying means by inducing pressure in the second storage means with a pressure inducing means disposed there within, or inducing pressure in the first storage means with the pressure inducing means disposed there within or both; and

c. conveying the sealant from the second storage means outwardly out of the second storage means through a third conveying means by inducing pressure in the second storage means with the second pressure inducing means disposed therein within.

20. The method as claimed in claim 19, wherein pressure inducing includes inducing pneumatic pressure in the first pressure inducing means.

21. The method as claimed in claim 19, wherein pressure inducing includes inducing pneumatic, hydraulic or combination pressure in the first pressure inducing means.

22. The method as claimed in claim 19, wherein pressure inducing includes inducing hydraulic pressure with pneumatic actuation in the second pressure inducing means.

23. The method as claimed in claim 19, wherein pressure inducing includes inducing pneumatic, hydraulic or combination pressure in the second pressure inducing means.

24. The method as claimed in claim 19, wherein pressure inducing includes dividing the first storage means into a sealant chamber and a pressure chamber with a movable piston of the pressure inducing means disposed there within.

25. The method as claimed in claim 19, wherein the pressure inducing includes dividing the second storage means into a sealant chamber, a first pressure chamber and a
second pressure chamber with a movable piston of the pressure inducing means disposed there within.

26. The method as claimed in claim 24, further includes providing the pressure chamber as air chamber or hydraulic chamber.

27. The method as claimed in claim 25, further includes providing the pressure chambers as air chambers, hydraulic chambers or combination thereof.

28. The method as claimed in claim 19, wherein the conveying includes the conveying of the sealant through the first conveying means, second conveying means and third conveying means, such that each conveying means may be a plurality of conveying lines with cam lock arrangement.

29. The method as claimed in claim 19, wherein the conveying includes the conveying of the sealant through the first conveying means, second conveying means and third conveying means, such that each conveying means may be a single conveying line with cam lock arrangement.

30. The method as claimed in claim 19, wherein it includes providing the first pressure inducing means with plurality of control valves to control the pressure and flow of sealant.

31. The method as claimed in claim 19, wherein it includes providing the second pressure inducing means with plurality of control valves to control the pressure and flow of sealant.

32. The method as claimed in claim 19, wherein it includes providing wheels means for moving the system and lifting lugs means for transportation.

33. The method as claimed in claim 16, wherein the said sealant may be a lubricant.

34. The method as claimed in claim 19 further includes providing a control panel for controlling first storage means, second storage means, first conveying means, second conveying means and third conveying means using plurality pressure regulators, plurality of valves, plurality of switches, plurality of pressure gauges, plurality of schematic circuits along with displaying and monitoring means.