FORM-2
THE PATENTS ACT, 1970
(39 OF 1970)
AND
THE PATENTS RULES, 2003
(As Amended)
COMPLETE SPECIFICATION
(See section 10; rule 13)
“Method and Apparatus for Lining Pipes with Environmentally Compatible
Impervious Membrane”
Inspar Robotic Technologies, Inc., a corporation organized and existing under the laws of
USA, of 499 South Tamiami Trail, Nokomis, Florida 34275 USA.
The following specification particularly describes the nature of this invention and the manner
in which it is to be performed:
TITLE
METHOD AND APPARATUS FOR LINING PIPES WITH ENVIRONMENTALLY
COMPATIBLE IMPERVIOUS MEMBRANE
BACKGROUND OF INVENTION
1. Field of the Invention
[0001] With general infrastructure within the US and around the world in a
precarious state of decay it has been the object of many to provide for a cost
effective method to perform in situ-rehabilitation of these properties. In the industrial
sector, pipe and transmission lines carrying volatile and dangerous or hazardous
materials are constantly at risk of failure due to age, neglect or lack of funds to
replace or repair with traditional methods. In the global municipal arena, waste
collection and water distribution systems are seriously compromised with failures
creating community disturbances, commercial loss and environmental incidents. The
US EPA Clean Water Act of 1989 outlines mandatory restrictions and covenants
imposed on municipalities to improve the conditions of their water and wastewater
systems. The EPA Conference of Mayors report of 2007 surveyed 1500 US Cities'
infrastructure needs resulting in $15B in needed repairs and upgrades. The RSCA
has also increased scrutiny on chemical processing facilities, petrochemical facilities
and pipeline transmission calling for proactive inspection and repair of millions of
miles of pipe, conduit and passageway.
[0002] The conventional lining materials and methods have undesirable
environmental impacts, e.g., leaching of styrene's, CFC's, VOC's and endocrine
disruptors into the effluent. Effects of endocrine disruptors are believed to include
growth defects and may result from relatively minor exposure to chemicals.
[0003] An additional undesirable impact results from the annulus created
between the interior pipe wall and the liner. This annulus not only propagates
infiltration but also exfiltration - the toxic effluents going back into the surrounding
ground, ground water, lakes, streams and aquifers. The conventional resins are
thermosetting resin. These resins shrink causing an annulus to form between the
pipe wall and the liner. This annulus permits infiltration of ground water into the
pipeline flow as well as pipeline effluent into the soil and ground water.
[0004] Generally the only reason that customers have their pipes rehabilitated
is due to erosion, corrosion, cracks and leaking joints. In a method that leaves an
- 2-
annular space, the method only allows for the exfiltation In the future. The way this
happens is that in the initial installation, the annular space between the method and
the manhole or vault is sealed with mortar or some other material. At that time (after
repair) it will pass a hydrostatic test but as age, corrosion, erosion and the constant
pressure continue from infiltration at the manhole will work on the seal, causing the.
seal to begin to leak. The infiltration then gets into the effluent that is flowing through
the manhole. Likewise the material flowing through the manhole can get into the
annular space finding cracks and open joints therefore exfiltrating to the surrounding
soils and water table around the pipe.
[0005] Footprint as defined in this disclosure would be that the other
rehabilitation methods are required to have their vehicles and equipment right at the
manhole/pipe access to facilitate their repair process. Due to access often times
being in yards, medians, fields, woods, creeks, etc., the vehicles tear up soils, grass,
remove trees, etc. Most often these methods have to excavate the manhole or vault
to facilitate inserting their liners. Often times in creek or drainage culverts the
contractors have to put their equipment directly in the water thereby leaking oils,
fuels, etc. into the water. Also in these applications, the thermosetting resin leaches
into the rivers, creeks, lakes, ponds, killing fish and organisms etc., due to inflation of
the "bag" or "sock" with hot water or steam. Additionally with cured In place,
(hereinafter "CIPP") and use of high density polyethylene (hereinafter "HOPE") used
in slip lining, the pipe capacity is downsized so much that the rehabilitated
(narrowed) pipe increases flow velocities. This results in creek scour that causes
loss of stream banks, plant life and animal life. Addtionally in these applications with
the water infiltrating into the annular space through joints and cracks, the infiltrating
water beings surrounding soils with it. In time this results in a large voids around the
pipe and causing the formation of sink holes (economic as well as environmental) in
roads and yards caused by soils getting into the pipe.
[0006] The method of the present invention does not create an impact of
leaching CFC's, VOC's, or endocrine disrupters being emitted into air, water and
effluent and the method does not cause a footprint due to the use of an umbilical
allowing equipment to be as much as 400 feet or more from the access point of the
pipe. The umbilical can traverse unlimited times around buildings, trees, etc via the
use of roller quadrants. Contractors using the apparatus or method of the invention
- 3-
do not have to dig up or disrupt access paths as the umbilical is only 2" in diameter
and can be inserted into any access.
[0007] The present invention generally relates to apparatus and methods for
applying a liner to the interior surfaces of pipes, conduits and passageways. The
disclosure also more specifically speaks about the ability to remotely apply a
consistent and continuous lining in a pipe. The liner is inert after application and
does not contain and/or leach volatile organic compounds (VaC's) or
chlorofluorocarbons "CFC" or hydro fluorocarbons "HCFC's" or endocrine disruptors.
2. Description of Related Art
[0008] Prior art demonstrates numerous methods to rehabilitate pipelines,
conduits and passageways from the inside in order to restore asset integrity.
[0009] In situ repair methods incorporating a resin impregnated fiber lining
tube are described by Wood et ai, US Patent number 5409561 and Kliest, US Patent
6427726. In these cured-in-place (CIPP) methods, conventional resins include
polyester, vinyl ester and even epoxy resin form a matrix with a tubular textile
material, positioned within the deteriorated pipe section, are forced into intimate
contact with the pipe interior surface and allowed to cure. The cure time may be
hours or days. There are many instances and conditions where the above methods
are either not practical or are unsuitable.
[0010] Davis Patent number US 6986813 describes utilizing a polymer
product that is sprayed onto the interior pipe walls to form a seamed monolithic liner.
A seamed monolithic liner is created by the inability of the lining method or apparatus
to continuously line a section of pipe. As a result there are stop points in the lining
and replacement lining overlaps the previously applied liner, thereby causing a
seam. This patent attempts to overcome many problems identified in prior art.
Typical, prior art spray in type liners experience major problems as evidenced in the
plugging of spray tips, slow curing coatings resulting in surface sags and inconsistent
material application thickness and other constraints resulting in finished liner
thicknesses in the 0.200 - 0.400 inch range, rendering them unsuitable for many
applications.
[0011] Davis attempts to overcome the first constraint of spray tip plugging by
incorporating a blow off mechanism attached to the tip of the spray gun in an effort to
eliminate plugging during operation. Additionally, Davis purports to employ a fast
- 4-
setting material to eliminate sags. The combination of these two assumed
improvements actually result in a compounded problem. The Davis patent teaches
continuous blowing of air through the time of the spray gun as a method to prevent
clogging. Unfortunately adding air flow to the product stream only increases the
atomization of the spray resulting in higher static attraction to moving parts. Purging
the spray tip with compressed air does not eliminate the plugging problem. A
splatter shield is also mentioned to deflect errant spray material from occluding the
spray orifice. In practical operation, the root cause of the repeated clogging of the
spray tip is more a function of design.
[0012] In Davis, a spinning flat or slightly obliquely angled disc is used to
propel the projected fast setting lining material onto the pipe walls. This flat or
slightly obliquely angled spinning disc design as it relates to the direct right angle
diffusion of the spray causes a significant amount of rebounding/ricochet lining
material to accumulate on the splatter shield and air blow off mechanism, ultimately
resulting in total blockage of the tip and other crucial mechanical functions within a
short period of time. This does not allow for continuous operation or lining of more
than 10-20 feet of pipe without the need to retract the apparatus and clean.
[0013] The spinning disc design of Davis fails to satisfy the requirement for a
uniform lining thickness as well. As described, the resultant physics do not afford
equal dissipation of lining material in the full 360 degrees of circumference. As the
fast setting material is projected at the spinning disc at a generally perpendicular
angle, the high speed of the spinning disc induces a disproportionate amount of
material to the first 90 degree arc that is quickly thrown to the pipe walls. The
current apparatus due to its flat or slightly oblique design does not afford the coating
material any dwell time to equalize mass and distribute the coating material around
the circumference of the disc prior to being ejected. This ultimately results in thicker
coating or lining in the first 180 degrees of circumferential arc of the pipe wall. This
presents an unacceptable condition when uniformity is necessary to calculate
ultimate liner properties and performance which is required by end users.
Static build up:
[0014] There is no consideration in prior art for the disruption caused by static
build up.
- 5-
Static build up is caused by the high rpm's of the shaft and disc as they relate to
close proximity to pipe wall and the inherent need due to lining cure. Forced air is
not a cure for static build up. Static build up is controlled through high pressure and
high heat impingement of the lining components only. The forced dry air is to keep
the pipe surface as dryas possible and to keep product mist from coating camera
lenses as well as to force dry air to assure a dry working environment for the
apparatus.
[0015] Static build up in prior art is compounded by the fact that the apparatus
uses a "spray" pattern to send material from the tip to the spinner disc. This spray
naturally causes atomization of the lining material which results in more static charge
and also makes it easier for the static attraction of the shaft and disc to "pull" the
material as it passes by these parts.
[0016] This static attraction between coating materials and the shaft/disc
result in material stalactites and stalagmites depending on their positional
relationship to these devices.
[0017] These formations will in time severely impede if not halt the apparatus'
ability to continually line the pipe.
[0018] The build up of these formations will divert the flow from the tip to the
spinner disc resulting in additional disproportionate distribution of coating material to
the pipe wall.
[0019] Formations continue to grow as the lining process proceeds.
[0020] Formations eventually break off due to their increased weight and
centrifugal force being applied.
[0021] Formations that get imbedded in the uncured liner causing profiles in
the flow channel that will result in diminished flow capacity of the liner due to
increased coefficient of friction. Also the imbedded pieces causes "snag" areas in
mixed effluent pipelines such as sewage which results in solids - toilet paper etc getting
caught on them and building up sometimes to block pipeline flow.
[0022] Formations that are imbedded in the in the first few oscillation strokes
of the apparatus end up diverting or blocking the coating material from ever reaching
the pipe wall due to the straight projection off the spinner disc. This creates through
voids in the finished liner.
-6-
[0023] This situation results in the need to remove the prior art apparatus from
the pipe and clean many times to actually complete a full liner application hence
diminishing the claims of a faster method in prior art.
Spinner Disc Build Up:
[0024] Current art has an inherent design that has no way of stopping the
build up of coating material on the spinner disc.
[0025] In prior art the spinner disc is subject to a "spray" formation from the
tip.
[0026] Utilizing a spray pattern creates a "dry fall" effect at the point the
coating hits the spinner disc. This does not allow the disc to totally disperse the
lining material as the material does not have the weight and mass needed to
completely propei off the disc effectively. It does not have the wet out capabilities of
a tightly uniform stream of lining material as taught by the instant disclosure.
[0027] In prior art, spray is immediately propelled from tip at a set pressure
which in turn slows the rpm of the spinner disc due to direct force applied by the
sprayed coating material velocity. The initial required rpm is then never fully
achieved. The spinner motor from this point on is trying to regain the initial rpm with
failure.
[0028] A standard pneumatic motor is used in the prior art. The pneumatic
motor produces high rpm's and low torque. Air motors have been found to be a
necessity as electric motors with high rpm/high torque are too large for the apparatus
in small diameter pipe. Hydraulic units work but the need to supply hydraulic
pressure at 500 feet requires bulking up the umbilical with hoses, adding costly
pumps and additional weight and diameter to the umbilical.
[0029] The above mentioned "dry fall" effect starts to gradually slow the rpm of
the spinner disc due to the weight of the resulting build up. As the rpm slows due to
low torque, the effect becomes greater and greater having a "snowball" effect on the
apparatus, completely stopping the spinner disc and ultimately rendering the
apparatus incapacitated in as little as 10 minutes.
[0030] This results in lining material still being projected from the tip without
being dispersed by the disc. The material then drips to the bottom of the pipe
resulting in piles of lining only on the bottom of the pipe.
[0031] This results in the need to constantiy remove the apparatus from the
pipe and clean the shaft and disc which can take hours then reinserting to once
- 7-
again line for a short amount of time. This is a constant procedure with prior art.
This consistent required retraction and insertion can result in inter-coat de-lamination
of the liner due to possible contamination of the already installed liner while the
retraction process and cleaning process is being completed.
[0032] In prior art it is stated that the apparatus can line for hours and from
. intervals of 300-600 feet. This, however, is not possible in a single insertion and
retraction cycle. This adds considerable time to the process evacuating any
advantage in time or economics over other lining methods as stated in prior art.
Trajectory geometry:
[0033] Prior art utilizes a flat or maximum oblique angle in its spinner disc.
This design results in a straight stream of dissipation off the spinner disc.
[0034] Prior art uses relatively slow oscillation of the spinner disc rod with long
smooth linear strokes to overlap material to prevent sags and runs. This remains a
tight straight dissipation stream off the disc throughout the oscillation cycle.
[0035] The apparatus only coats in one direction in the pipe to complete the
coating.
[0036] All pipe has a natural profile whether it be at bell/spigot joints, welds,
tuberculation etc.
[0037] The prior art does not have the ability due to its design, mechanics and
straight or right angle stream to completely line the forward or backward edge of
these profiles as it relates to the position of the apparatus. The forward side of these
profiles do not get coated and therefore there are exposed areas in the existing pipe
wall.
[0038] Prior art also does not have the ability to reverse the rotation on the
spinner disc. There are many times in pipe where there will be a lateral intrusion - a
small pipe sticking into the main pipe - the maximum penetration is usually %". In
this instance there is no way that lining can be placed on the underside of this
intrusion pipe or any profile for that matter without counter rotation. The apparatus of
the instant invention has the ability to counter rotate either through transfer or air
from exhaust to intake and reverse. More typically this is done through electronically
switched bi-directional transmission or transfer case that is in between the shaft and
the air motor collet. The reason for this is that on high rpm air motors they easily
wear out if they are run in both directions. Compounding this problem in the prior art
- 8-
is that the unit does not have the ability to start and stop flow. Flow must be stopped
while the motor is being reversed in rotation.
Multiple starts and stops:
[0039] Prior art design and mechanics do not allow to open and close the
valving rod or spray tip stopper more than one open and close cycle. The prior art
uses a spray tip orifice that is machined so that the valving rod seats inside it. When
this is open, spray comes through the orifice. It is then closed and residual mix
material encapsulates this area and basically locks it into that position. The prior art
mechanics does not have the pull force or the ability to have a momentum surge on
the valving rod to break this free - hence the valving rod cannot be remotely opened
up more than one cycle - open/close - done. The present invention apparatus uses
a different sealing method at the interface of the termination rod (valving rod in prior
art) end and the stream orifice to seal - mixed product encapsulation of the area is
made to be a minimum through this design. The instant invention also has a
different design of the termination rod actuator - it has a much higher pull force
coupled with a function that allows for some "free" pull force momentum to build prior
to actuating the termination rod. This allows the rod to brake free therefore allowing
unlimited open and close cycles.
[0040] Regarding the prior art, in the event that there is a malfunction in
control systems or an impediment of the umbilical retraction which is common, the
apparatus must be disengaged from continuing to spray. If not the result is heavy
rings in the liner. If this event happens the apparatus must be retracted from the
pipe and the impingement block completely disassembled, cleaned, reassembled
and re inserted into pipe. This is a very time consuming process. This design and
mechanical flaw also does not allow the apparatus to complete sleeve or individual
repairs in the pipe unless you do them one at a time due to the necessity to clean
after every valving rod cycle.
Dimensional Restrictions on Insertion and Retraction:
[0041] Equipment of the prior art, due to its overall length, cannot be inserted
or retracted from an underground pipe with the access being a manhole or vault with
a diameter or horizontal dimension or less than 5 feet.
- 9-
[0042] This overail dimension is the direct result of the claims for the
method/mechanics of osciilation to afford slow dissipation and overlapping of the
lining material.
[0043] Additionaily the 23" bend radius and mechanics of the attachment
bracketing of the prior art umbilical is such that it significantly increases the overail
dimension of this apparatus.
[0044] Typicaily in the private sector and in the municipal market sectors ail
underground pipes are only accessible through the above mentioned accesses.
Rarely is there excavation afforded to ailow insertion of apparatus into the pipe. The
prior art apparatus can be disassembled then reassembled as it is being inserted in
the pipe. This is a very time consuming process. This, however, does not afford this
apparatus the ability to coat the entire pipe. The unit must stop lining to be
disassembled on retraction. This stoppage must occur in manholes and vaults with
a diameter of horizontal dimension of less than five feet. This results in as much as
16"-30" of pipe not being coated in a typical manhole or vault. There is currently no
acceptable way afterward to line this section that is void of lining material. Prior art
creates a void or in the pipe lining for the pipe not the manhole. Due to its length
from the osciilation stroke, the umbilical bend radius and equipment design, the prior
art lining equipment has to be stopped in a 4' manhole with 30' of the robot still
inside the pipe. At this point ail lining processes must be stopped. There Is no way
after this in a smail diameter pipe to get in and manually line the pipe section that
was missed.
[0045] Due to the design and mechanics of the prior art, it cannot line vertical
pipe or pipe with a slope of more than 30 degrees.
Diameter:
[0046] Due to the design and mechanics of the prior art, it cannot be utilized in
a pipe with a diameter of less than 10". Prior art states that it can be used in 6" pipe.
The basic dimensions however do not ailow for this as filed in the drawings. This is
evident to a person skiiled in the art after examination of the detailed description of
the equipment in Davis patent US Pat. 6986813 discussed above. Review of the
description and drawings demonstrate it would be impossible to be short enough or
narrow enough to fit into a 6" pipe.
- 10-
[0047J Over and above the fact that the unit's dimensions restrict its ability to
line pipe with diameters less than 10", its function of mechanics also severally
impedes this ability. The unit utilizes oscillation. This results in all oscillating parts to
be on the exterior of the apparatus and in close proximity to the pipe wall. No matter
how long the determined length of that oscillation may be (5"-36") the entire length
and width of the carriage or shuttle plate is moving. Pursuant to prior art drawings
this length is longer that the length of the base assembly when the spray head is
considered. Example: if the oscillation is set for 10", the entire length of the unit is
moving 10" on every stroke exposing the entire length to profile or offsets. The full
width and length of the upper apparatus shuttle plate is in motion. The apparatus as
designed also has many right angle projections that can get caught on joints and or
profiles in pipe wall.
[0048J Additionally due to the apparatus design and mechanics as it relates to
external part oscillation it Is very easy for it to get "hung up" in small diameter pipe.
All pipe systems have profiles, sags and offsets. When the current apparatus
encounters these obstructions it will stop the oscillation process. This may only be
momentary or for extended lengths of time. In either case it causes a build up or
"ringing" in the new coating which is unacceptable. If the stoppage of oscillation
occurs for an extended length of time it can actually close off the pipe entirely with
lining material and/or lock the apparatus in the pipe.
[0049] The external oscillation parts are all on the exterior of the unit. This
exposes them to all the overspray and existing contaminants that are in the pipe
while being coated. This eventually impedes their function resulting in diminished
capabilities or incapacitation.
SUMMARY OF DISCLOSURE
[0050J This disclosure teaches an in situ pipe liner spay apparatus and
method that allows spraying of an isocyanate and amine resin mixture or other
mixtures onto the 3600 circumference of the pipe interior wall. The mixture can line
the pipe walls. The lining components are mixed in correct proportion in the
impingement block of the apparatus within the pipe. The components may be
heated within the apparatus for fast reaction and curing on the pipe walls. This
avoids slumps or other undesirable variations of the lining layer. The device can
- 11 -
apply a lining thickness of between 0.05" and in excess of 4" in a single pass of the
spray assembly.
[0051] The apparatus includes an umbilical comprising at least one air hose,
at least one electrical power cable, at least one video communication cable and
lining component hoses. The housing of the apparatus includes at least one heater
for heating the lining components.
[0052] The disclosure teaches an in situ pipe liner spray apparatus having a
reciprocating capability (forward and reverse) of between 0.001" and 5.00" controlled
by a reciprocating head. This means the dissipation device and rotating shaft
longitudinally moves back and forth relative to the apparatus (hereinafter termed
"forward and reverse"). This allows the apparatus to apply multiple layers of lining to
the pipe. The dissipation device comprises a dissipation device shaped as two
asymmetrical reversely aligned cones with a center top attached to a rotating shaft
(extending from the apparatus rotating head) and with an acute angled flange
oriented to the reciprocating head.
[0053] The reciprocating head of the apparatus includes an impingement
block wherein the impingement block mixes the lining components and projects the
lining at a specific angle of trajectory to the dissipation device.
[0054] The apparatus pressurizes the liquid lining material and allows it to exit
from a impingement block nozzle maintaining a near constant diameter stream prior
to contacting a conical rotating dissipation device (hereinafter "dissipation device").
The surface of the dissipation device forms an acute angle to the lining stream. The
dissipation device may rotate at 20,000 to 45,000 RPM at high torque of
approximately 20 foot pounds.
[0055] The rotational direction of the dissipation device can be remotely
changed from clockwise to counter clockwise. The pressures, velocities and flow
rates of the lining material stream can be remotely adjusted to the apparatus via the
umbilical connection that is directed out of the stream orifice (or spray tip) to the
dissipation device.
[0056] The dissipation device has an inverted conically sloped surface contact
area proximate to the center top for receiving the lining material stream that
decelerates the pressurized stream flow inertia and evens the material dissipation
into the outer flange. The dissipation device is designed to be self cleaning by its
- 12 -
rotation function and pressurized trimming of excess material, thereby eliminating
material build up.
[0057] The dissipation device also allows a dwell time for material to evenly
distribute inside the compounded conical geometry of the diffusion device prior to
being cast onto the pipe wall. This facilitates a symmetrical lining layer on the pipe
surface.
[0058] The apparatus subject of this disclosure also discharges negatively
charged ions over the rotating shaft and dissipation device. This impedes static
charge and the resulting coating material build up.
[0059] Utilization of a shaft scraper appendage eliminates build up due to any
possible static charge or material overspray residuals on the spinner shaft.
[0060] It will be appreciated that the linings may have a cure time of 3
seconds to one minute, thereby allowing the application of multiple layers of lining.
The apparatus subject of the disclosure may line pipes having interior diameters
between 5.5" and 54".
[0061] One must first fully grasp the need for exact and precise
methods/mechanics required to utilize a remote device for dispensing an ultra fast
cure lining material in a pipe and especially in small diameter pipe. Any design flaw,
mechanical flaw, or controls system flaw will cause the system to fail in a matter of
seconds. These failures can be catastrophic. The material being dispersed typically
flash cures or gels in 4-6 seconds. It only takes an instant for the apparatus to
become totally incapacitated or even cause its own self engulfment and to get
permanently lodged in smaller diameter pipe. While prior art suggests that its
methods and mechanics will improve the current technology in spray lining, it does
not. It appears that the prior art was only tested and utilized in a lab environment
and never tested under real world conditions. The prior art was based on evidence
established in short segments of test pipe under ideal conditions. Underground pipe
has no ideal conditions.
SUMMARY OF DRAWINGS
[0062] Figure 1 illustrates the apparatus subject of this disclosure. Illustrated
is the dissipation device, rotating shaft, impingement block, reciprocating head, front
- 13 -
housing and rear housing. Also illustrated are the articulation junctures between the
housings and the reciprocation head.
[0063] Figures 2 & 3 are side views of the apparatus showing the change in
position of the reciprocating head to the front housing.
[0064] Figure 4 is a cross sectional view of the dissipation device showing the
path of the liner on the device and off the outer device flange for lining a pipe wall.
[0065] The accompanying drawings, which are incorporated in and constitute
a part of the specification, illustrate preferred embodiments of the invention. These
drawings, together with the general description of the invention given above and the
detailed description of the preferred embodiments given below, serve to explain the
principles of the invention.
DETAILED DESCRIPTION OF DISCLOSURE
[0065] This disclosure teaches a method and apparatus that allows remote
installation of liners inside pipes for distances exceeding 1,000 linear feet with only
one insertion and one extraction of the apparatus. In one embodiment, the liner is a
reaction product of isocyanate and amine resin mixed in situ at high temperature and
pressure immediately prior to spraying the liner on the pipe wall. In one
embodiment, the temperature may be within the range of 140°F to 170°F with the
ideal temperature of 155°F. The pressure of the liquid components may be between
1700 psi to 3500 psi depending upon the viscosities of the materials and the
necessity for molecular cross linking. The cured liner is inert and free of VOC's,
carbon fluorocarbons and endocrine disrupters. The cured liner is impervious to
influent and effluent. Therefore a liner installed with the apparatus of the invention
and the method disclosed herein will stop effluent from entering the ground and
ground water.
[0066] The disclosure teaches an apparatus that by its design can be remotely
inserted and retracted from all manholes and/or vaults with diameters/horizontal
dimensions of approximately 18" while still achieving the lining of the entire pipe.
[0067] The apparatus of the disclosure teaches an internal forward and
reverse assembly, i.e., reciprocating head, rotating shaft and dissipation device,
allowing it to be fully functional in small diameter pipes with bends, sags, offsets and
joints. The apparatus utilizes articulated junctures separating housing sections and
the reciprocating head.
- 14 -
[0068] Figure 1 iliustrates a prospective view of one embodiment 100 of the
disclosure. Illustrated is the dissipation device 400 mounted on a rotating shaft 110.
The rotating shaft extends into the reciprocating head 105 to an air turbine motor
(not shown). Mounted on the top of the reciprocating head are the impingement
block 111, the connected termination rod 121 and the termination rod actuator 120.
The forward housing 102 extends from the articulating juncture 103 separating the
reciprocating head and the forward housing. Mounted on top of the forward housing
are television cameras. Mounted beneath the housing are wheels 108. Also
mounted to the housing are skids 106. Separating the forward housing and the rear
housing 101 is the articulating juncture 109. Also illustrated is the umbilical 104
containing air hoses, liquid liner components, television cables and electrical wires.
The apparatus is shown on an interior pipe surface 485.
[0069] The apparatus is moved at a continuous predetermined speed through
the pipe. The articulating spaces between the housing segments and reciprocation
head allow the apparatus to traverse around bends in the pipe or over protrusions in
the bottom of the pipe. The direction of rotation of the dissipation device is
reversible. This allows the dissipation to line all sides of a protrusion within the pipe
interior. There are many times when there will be a lateral intrusion, e.g., a small
pipe sticking into the main pipe. The maximum penetration is usually %". In this
instance there is no way that lining can be placed on the underside of the intruding
pipe or any profile with counter rotation. The dissipation device can be counter
rotated either through transfer of air from exhaust to intake and reverse. More
typically this is done through electronically switched bi-directional transmission or
transfer case that is that is between the shaft and the motor collet. (High rpm air
motors easily wear out if they are run in both directions. The impingement block also
has the ability to effectively stop and restart liner flow as required in the rotation
reversing process.
[0070] The apparatus has a compounded effect through the cohesive
mechanical action on the dissipation of the material stream on to the pipe walls.
Through the action of the fast high velocity forward and reverse action and the
instantaneous stop/start action at the end of each reciprocal stroke, the cohesive
mechanical action promotes a "bullWhip" or "wave" geometry of liner material with
high velocity. The resulting dissipation stream assures the lining of all sides of
profiles (protrusions and insets) in the pipe wall and is not contingent on the
- 15 -
apparatus lining in two different directions to achieve full coverage of these profiles.
Additionally, the remote control of the apparatus to reverse the rotational direction of
the dissipation device affords it the ability to apply lining to the underside of profiles
(protrusions and insets). The shape of the dissipation device is designed to be selfcleaning
of the lining material through the operation of rotational forces and the
cutting forces of the pressurized product streams velocity.
[0071] The apparatus maintains the unlimited ability for the supply stream to
be remotely started and stopped or adjusted to facilitate stopping for control
malfunctions, and the installation of joint sleeve only applications and spot repairs in
pipeline with the need to retract and clean the impingement block in-between
every start and stop function. Sleeves are installed in line segments of pipe. They
are typically from 2' to 8' in length. Often the pipe is in suitable shape but there may
simply be small segments that have cracks or offset joints. In this instance the
apparatus would be Inserted In the same manner however it would be precisely
located at these areas to only line these segments In lieu of the whole pipe. With the
ability to stop and start the apparatus unlimited times many of these sleeves can be
installed. Sometimes customers will only want a 3' sleeve installed over joints only
with the joint being in the center of the sleeve. Installation of these seams is
facilitated by use of the video camera at a control station.
[0072] A method and apparatus that can line pipe, conduits, structures and
passageways from horizontal through varying degrees vertical to fully vertical.
Operation in a fully vertical position would require change in the roller quadrants and
guides as they would have to be elevated and centered over the full vertical pipe
application.
[0073] The apparatus subject of this disclosure comprises an umbilical
conveying pressurized air and liquid components of the lining material. The two
insulated high pressure fluid hoses are heated via a 120V loop circuit. Also included
in the umbilical are two twelve wire Kevlar reinforced communication cables. The
umbilical includes one or more high heat resistant Kevlar reinforced fluid (air) hoses.
The umbilical completely encapsulates the hoses and cables in a dive line Kevlar
reinforced semi rigid molded polyurethane sleeve to accommodate strain relief.
Other cables or tubes may be connected to the apparatus through the umbilical.
There may be a tether attached to the apparatus. The umbilical or tether may
extend to the ground surface or to a manhole. The apparatus is remotely controlled
- 16 -
by means of the tether or umbilical. The umbilical has a bend radius of
approximately between 8" and 12" due to the method of umbilical reinforcements for
pulling the robot.
[0074] In one embodiment, the umbilical fluid hoses (containing component
liquid portions of the liner material) are terminated with a split port coupling block
with individual shut off valves. The coupling block can be attached to a receiving
block. Both blocks may be located in the lower portion of the rear housing
(descri bed infra).
[0075] It will be appreciated that the liquid liner components are under high
pressure. In one embodiment, the receiving block is machined to accept coupling
block with a high pressure seal face and is vertically ported to accept fluid flow from
the coupling block. The receiving block is also horizontally ported and threaded at a
right angle to vertical ports to receive common JIC fittings. 90 degree JIC fittings are
mechanically attached to the receiving block to face in reverse of the forward end of
the rear lower housing. In this embodiment preformed radius fluid hoses extend in a
reverse direction to the rear lower housing unit for a determined length. The
preformed fluid hoses have an approximate 2" radius achieving a horizontal
orientation toward the rear lower housing unit. Preformed fluid hoses attach to Yi" ID
rigid high pressure stainless steel flare tubing. The tubing is incorporated into
machined grooves in both lower rear housing and forward lower housing unit. The
tubing is split and then rejoined with flexible fluid hoses at the articulation juncture
between the rear housing unit and the forward housing unit.
[0076] In one embodiment of the apparatus, the apparatus is comprised of
several housing components with articulated junctures between the attached
housing units. The umbilical feeds into the housing unit designated the rear housing.
Side panels of the housing unit can be opened to provide access to equipment,
cables or hoses.
[0077] The housing units may contain one or more heaters for the liquid liner
components. Polyurea, the product of the mixture of isocyanate and amine resin,
needs to mix between 1400 F and 1700 F to acquire the physical properties and full
cure. The fluid in the apparatus lines cools quickly. In prior art applications of pipe
less than 24", there was not sufficient flow through the lines to stop the product from
cooling. Accordingly the qualities of the lining were poor. In the event the unit had to
stop for even a few seconds the product cooled too much to start lining. This was
- 17 -
due to viscosities becoming very rapidly thixtropic - again as it will shoot out poorly
mixed product that is of "goo" consistency and will not flow. The instant application
teaches heating the product continually to the point of entering the impingement
block. This achieves consistent proper mixing and the ability to start and stop
unlimited times as well as simply stop and let the apparatus sit in the pipe for hours
and then start lining again. The temperature also affects the cure time of the
mixture.
[0078] The housing unit may also comprise top mounted electric lamps to
illuminate the pipe for the video cameras. This illumination can be particularly usefui
in large diameter pipes. The next housing unit is designated the forward housing
unit. It may contain an air ionization unit generating negatively charged air. It also
contains a heater for the lining components.
[0079] At least one video camera may be mounted on the top of the forward
housing. The camera may contain built in infrared lighting to supply light for the
camera. Multiplex video/control cables extend through the umbilical and may be
connected to the apparatus via common friction fit electrical connections. Electrical
connectors are attached to the apparatus via common threaded, braided stainless
steel strain relief fittings attached to the rear housing vertical face machined borings.
Once inside the lower rear housing unit, the wires are split. Wires are terminated at
the solenoid for the function of the solenoid unit. Wires traverse through the rear
lower housing unit in the same manner as the air lines and may be terminated in two
250V relays that are mounted in machined recesses in the forward upper housing
unit. These relays work in conjunction with the air solenoid to facilitate in and out
functions of the pneumatic actuator for the reciprocating head. Relays may also be
connected via wires to electromagnetic sensors that are attached to the exterior of
pneumatic actuators. The sensors are fully adjustable along the exterior of the
actuators to adjust the stroke length of the actuator function. The stoke length may
be determined by the user depending upon the application. In the case of
electromagnetic rod actuators, these wires suppiy power and function to a
programmable logic controller (PLC) and actuators.
[0080] The pneumatic or electromagnetic reciprocation actuator can be affixed
in the forward lower housing unit. Actuator rods traverse through the forward lower
housing unit via machined bore in the vertical face of the housing unit and are
attached to rear vertical face of the reciprocation head. The reciprocation head is
- 18 -
attached to the forward lower housing unit via steel alignment rods via threaded
borings in the vertical face of the rear reciprocation head. The alignment rods
extend reversely and longitudinally parallel to reciprocation head and penetrate
orifices of linear bearings set in machined recesses in between upper forward
housing unit and lower forward housing unit. These alignment rods maintain
reciprocation head alignment during the reciprocation function. They are protected
from damage by enclosure within the front housing unit and the reciprocation head.
[0081] Further, a pneumatic or electromagnetic controlled termination rod
actuator is affixed to the top of the reciprocation head. As will be discussed, the rod
actuator controls the termination rod which penetrates the impingement block. The
impingement block mixes the liner components and projects the liner to the
dissipation device extending in front of the reciprocation head.
[0082] In one embodiment, the termination rod actuator's stroke length in the
pneumatic function is a set non-adjustable 3/8". The pneumatic actuator's function is
controlled via electrical signal to the solenoid in the rear lower housing unit as
previously discussed. The electromagnetic actuators function is controlled via the
programable logic controller (PLC).
[0083] The reciprocating head is attached to the front housing at an
articulating juncture. The reciprocating head is moveable in relation to the forward
housing. The reciprocating head can move along the longitudinal axis of the pipe in
a forward or reverse direction in relation to the forward housing. This is sometimes
referred to as an oscillating motion. In one embodiment, the head moves between
0.001 and 5 inches. The movement of the reciprocating head moves the
impingement block and dissipation device in unison. The reciprocating housing
moves on rods extending internally within the housing and reciprocating head. This
is unlike the prior art and protects the steel rod, which provide stability to the
reciprocating head, from damage. The front housing and the reciprocating head are
separated by a variable space. This is sometimes referred to as the common
reciprocation space. A tether may be attached to the front face of the front housing
(preferably beneath the reciprocating head).
[0084] Returning to the pathway of the fluid tubing, rigid tubing is joined again
with flexible high pressure hose at brackets on both sides of the reciprocating head.
Flexible tubing then extends to the impingement block coupling and is joined to the
impingement block. The impingement block coupling is vertically ported and
- 19 -
machined faced to be received by the machined upper face of the impingement
block. It will be appreciated that the design of this embodiment aliows the
reciprocation head to reciprocate at high speed while allowing high pressure fluid
hoses to reciprocate at the point of the mentioned radiuses at the rear housing.
[0085] One embodiment of the air pathway from the umbilical attaches via a
quick disconnect fitting that is extended In reverse from the lower housing through
machined borings in said vertical face of the rear housing unit. An air hose which
extends reversely from rear lower housing unit is affixed to rear housing unit via
stainless steel braided strain relief. Inside the rear housing unit, the air hose is split
via common fitting into to 3/8" ID flexible hoses.
[0086] One flexible hose is attached via common fitting to a 4 way 24VDC
common solenoid valve mounted in the rear housing unit. The other flexible hose
continues through the multiple machined bored orifices, vertical faces of rear and
forward housing units. This flexible hose then terminates at the front housing unit
front face machined boring. At this termination the air flow is re-established through
extendable and retractable pre coiled flexible air hose to facilitate reciprocation at the
common reciprocation space. This pre coiled air hose terminates at the rear of the
reciprocation head and is mounted in a pre bored orifice in the rear of the vertical
face of reciprocation head. The air flow is re-established through the flexible air
hose and is connected to the turbine air motor.
[0087] Figures 2 and 3 illustrate the operation of the pre-coiled flexible air
hose 122 located in the articulated juncture 103A between the forward housing 102
and the reciprocating head 105. It will be appreciated that the reciprocating head
extends forward from the forward housing in Figure 3. Also illustrated is the
dissipating device 400, the rotating shaft 110, the shaft scraper 112, the
impingement block 111, the termination actuator 120 and the termination rod 121.
Also illustrated are the front wheels 108 and the back wheels 107, the rear housing
101, the umbilical 104 and the articulated juncture 109 between the rear housing and
the forward housing. Also shown is the pipe wall 485.
[0088] The second flexible hose at the split in the rear housing unit is attached
to the solenoid for air flow to the solenoid. The solenoid affords the splitting and
control of four separate actuation or flow sequences. One hose from the solenoid
traverses forward through the rear housing unit and is connected to a common fitting
at the vertical face boring in the forward housing unit. Flexible hose is then re-
- 20-
established via a fitting in the articuiation space between the back and front lower
housing units. The flexible hose is then reattached to the back vertical face of the
forward housing unit. The flexible hose is then re-established inside the forward
housing unit and is connected to by common fitling and flow control valve to the
"push" intake port of a pneumatic actuator that affords a reciprocation function. A
second flexible hose form the exhaust port in the solenoid travels with the exact
same path and design as the first hose but connects to the "pull" end of the
pneumatic actuator via a common fitting and flow control valve. In pneumatic
sequencing for reciprocation, the speed of reciprocation is adjustable via the flow
control valves. In electromagnetic sequencing, the reciprocation speed is
determined by adjustment of the programmable logic controller (PLC) via electrical
current. It will be appreciated that an electromagnetic actuator does not need the air
supply and is controlled via electrical current and PLC which replaces the solenoid.
[0089] The third and fourth flexible air lies from the exhaust ports of the
solenoid travel with the same design and path as the air lies to the pneumatic
actuator but traverse through the front lower housing unit in the same fashion as the
turbine motor air supply as stated earlier. These two air lines then connect via
common fitting to the "push" and the "pull" ports of the pneumatic termination rod
actuator which is located and mounted on the top of the reciprocation head.
[0090] It should be noted that the pneumatic termination rod actuator is often
replaced with an electromagnetic rod actuator for certain applications and is
controlled with an electronic PLC in lieu of a solenoid. With both the reciprocation
and termination rod functions, it is a quick retrofit to interchange these methods.
[0091] A termination rod actuator and termination rod are mounted on top of
the reciprocating head. The termination rod is extendible into an impingement block.
The action of the termination rod is simply one forward one reverse stroke of the rod
that opens and closes the stream orifice. The two heated components of the liner
material come together and are mixed in an adjustable impingement module inserted
into the impingement block. The module is attached to the isocyanate and amine
resin product feeds. In one embodiment, the isocyanate enters at the rear of the
module and the amine resin enters at the front of the module. The module may be
adjustable by creating up to six orifices that line up with the feed orifices of the
impingement block. A variation in size of the drilled orifices adjusts the amount of
flow based on volume and is in direct relationship to the viscosity of the isocyanate
- 21 -
and amine resin. The module is slid over the termination rod. The module fits into
the front of the impingement block. A male fitting of the module fits through the
impingement block. The stream tip is pushed onto the male component of the
module. A stream tip cap is then threaded on the impingement block, thereby
locking the module in place. Air is supplied to the stream tip cap via a small boring in
the front of the impingement block. The air is supplied to this boring via a channel
that is cast in the impingement block and in which has an opening orifice on the
bottom of the block. A small air line is connected to this orifice to supply air to the
channel and ultimately to the spray stream cap. There may be a second threaded
connector on the back side of the impingement block at the orifice. This connector
comprises a threaded sealing nut with a vicon seal that compresses against the
termination rod.
[0092] The termination rod penetrates through the front and back of the
conical shaped module mounted within the impingement block. When the
termination rod is fully extended forward, the end of the rod is seated on the back
side of the stream tip to seal the liner flow. When the termination rod is retracted,
the rod end passes through the drilled module orifice allowing product to flow into the
module orifice and mix at high pressure. The product then streams from the stream
tip to the dissipation device.
[0093] The two components of the liner material come together and are mixed
in the impingement block. The components are isocyanate and amine resin.
[0094] The termination rod actuators are attached to machined termination
rods via machine threads. Termination rods traverse forward from the actuator
connection in a slight downward and adjustable angle. The termination rod
penetrates impingement block in the center preferably with a compression fitting with
a kalrez seal and orifice that is attached via a threaded boring in the impingement
block. The termination rod then traverses through a polymer module until it reaches
a termination point at the back recessed side of a machined stream tip. The stream
tips may be machined with variable sized orifices from 0.015" to 0.090" depending
upon the flow needed for the particular lining application. The instant invention also
has a different design of the termination rod actuator - it has a much higher pull
force coupled with a function that allows for some "free" pull force momentum to
build prior to actuating the termination rod. This allows the rod to brake free
therefore allowing unlimited open and close cycles.
- 22-
[0095] The polymer module has a 0.125 longitudinally ported orifice to receive
the termination rod. The termination rod is self sealing due to light compression to
the module surface. The module is drilled with orifices at right angle to the
longitudinal orifice in the module. These orifices range from 0.010" to 0.080
depending on the flow needed. The orifices serve as supply ports for the lining
components. A minimum of two and a maximum of six orifices are drilled into the
module at right angles. These orifices facilitate the flow of both components of the
lining material from a spray tip. It will be appreciated that the lining components are
separated completely and maintained in separate storage containers until they
impinge at high pressure and heat inside the mixing module as described above.
Upon mixing in these conditions (heat and pressure), there is a snap cure of
between approximately 3 seconds to 1 minute depending upon the product and
application criteria. In one embodiment utilizing the reaction product of isocyanate
and amine resin, the product cures in approximately 5 seconds.
[0096] The components enter the impingement block separately and enter into
the chambers via machined orifices. The chambers may contain a mesh screen to
filter impurities out of the components. These screens may also be in line in various
impingement block designs depending on size constraints of pipe to be lined. Once
filtered, the product flows via orifices to the face of a recessed orifice in the
impingement block that holds the described module. This recessed orifice has
circumferential groves in which align with the pre drilled orifices in the module. Once
under pressure, these grooves fill up with product. Upon remote activation of
termination rod, the rod is partially retracted reversely out of the module orifice
allowing product in grooves to enter the mixing chamber via pre drilled orifices. The
product is then projected due to applied pressure through the stream tip orifice and a
predetermined and adjustable angle to be received on the landing slope of the first
inverted conical section of the rotating dissipation device. This landing slope is
proximate to the center top of the dissipation device.
[0097] The dissipation device may be comprised of high density nylon, Kevlar
reinforced nylon, or metal. Other materials may be used such as fiber reinforced
polymers. The angles of the side walls of the dissipation device may be
approximately 80 degrees for the center top and approximately 60 degrees for the
outer flange.
- 23-
[0098] The reciprocating head also contains a high velocity and high torque air
turbine motor. This motor powers a rotating shaft that extends from the front of the
reciprocating head. In one embodiment, the rotating shaft is 12 inches long. In
another embodiment, the rotating shaft is 6 inches long. The rotating shaft may be
comprised of high density nylon, Kevlar reinforced nylon, or metal. A dissipation
device is mounted on the end of the rotating shaft and at a preset distance from the
impingement block. The dissipation device can rotate between 20,000 and 45,000
rpm at high torque of approximately 20 foot pounds.
[0099] Mounted on the reciprocating head adjacent to the rotating shaft is an
optional shaft scrap'er. This long slender device removes overspray and deposits on
the rotating shaft.
[0100] Proximate to the mounting hardware of the shaft scraper is the air tube
outlet for the air ionization unit generating negatively charged air. This generator
may be located in the first rear housing with a tube traversing the front housing and
into the reciprocating head. The tube blows a stream of negatively charged air
across the rotating shaft and into the dissipation unit. This eliminates static. Static
electricity entraps small quantities of the liquid liner onto surfaces of the apparatus,
i.e., the rotating shaft and dissipation device. The entrapment continues until the
rotating shaft and dissipation device are heavily coated and their function is
interrupted. This can force shut down of the apparatus for cleaning before lining can
continue.
[0101] The operation of the shaft scrapper and ionization unit result in
continuous lining of the pipe. This lining process benefits the environment by
creating a well bonded and uniform thickness pipe liner. The absence of fault
minimizes the migration of effluent from the pipe.
[0102] The design of the dissipation device minimizes unintended and
undesired back spray upon the lining apparatus. Prior art using an oblique or flat
rotating device to disperse the lining mixture has experienced spray blocking the
spray tip.
[0103] The forward and reverse motion of the reciprocating head may cause
the dissipation device to move forward and reverse between 0.001 to 5 inches. The
impingement block and termination rod are mounted on top of the reciprocating
head, thereby causing the stream from the impingement block to maintain its fixed
relationship to the dissipation device.
- 24-
[0104] The impingement block mixes the liner components. The liquid liner is
projected out of an orifice of the impingement block by the withdrawal or retraction of
the termination rod to the termination rod actuator.
[0105] Figure 4 illustrates the liquid liner 420 streaming from the impingement
block to the dissipation device 400. The liner streams on to the center flange 401
near the center top 403. Also shown is the center annulus 410 where the rotating
shaft (not shown). The liquid liner flows down the side 421 of the center flange to the
pocket 422 formed at the juncture 405 of the two opposing acute sides of the
dissipation device. The liner material 422 has an opportunity dwell within the pocket
405 and where the curing process can continue. The liner material progresses up
the slope of the outer flange and is pulled over the edge 404. The liner material is
shown at the edge 424 and pulled 425 to the sides of the pipe wall 485 where it
cures and forms and inert liner.
[0106] Continuing, the angle of trajectory of the liquid liner causes it to stream
onto the interior acutely angled side of the rotating dissipation device. This is
proximate to the center top of the device. The liner strikes the dissipation device at
between 1700 to 3,500 psi dependant on material viscosities. The dissipation device
is shaped like a letter "W". The middle portion is designated the center top. The
inside portion of the bottom of the W is the pocket segment of the dissipation device
wherein the liquid liner can briefly dwell and equalize its mass before being pulled
over the outer flange by the operation of centrifugal force. Due to the rapid rotation
of the dissipation device, the curing liquid liner sprayed from the device evenly lines
the interior pipe in a 360 degree circumference.
[0107] The path of the liquid liner begins at the landing zone proximate to the
center top of the rapidly rotating dissipation device. The liner material descends
down the acute slope to the pocket area formed at the intersection of the interior
slope and outer flange. The liner material progresses up toward the outer flange
where it is thrown against the pipe wall surface. The timing of this progression is
critical in consideration of the cure time of the liner. It is undesirable for the liner to
cure while within the dissipation device. Also it is undesirable for the liner to be
coated onto the pipe wall too long before it cures. This can result in the liner sagging
or migrating from the top of the pipe. The configuration or geometry of the
dissipation device may be specifically selected to address these concerns.
- 25-
[0108] The dissipation device also has a self cleaning function. Small
quantities of liquid liner material may migrate toward the center top. The high
velocity stream from the stream orifice of the impingement block trims these
quantities of liner material.
[0109] The dissipation device of the instant disclosure has the ability to
counter rotate either through transfer or air from exhaust to intake and reverse.
More typically this is done through electronically switched bi-directional transmission
or transfer case that is in between the shaft and the air motor collet. The reason for
this is that high rpm air motors easily wear out if they are run in both directions.
Compounding this problem in the prior art is that the units do not have the ability to
start and stop flow of the lining material. Flow must be stopped while the motor is
being reversed in rotation. The flow may be readily stop by movement of the
termination rod.
[0110] In one embodiment, each housing unit is supported on skids which
permit the apparatus to be pulled through the pipe during the lining operation. The
skids may be made of metal. This pulling may utilize a tether attached to the front
housing. In another embodiment, the height of the skids may be adjustable in order
that the rotating shaft and dissipation device are proximate to the center point of the
circular pipe.
[0111] In another embodiment, each housing unit includes one or more
powered wheels or tracks. The direction of the apparatus, e.g., forward and
backward, can be remotely controlled utilizing the lights and cameras. The tracks
can be powered by air or electricity. In one embodiment, the tracks are powered by
24V gear driven servo motors that are located inside the track apparatus.
[0112] Speed of the robot apparatus is determined by a formula that takes
flowlrequired liner thickness/pipe diameter into account. Speed is controlled
remotely by a speed control that is wired to an encoder on the umbilical reel. This
encoder is a 2400 bit and is connected to a program logic controller (PLC). If speed
is set for example at 2 feet per minute, the encoder adjusts the reel speed
automatically no matter the torque on the umibilcal or diameter of umbilical on the
reel. The reel will constantly pull at whatever speed determined through the formula
the apparatus needs to travel at. This can be adjusted "on the fly" if a different iining
thicknesses in different areas of the pipe segment. Direction or precise location of
the apparatus in the pipe, while helped by the camera, is really controlled by a
- 26-
positioning indicator in the remotely positioned control room. The lining operation is
monitored and controlled from the control room. Again an encoder sends a signal to
a data display telling the operator at what foot mark he is at in the pipe.
[0113] This specification is to be construed as illustrative only and is for the
purpose of teaching those skilled in the art the manner of carrying out the invention.
It is to be understood that the forms of the invention herein shown and described are
to be taken as the presently preferred embodiments. As already stated, various
changes may be made in the shape, size and arrangement of components or
adjustments made in the steps of the method without departing from the scope of
this invention. For example, equivalent elements may be substituted for those
illustrated and described herein and certain features of the invention may be utilized
independently of the use of other features, all as would be apparent to one skilled in
the art after having the benefit of this description of the invention.
[0114] While specific embodiments have been illustrated and described,
numerous modifications are possible without departing from the spirit of the
invention, and the scope of protection is only limited by the scope of the
accompanying claims.
- 27-
CLAIMS
1. An in situ pipe lining apparatus comprising:
a) an umbilical comprising at least one air hose, at ieast one electrical
power cable, at least one video communication cable, and lining
component hoses;
b) a housing including at least one heater for heating lining components;
c) a reciprocating head moveably attached to the housing and including a
rotating shaft holding a rotating dissipation device shaped as two
asymmetrical reversely aligned cones with a center top attached to the
rotating shaft and with an acute angled flange oriented to the
reciprocating head;
d) an impingement block attached to the reciprocating head wherein the
impingement block mixes the lining components and projects the lining
at a specific angle of trajectory to the dissipation device; and
e) a remotely activated termination rod extending through the
impingement block wherein heated and pressurized lining components
enter the block and are mixed and projected out of a stream tip orifice
to the dissipation device by retraction of the termination rod.
2. The apparatus of claim 1 further comprising a first lining component of heated
isocyanate and a second lining component of a heated amine resin.
3. The apparatus of claim 1 further comprising applying a lining containing no
volatile organic compounds or chlorofluorocarbons.
4. The apparatus of claim 3 wherein the apparatus heats and highly pressurizes
the liner components and causes the mixed liner to cure in approximateiy 5
seconds.
5. The apparatus of claim 1 wherein the liner Is impervious to effluent and
prevents the migration of effluent from the pipe into the environment.
6. The apparatus of claim 1 further comprising a stream of negatively charged
ions directed to the dissipation device.
7. The apparatus of claim 1 further comprising the dissipation device rotating In
a range of between 20,000 and 45,000 rpm.
8. The apparatus of claim 1 further comprising a motor driven propulsion device
to move the apparatus forward and reverse in a pipe.
- 28-
9. The apparatus of claim 1 further comprising articulated housing sections
permitting the apparatus to manoeuvre through bends.
10. The apparatus of claim 1 further comprising a dissipation device having an
acute angle to the lining stream proximate to the center top attached to the
rotating shaft, a pocket segment and an acutely angled flange oriented to the
reciprocating head and wherein the lining stream impacts the dissipation
device and moves forward and up an interior acute angled flange of the
spinning surface to the pocket segment and up the acute angled flange
wherein the lining is projected off of the flange edge and onto the pipe wall.
11. The apparatus of claim 7 further comprising lining material that moves back
toward the center top is removed by the force of the lining stream projected
from the impingement block.
12. The apparatus of claim 1 further comprising the dissipation device moving
forward and reverse in relation to the apparatus.
13. The apparatus of claim 12 further comprising the dissipation device moving
between 0.001 to 5 inches in a forward and reverse direction.
14.The apparatus of claim 1 further comprising a remotely activated termination
rod extending through the impingement block wherein heated and pressurized
lining components enter the block and are mixed and projected out of a
stream tip orifice to the dissipation device by retraction of the termination rod.
15.The apparatus of claim 14 further comprising the projected lining strikes the
dissipation device in a range of between 1700 to 3,500 psi.
16. An in situ pipe lining apparatus comprising:
a) an umbilical comprising at least one air hose, at least one electrical
power cable, and hoses for lining components;
b) a first rear housing attached to a second front housing and the second
housing attached to a reciprocation head;
c) at least one heater for the heating the lining components;
d) an air powered turbine located in the reciprocation head rotating a shaft
holding an inverted conical rotating dissipation device;
e) an impingement block attached to the top of the reciprocation head for
mixing the lining components and projecting the lining to the dissipation
device; and
- 29-
f) a generator of negatively charged air located in the first rear housing
and projecting the air onto the dissipation device.
17. The pipe lining apparatus of claim 16 further comprising:
a) a four way air valve solenoid;
b) a push port connected to a pneumatic or electromagnetic actuator;
c) a pull port connected to the pneumatic or electromagnetic actuator;
d) a push port connected to a pneumatic or electromagnetic termination
rod actuator; and
e) a pull port connected to the pneumatic or electromagnetic termination
rod actuator.
18. A in situ pipe lining method comprising:
a) placing a pipe lining apparatus into the interior of a pipe to be lined;
b) connecting the apparatus to an umbilical attached to resources
comprising air, lining components, and electricity;
c) causing the apparatus to move at a predetermined speed along the
longitudinal axis of the pipe;
d) heating the lining components in the apparatus;
e) activating a motor to rotate a dissipation device between 20,000 and
45,000 rpm;
f) mixing the lining components of isocyanate and amine resin in an
impingement block;
g) projecting the lining on to the rotating dissipation device at 1700 to
3500 psi;
h) allowing the liner to dwell and equalize mass within the dissipation
device;
i) partially curing the liner;
j) distributing the liner in a 360 degree arc around the pipe from the
dissipation device; and
k) forward and reversely moving a reciprocating head between 0.001 and
5 inches thereby moving the dissipation device and the impingement
block in unison.
19. The method of claim 18 further comprising lining a pipe in a thickness
between 0.05 inches to greater than 4 inches.
- 30-
20. The method of claim 18 further comprising creating an inert lining and
blocking the migration of fluids from the pipe into the environment.
Dated this 15th day of September 2010
Of Anand and Anand, Advocates
Agents for the Applicants
- 31 -
Abstract
[0115] A method and apparatus for remotely installing a monolithic liner in a
conduit is disclosed. The apparatus includes a main component body inciuding
electromagnetic actuators, pneumatic cylinders, iinear actuators relays, solenoids,
ion generator, attachment points for tethers, umbilical, cameras and diameter
specific guides and a reciprocation head attached thereto. The longitudinally
traversing reciprocation head incorporates a fiuid driven rotary turbine motor
assembly communicating with shaft and self cleaning dissipation device integrating
both conical and inverted cone surfaces. Also included on the reciprocating
assembly is an impingement block for the efficient mixing of products and a
termination mechanism for the precise remote control of product flow. Additionally,
the assembly provides the ion generator to direct a stream of negatively charged air
flow to the shaft and the diffusion device to effectively prohibit excess material
accumulation.
- 32 -
Inspar Robotic Technologies, Inc
No.
Sheet 101'3
03 Sheets
Sheet
A
II
II I
I :s
I[
.,...
<0
c::>
gs - .,...
'Cc\.::J> I II
.,... 1'- -<':> , I
I '"'""
i:21
c.::i
I , ""t Li::
~c::>, II co
, .c,:.:.>.
I
~... ,
II I. l()
I -c::>
II
<..':>.
.,... ~
,- -cc::::>> 0 -- ~, 0
0"* (Archana Shanker)
Of Anand and Anand Advocates
Agents for the Applicant
400
110
z:;.
o .t.i,l
'"~
;:0 g..
~
o
;;t
o
::T
:::>
!2.
o
«>
0;.
til
:;-
o
~
102 "-~ : \ '\ : ~t , "j' ; 5 ? 122 108 77::1 485 FiG. 2
109
104 107 101
109
102
\ 111
UJ
;>
'-" >->
110 <.:.>.,
I I W
Q J ._ -OJ _ _ _ .__
> •
::s __.-- - -- - _._. -
~ -......,,:;_.-. - " ..~ -. ._- - -
>c.
(0", ~ 5. ~ 107101 105
:.>"»113 485
o ::> ~
~_:':">0"
~~!\ "0<"
"00", =:(')::s 0"',.. ll>-", am-:!-
~
T
112
~~
400
<:> cnc"n"
::T::T
'~" ~co
til
Inspar Robotic Technologies, Inc
No.
Sheet 301'3
03 Sheets
Sheet
(Archana Shanker)
Of Anand and Anand Advocates
Agents for the Applicant