Note: Descriptions are shown in the official language in which they were submitted.
CA 02707023 2012-08-27
METHODS AND SYSTEMS FOR ABRASIVE CLEANING AND
BARRIER COATING/SEALING OF PIPES
FIELD OF INVENTION
This invention relates to renovating of the interiors of pipes, and in
particular to
methods, systems and apparatus for abrasive cleaning and providing protective
barrier
coatings in a single operation to the interior walls of small diameter metal,
PEX type,
CPVC and plastic type pressurized pipes such as pressurized drain lines, hot
water lines,
cold water lines, potable water lines, natural gas lines, HVAC piping systems,
fire
sprinkler system lines, and the like, that are used in multi-unit residential
buildings, office
buildings, commercial buildings, and single family homes and the like.
BACKGROUND AND PRIOR ART
Over time building piping systems such as those used in commercial buildings,
apartment buildings, condominiums, residential homes and the like, that have a
broad
base of users commonly develop problems with the building pipes such as with
their
water and plumbing pipes, and the like. Presently when a failure in a piping
system,
such as a leak occurs the repair method can involve a number of separate
repair
applications. Those repair applications often involve a specific repair to the
area of
failure such as replacing that section of pipe or the use of a clamping devise
and a gasket.
1
WO 2009/070135 CA 02707023 2010-05-27 PCT/US2007/024504
However, these popular types of repair applications can cause additional
problems with
the building piping system.
Problems such as low water flow, or discolored water can result from build-up
of
materials, and the like occurring inside the pipe that has not been properly
cleaned.
Additional problems associated with installing a cut pipe that has not been
reamed or
deburred can cause water turbulence as the water flows over an unreamed burr
or lip left
inside the pipe. Such problem can be a prime cause of erosion corrosion inside
the pipes
which quickens the deterioration and lifespan of the pipes.
Traditional techniques to correct for a potential leak, an actual leak,
buildup or
blockage or reducing or removing an unreamed lip or burr have included
replacing some
or all of a building's pipes. In addition to the large expense for the cost of
the new pipes,
additional problems with replacing the pipes can include the immense labor and
construction costs that must be incurred for these projects. In addition the
down time to
the piping systems undergoing the repairs adds extra expense and discomfort to
those
needing to use the piping systems.
There are additional complications since most piping systems are located
behind
finished walls or ceilings, under floors, in concrete or underground. From a
practical
viewpoint simply getting to the problem area of the pipe to make the repair
can create the
largest problem. Reaching to the pipe for making repairs can require tearing
up the
building, cutting concrete and/or having to dig holes through floors, the
foundation or the
ground. These labor intensive repair projects can include substantial
demolition of a
buildings walls and floors in order to access the existing piping systems. For
example,
tearing out of the interior walls to access the pipes is an expected result of
the demolition
necessary to fix existing pipes.
2
WO 2009/070135 Additionally, there are usually substantial
time-consuming costs for removing the CA 02707023 2010-05-27
PCT/US2007/024504
debris and old pipes from the worksite. With these projects both the cost of
new pipes,
the ancillary repair to the building and the additional labor to install these
pipes require
expensive and time consuming expenditures. Further, there are additional added
costs for
the materials and labor to replumb these new pipes along with the necessary
wall and
floor repairs that must be made after the repairs to clean up for the
demolition effects.
Under current repair applications, just reaching at and fixing a pipe behind
drywall is not completing the repair project. The drywall or wall covering
surfaces must
also be repaired, and just these types of repairs can be extremely costly.
Additional
expenses related to the repair or replacement of an existing piping system
will vary
depending primarily on the location of the pipe, the building finishes
surrounding the pipe
and the presence of hazardous materials such as asbestos encapsulating the
pipe.
Furthermore, techniques for making piping repair take considerable amounts of
time
which results in lost use and lost revenue from tenants and occupants of
commercial type
buildings since tenants cannot use the buildings until the repairs are done.
Finally, the current pipe repair techniques are usually only temporary. Even
after
encountering the cost to repair the pipe, the cost and inconvenience of
tearing up walls or
grounds and if a revenue property the lost revenue associated with the repair
or
replacement, the repaired and/or new pipe(s) will still be subject to the
corrosive effects
of water type fluids that flow through the pipes.
Governments and municipalities are now beginning to recognize and deal with
corrosive effects of metal building piping systems. On September 30, 2005, the
State of
California recognizing the negative effects of corrosive water on metallic
piping systems
3
WO 2009/070135 CA 02707023 2010-05-27 PCT/US2007/024504
signed into law Assembly Bill 1953, which reduces the allowable amount of lead
in
potable water delivery systems(such as through metal pipes) to 0.25%. The bill
states:
"No person shall introduce into commerce, for use in California, any pipe,
pipe or
plumbing fitting, or fixture intended to convey or dispense water for human
consumption
through drinking water or cooking that is not lead free, as defined in
subdivision (e). This
includes kitchen faucets, bathroom faucets, and any other end-use devices
intended to
convey or dispense water for human consumption through drinking or cooking."
Over the years many different attempts and techniques have been proposed for
cleaning water type pipes with chemical cleaning solutions. See for example,
U.S.
Patents: 5,045,352 to Mueller; 5,800,629 to Ludwig et al.; 5,915,395 to Smith;
and
6,345,632 to Ludwig et al. However, these systems generally require the use of
chemical
solutions such as liquid acids, chlorine, and the like, that must be run
through the pipes as
a prerequisite prior to any coating of the pipes.
Other systems have been proposed that use dry particulate materials as a
cleaning
agent that is sprayed from mobile devices that travel through or around the
pipes. See for
example, U.S. Patents: 4,314,427 to Stolz; and 5,085,016 to Rose. However,
these
traveling devices generally require large diameter pipes to be operational and
cannot be
used inside of pipes that are less than approximately 4 inches in diameter,
and would not
be able to travel around narrow bends. Thus, these devices cannot be used in
small
diameter pipes under 2 inches in diameter that also have sharp and narrow
bends.
In some cases, compressed air carrying particles of abrasive material is blown
through the pipe. Such a method is described, for example, in U.S. Pat. No.
5,622,209 to
Naf and in U.S. Patent 5,007,461 to Naf. In the Naf 5,007,461 patent the
abrasive
4
WO 2009/070135 CA 02707023 2010-05-27 PCT/US2007/024504
cleaning method described involved the use of compressed air alone with a
continuous
feed of abrasive material. And in the 5,622,209 to Naf, the interior of the
pipe is
subsequently coated with an adhesive resin, such as an epoxy resin, which is
also applied
by use of compressed air to blow it through the pipe.
The Naf patents described continuously blowing, large amounts of
sand(approximately 200 Kg) that required extensive amounts air volume and
pressure.
Pre-drying took approximately 30 minutes, and a special separator was
installed at the
conduit outlet; the fine solid material exiting (apparently mainly calcium
deposits and
rust) entered a special separator. Then a feeding device for the abrasive
medium (dry
regular sand with a grain size of 2 to 4 mm) was installed in the conduit
between the
compressor and the air inlet. A separator with a cyclone separator with
pressure gauge
and regulating valve was installed at the air outlet. Then work was done for
approximately 8 minutes at a mean overpressure of approximately 1 atmosphere
at
highest compressor output and greatest abrasive medium feed. At the end of
blowing
approximately 200 kg of abrasive medium had been blown through the conduit to
be
cleaned. At the end of blowing, the air exiting at the separator had a
temperature of -
50° C. These elaborate blowing processes using great amounts of
abrasive
material are prone to problems.
These processes of using compressed air in this way can only be used on
relatively
small diameter pipes, and this cleaning technique easily results in blocking
of the pipe, or
major leaks in the pipe when weakened after cleaning by constant high pressure
and large
amounts of abrasive material being used. Also, the pipes are often not be
adequately
cleaned by such a processes when major frictional resistance occurs in the
pipe system.
5
WO 2009/070135 U.S. Patent. 5,924,913 of Reimelt attempts to
overcome these problems by using a CA 02707023 2010-05-27
PCT/US2007/024504
suction at one end of a section of pipe. Reimelt specifically discusses the
problems with
NOT wanting to use compressed air supplies for renovating pipes since they
result in
damage to the interior of the pipes, blockages in the pipes and result in
pollution. See
column 2, lines 39-62. However, the Reimelt technique of only using a
suction(low
pressure) at one end of a pipe section can also result in blockages and other
problems.
When an abrasive agent is repeatedly moved back and forth, it will gradually
become
mixed with the debris removed from the pipe surface, diluting or reducing the
cleaning
effect. Additionally, the Reimelt techniques require the use of heating
devices such as
wires that must be pulled or towed through pipe sections which adds additional
expense
and can also result in the dragged heating device damaging the interior of the
pipes or
even getting stuck in the pipes. Also, the Reimelt technique cannot be used
with cleaning
entire piping systems having bends and t-branches cannot be cleaned unless
every pipe
section is potentially taking apart and separately cleaned. Also, Reimelt
cannot be used
with small pipes that need to be cleaned since the suction and heating devices
cannot
easily pass through pipes smaller than approximately 2 & 1/2 inches in
diameter.
Thus, the need exists for solutions to the above problems where providing a
processes of abrasive cleaning in small diameter pressurized pipes, up to 2
inches in
diameter, that can be deburred, cleaned effectively and efficiently, in-place,
without
clogging the pipe during the cleaning process, with minimal damage to the pipe
and
without large quantities of abrasive material being used. A further
application of a barrier
coating and sealing leaks is accomplished in piping systems in a single
operation, further
6
WO 2009/070135 CA 02707023 2010-05-27 PCT/US2007/024504
protecting the piping system and all it's components from the effects of
corrosion, thereby
reducing the leaching of heavy metals such as lead into the water supply.
SUMMARY OF THE INVENTION
A primary objective of the invention is to provide methods, systems and
devices
for abrasive cleaning and preparation to the interior walls of the pipe and
providing a
protective barrier coating of pressurized pipes in buildings without having to
physically
remove and replace the pipes, where the pipes are cleaned, deburred, leaks
sealed and the
barrier coating is applied in a single operation.
A secondary objective of the invention is to provide methods, systems and
devices
for abrasive cleaning and repairing interior walls and sealing leaks, in a
single operation
in pipes by initially cleaning the interior walls of the pipes.
A third objective of the invention is to provide methods, systems and devices
for
abrasive cleaning and repairing interior walls and sealing leaks, in a single
operation in
pipes by applying a corrosion protection barrier coating to the interior walls
of the pipes
that provides a barrier coating and seals leaks in one operation.
A fourth objective of the invention is to provide methods, systems and devices
for
abrasive cleaning, repairing interior walls, sealing leaks, by applying a
corrosion
protection barrier coating to the interior walls of the pipes in a single
operation, in pipes
in buildings in a cost effective and efficient manner.
A fifth objective of the invention is to provide methods, systems and devices
for
abrasive cleaning, repairing interior walls, sealing leaks, by applying a
corrosion
protection barrier coating to the interior walls of the pipes in a single
operation, in pipes
which is applicable to small diameter piping systems up to approximately 2
inches in
7
WO 2009/070135 CA 02707023 2010-05-27 PCT/US2007/024504
diameter in piping systems made of various materials such as galvanized steel,
black
steel, lead, brass, copper or other materials such as CPVC(Chlorinated
Polyvinyl
Chloride) type, PVC(polyvinyl chloride) type, PEX(cross-linked polyethylene)
type and
composites including plastics, as an alternative to pipe replacement or
repair.
A sixth objective of the invention is to provide methods, systems and devices
for
abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a corrosion
protection barrier coating to the interior walls of the pipes in a single
operation which is
applied to pipes, "in place" or insitu minimizing the need for opening up
walls, floors
ceilings, or grounds.
A seventh objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
which minimizes the disturbance of asbestos lined piping or walls/ceilings
that can also
contain lead based paint or other harmful materials.
An eighth objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
where once the existing piping system is restored with a durable epoxy barrier
coating the
common effects of corrosion from water passing through the pipes will be
substantially
delayed if not stopped entirely.
A ninth objective of the invention is to provide methods, systems and devices
for
abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a corrosion
protection barrier coating to the interior walls of the pipes in a single
operation, to clean
out blockage where once the existing piping system is restored, users will
experience an
8
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
increase in the flow of water, which reduces the energy cost to transport the
water.
Additionally, the barrier epoxy coating leak sealant being applied to the
interior walls of
the pipes can create enhanced hydraulic capabilities again giving greater flow
of water
with reduced energy costs.
A tenth objective of the invention is to provide methods, systems and devices
for
abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a corrosion
protection barrier coating to the interior walls of the pipes in a single
operation, where
customers benefit from savings in time associated with restoration of an
existing piping
system.
An eleventh objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
where customers benefit from the economical savings associated with the
restoration and
in-place leak repair of an existing piping system, since walls, ceilings,
floors, and/or
grounds would not need to be broken and/or cut through.
A twelfth objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
where income producing commercial properties experience savings by remaining
commercially usable, and any operational interference and interruption of
commercial
income-producing activities is minimized.
A thirteenth objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
9
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
where health benefits accrue, as the water to metal contact will be stopped by
a barrier
coating thereby preventing the leaching of metallic and potentially other
harmful products
from the pipe into the water supply such as but not limited to lead from
solder joints and
from lead pipes, and any excess leaching of copper, iron and lead.
A fourteenth objective of the invention is to provide methods, systems and
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation where the pipes are being restored and repaired, in-place, thus
causing less
demand for new metallic pipes, which is a non-renewable resource.
A fifteenth objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
using a less intrusive method of repair where there is less building waste and
a reduced
demand on expensive landfills.
A sixteenth objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation,
where the process uses specially filtered air that reduces possible impurities
from entering
the piping system during the process.
A seventeenth objective of the invention is to provide methods, systems and
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation, where the equipment package is able to function safely, cleanly,
and efficiently
in high customer traffic areas.
10
WO 2009/070135 An eighteenth objective of the invention is to provide
methods, systems and CA 02707023 2010-05-27
PCT/US2007/024504
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation where the equipment components are mobile and maneuverable inside
buildings and within the parameters typically found in single-family homes,
multi unit
residential buildings and various commercial buildings.
A nineteenth objective of the invention is to provide methods, systems and
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation, where the equipment components can operate quietly, within the
strictest of
noise requirements such as approximately seventy four decibels and below when
measured at a distance of approximately several feet away.
A twentieth objective of the invention is to provide methods, systems and
devices
for abrasive cleaning, repairing interior walls, sealing leaks in pipes, by
applying a
corrosion protection barrier coating to the interior walls of the pipes in a
single operation
where the barrier coating leak sealant material is applied to a variety of
piping
environments, and operating parameters such as but not limited to a wide
temperature
range, at a wide variety of airflows and air pressures, and the like.
A twenty first objective of the invention is to provide methods, systems and
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation where the barrier coating leak sealant material and the process is
functionally
able to deliver turnaround of restored piping systems to service within
approximately
twenty four hours or less.
11
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
A twenty second objective of the invention is to provide methods, systems and
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation, where the barrier coating material is designed to operate safely
under NSF
(National Sanitation Foundation) Standard 61 criteria in domestic water
systems, with
adhesion characteristics within piping systems in excess of approximately 400
PSI.
A twenty third objective of the invention is to provide methods, systems and
devices for abrasive cleaning, repairing interior walls, sealing leaks in
pipes, by applying
a corrosion protection barrier coating to the interior walls of the pipes in a
single
operation where the barrier coating material is designed as a long-term, long-
lasting,
durable solution to pipe corrosion, pipe erosion, pinhole leak repair and
related water
damage to piping systems where the barrier coating extends the life of the
existing piping
system.
A twenty fourth objective of the invention is to provide methods, systems and
devices for both cleaning and coating interiors and leak sealing, the interior
of pipes
having diameters of up to approximately 2 inches using dry particulates, such
as sand and
grit, prior to coating the interior pipe walls.
A twenty fifth objective of the invention is to provide methods, systems and
devices for abrasive cleaning, coating interiors and sealing leaks of pipes
having
diameters of up to approximately 2 inches, in or around buildings, without
having to
section off small sections of piping for abrasive cleaning, coating and leak
sealing
applications.
12
CA 02707023 2012-08-27
A twenty sixth objective of the invention is to provide methods, systems and
devices for abrasive cleaning the interiors of an entire isolated piping
system in a building
in a single pass run operation.
A twenty seventh objective of the invention is to provide methods, systems and
devices for applying a barrier coating and leak sealing compound to the
interiors of an
entire isolated piping system in a building in a single pass run operation.
A twenty eighth objective of the invention is to provide methods, systems and
devices for abrasive cleaning, of pipes having diameters of approximately 3/8
of an inch
up to approximately 2 inches, in or around buildings, without having to
section off small
sections of piping for abrasive cleaning, where the abrasive cleaning reduces
or
eliminates the lip or burr associated with unreamed pipe. i.e.: deburring
installed pipe.
A twenty ninth objective of the invention is to provide methods, systems and
devices for abrasive cleaning the inside walls of piping systems having bends
of up to
approximately ninety degrees and branches, such as t-branches coming out from
the
pipes, using a compressed gas source at one end in combination with a vacuum
generator
at another end of the piping system so that the entire system can be cleaned
in a single
pass run.
A thirtieth objective of the invention is to provide methods, systems and
devices
for barrier coating and leak sealing the inside walls of piping systems having
bends of up
to approximately ninety degrees and branches, such as t-branches coming out
from the
pipes, using a compressed gas source at one end in combination with a vacuum
generator
at another end of the piping system so that the entire system can be cleaned
in a single
pass run.
13
WO 2009/070135 The novel method and system of abrasive cleaning during
pipe restoration CA 02707023 2010-05-27
PCT/US2007/024504
prepares small diameter piping systems such as those within the diameter range
of up to
approximately 2 inches which can include straight and bent sections of piping
and t-
branches for the application of a protective barrier coating leak sealant.
The novel method of abrasive cleaning and prepares the piping system for
application of a barrier coating and leak repair, in a single operation and
can be applied
to potable water lines, natural gas lines, HVAC piping systems, hot water
lines, cold
water lines, pressurized drain lines, and fire sprinkler systems.
The novel method of abrasive cleaning allows for a method of abrasive cleaning
in pressurized pipes up to 2 inches in diameter that reduces the amount of
abrasive
material required, reduces the physical impact and damage to the interior pipe
wall and
reduces clogging of abrasive material and debris in the pipe, during the
cleaning stage.
The novel method of abrasive cleaning allows for a method of abrasive cleaning
in pressurized pipes up to 2 inches in diameter that reduces or eliminates the
unreamed lip
inside an unreatned or improperly reamed pipe.
The novel method of abrasive cleaning with the use of a vacuum air filter
reduces
the effects of friction loss in small diameter pipes up to 2 inches, enhancing
exiting of the
abrasive material and debris and enhancing impact effectiveness of the
abrasive material.
The novel use of the vacuum air filter used without the compressor enhances
the
drying of the pipe, during the pre cleaning drying stage, enhances the release
of spent
abrasive and debris during the cleaning stage and enhances the drying of the
barrier
coating, during the drying stage.
The novel method of abrasive cleaning and application of an epoxy barrier
coating
leak sealant is applied to pipes right within the walls eliminating the
traditional and
14
WO 2009/070135 CA 02707023 2010-05-27PCT/US2007/024504
expected destruction of the walls that is usually associated with a re-piping
job. Typically
a piping system or section of pipe can be isolated and the restoration of the
system or
section of pipe can be completed in less than one to four days (depending upon
the
building size and type of application) with piping fluid flow(such as water)
restored
within less than approximately 24 to approximately 96 hours.
For most applications, there are no walls to cut, no large piles of waste, no
dust
and virtually no lost use of the building. Entire building piping systems can
be cleaned
within one run through pass of using the invention. Likewise, an entire
building piping
system can be cleaned, coated and leaks sealed within one single pass
operation as well.
Once cleaned, the applied epoxy coating not only seals the leak but creates a
barrier coating on the interior of the pipe in the same operation. The
application process
and the properties of the epoxy coating ensure the interior of the piping
system is fully
coated and leaks repaired.
Currently, there are primarily three types of metallic piping systems that are
commonly used in the plumbing industry: copper, steel and cast iron. New steel
pipes are
treated with various forms of barrier coatings to prevent or slow the effects
of corrosion.
A common barrier coating used on steel pipe is the application of a zinc based
barrier coat commonly called galvanizing. New copper pipes usually have no
barrier
coating protection. For years copper pipes were thought to be corrosion
resistant offering
a lifetime trouble free use as a piping system.
Under limited circumstances that involved a combination of factors of which
the
chemistry of water and installation practices a natural occurring barrier
coating could
15
WO 2009/070135 CA 02707023 2010-05-27PCT/US2007/024504
sometimes form on the inside of copper pipes which would act as a barrier
coating,
protecting the copper piping system against the effects of corrosion from the
water.
However, in recent history, due to changes in the way drinking water is being
treated and
changes in installation practices, these natural occurring barrier coatings on
the inside of
copper pipes are not being formed or if it was formed it is now being washed
away. In
either case without an adequate natural occurring barrier coating, the copper
pipe is
exposed to the effects of corrosion/erosion, which can result in premature
aging and
failure of the piping system, most commonly referred to as a pinhole leak.
With galvanized pipe the zinc coating wears away leaving the pipe exposed to
the
effects of the corrosive activity of the water. This results in the pipe
rusting and
eventually failing.
The invention can also be used with piping systems having plastic pipes,
PEX(cross-linked polyethylene) type pipes, CPVC(Chlorinated Polyvinyl
Chloride) type
pipes, PVC(polyvinyl chloride) type pipes, composite material, and the like.
The novel method and system of abrasive cleaning and corrosion control by the
application of an epoxy barrier coating and sealant can be applied to existing
piping
systems in-place, in the same operation.
The invention includes novel methods and equipment for abrasive cleaning and
providing barrier coating corrosion and repair methods for sealing leaks for
the interior
walls of small diameter piping systems in the same operation.
The novel process method and system of abrasive cleaning and internal leak
repair
and corrosion control includes at least three basic steps: Air Drying a piping
system to be
serviced; profiling the piping system using an abrasive cleaning agent; and
applying the
barrier coating leak sealant to selected coating thickness layers inside the
pipes.
16
WO 2009/070135 The novel invention can also include two additional
preliminary steps of: CA 02707023 2010-05-27
PCT/US2007/024504
diagnosing problems with the piping system to be serviced, and planning and
setting up
the barrier coating leak repairs project onsite. Finally, the novel invention
can include a
final end step of evaluating the system after applying the barrier coating
leak repair and
re-assembling the piping system.
A preferred method of cleaning out pipe systems, can include the steps of
generating pressurized gas into one end of a piping system having pipes,
intermittently
injecting bursts of abrasive particles into the pressurized gas into the end
of the piping
system, cleaning interior wall surfaces of the pipes with the intermittent
bursts of the
abrasive particles, reducing burrs, interior lips and excess seam joint edges
in the interior
wall surfaces of the pipes, and generating a vacuum suction at another end of
the piping
system to remove the abrasive particles and debris caused by the cleaning of
the interior
walls of the pipes.
The pipes can be small pipes having diameters of approximately 3/8 of an inch
to
approximately 2 inches, and preferably diameters of approximately 3/8 of an
inch to
approximately 1 & 3/4 inches. The pipes can be metal pipes such as copper
pipes and steel
pipes, as well as other types of pipes such as but not limited to
CPVC(Chlorinated
Polyvinyl Chloride) type, PVC(polyvinyl chloride) type, PEX(cross-linked
polyethylene)
type and composites including plastics.
The intermittent bursts can include introducing a cumulative amount between
approximately 0.15 kg to less than 5 kg of abrasive particulates per a piping
length of
between approximately 1/3 m to approximately 100m.
17
WO 2009/070135 For pipes having diameters of between approximately
3/8 inch to approximately 1CA 02707023 2010-05-27
PCT/US2007/024504
inch, the cumulative amount of the abrasive particles can be between
approximately
0.15kg to less than approximately 3kg.
For pipes having diameters of between approximately 1 & 1/4 inches to
approximately 1 &3/4 inches, the cumulative amount of the abrasive particles
can be
between approximately 0.5kg to less than 5kg.
For pipes having diameters of between approximately 1 & 3/4inches to
approximately 2 inches, the cumulative amount of the abrasive particles can be
between
approximately 0.5kg to less than 5 kg.
The method can include cleaning the interior walls of the pipes while the
pipes
have a temperature of between approximately 25C to approximately 40C.
For cleaning copper pipes, the abrasive particulates can be selected from at
least
one of: Silica, Garnett and Aluminum Oxide, with Garnet and Aluminum Oxide are
most
preferable since Aluminum Oxide is hard and Garnet is readily available and is
environmentally desirable. The mesh size for particulates for copper pipes can
be a range
between 12 to 45 mesh sizes.
For cleaning steel pipes, the abrasive particles can be selected from at least
one of:
Silica, Garnett, Silicon Carbide and Aluminum Oxide, with Silica, Silicon
Carbide and
Aluminum would be most preferable in view of the their hardness for steel
pipes. The
mesh size for particulates for steel pipes can be a range between 12 to 60
mesh sizes.
With a piping diameter of approximately 1/2 inch, the air pressure can be
approximately 2 to approximately 6 bar, and the abrasive particulates per shot
are
approximately 25 to approximately 80 grams.
18
WO 2009/070135 CA 02707023 2010-05-27 PCT/US2007/024504
With a piping diameter of approximately % of an inch, the air pressure can be
approximately 2 to approximately 6 bar, and the abrasive particulates per shot
are
approximately 40 to approximately 120 grams.
With a piping diameter of approximately 1 inch, the air pressure generated can
be
approximately 2 to approximately 6 bar, and the abrasive particulates per shot
are
approximately 60 to approximately 160 grams.
With a piping diameter of approximately l& 1/2 of an inch, the air pressure
generated can be approximately 3 to approximately 7 bar, and the abrasive
particulates
per shot are approximately 75 to approximately 200 grams.
With a piping diameter of approximately 1 & % of an inch, the air pressure
generated can be approximately 3 to approximately 7 bar, and the abrasive
particulates
per shot are approximately 75 to approximately 200 grams.
The novel method can also include the steps of coating the interior walls of
the
cleaned piping system with a barrier coating leak sealant with the compressed
air source
and the vacuum source attached to the piping system.
A preferred system of cleaning out building pipe systems having pipes with
bends
of approximately 90 degrees and t-branches would include a generator for
generating
pressurized/compressed gas into one end of a piping system, a source for
intermittently
injecting bursts of abrasive particles into the pressurized gas and into the
end of the
piping system, the intermittent bursts for cleaning interior wall surfaces of
the pipes and
reducing burrs, interior lips and excess seam joint edges in the interior wall
surfaces of
the pipes, and a vacuum source for generating a vacuum suction at another end
of the
piping system to remove the abrasive particles and debris caused by the
cleaning of the
interior walls of the pipes. Another source can be added for coating the
interior walls of
19
CA 02707023 2012-08-27
the cleaned pipes with a barrier coating using the pressurized/compressed gas
generator
and vacuum source.
Further objects and advantages of this invention will be apparent from the
following detailed description of the presently preferred embodiments which
are
illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
Fig. 1 shows the general six steps that is an overview for profiling and
abrasively cleaning
interior walls of pipes and applying the barrier coating leak sealant to the
wails.
Figures 2A, 2B, 2C and 2D shows a detailed process flowchart using the steps
of Fig. 1
for providing the abrasive cleaning and applying the barrier coating leak
sealant.
Fig. 3 shows a flow chart of the set up of the invention.
Fig. 4 shows an illustration of the effects of deburring and water turbulence,
before and
after the cleaning and coating process is used.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail
it
is to be understood that the invention is not limited in its application to
the details of the
particular arrangements shown since the invention is capable of other
embodiments.
Also, the terminology used herein is for the purpose of description and not of
limitation.
20
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
Fig. 1 shows the general six steps for a project overview for applying the
barrier
coating leak sealant to an existing piping system, which include step one, 10
program
diagnosis, step two, 20 project planning, step three, 30 drying piping system,
step four 40,
profiling and deburring the piping system, step five, 50 applying barrier
coating leak
sealant to the interior walls of the pipes in the piping system, and final
step six 60
evaluation and return to operation of the piping system.
Step One¨Problem Diagnosis 10
For step one, 10, several steps can be done to diagnose the problem with a
piping
system in a building, and can include:
(a) Interview onsite engineering staff, property managers, owners or other
property
representatives as to the nature of the current problem with the piping
system.
(b) Evaluation of local and on-site water chemistry being used in the piping
system
for hardness and aggressive qualities.
(c) Engineering evaluation, if necessary, to determine extent of present
damage to the
wall thickness of the piping and overall integrity of the piping system.
(d) Additional on-site testing of piping system, if necessary, identifying
leaks or the
nature or extent of leaking.
(e) Corrosion control, leak sealing proposal development for client, including
options
for pipe and fitting replacement where necessary.
After completion of step one, 10, the project planning and setup step 20 can
be
started.
Step Two¨Project Planning and Setup 20
For step two, 20, several steps can be followed for planning and setup for
restoring the
integrity of the piping system in a building, and can include:
(a) Complete contract development with client, after the diagnosis contract
has
started.
(b) Commence project planning with site analysis crew, project management
team,
and on-site engineering/maintenance staff.
(c) Plan delivery of the equipment and supplies to the worksite.
(d) Complete equipment and supply delivery to worksite.
(e) Commence and complete mechanical isolation of the piping system.
(f) Commence and complete set up of hosing and equipment.
Step Three¨Air Drying ¨ Step I Method of Corrosion Control and Leak Repair 30
For step three, 30, the piping system to be prepared for the coating by drying
the
existing pipes, and can include:
(a) Piping systems are mapped.
21
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
(b) Isolation of piping systems or pipe sections are prepared and completed.
(c) The isolated piping system to receive the barrier coating leak sealant is
adapted to
be connected to the barrier coating equipment.
(d) The isolated pipe section or system is drained of water.
(e) Using moisture and oil free, hot compressed air, a flushing sequence is
completed
on the piping system to assure water is removed.
(f) Piping system is then dried with heated, moisture and oil free compressed
air. The
piping system is heated in the approximate range of approximately 25 to
approximately 40 degrees Celsius
(g) Length of drying sequence is determined by pipe type, diameter, length
complexity, location and degree of corrosion contained within the piping
system,
if any.
(h) Exiting debris is captured with use of an air filter vacuum, drawing air,
which can
be used simultaneously with the compressor.
(i) Inspections are completed to assure a dry piping system ready for the
barrier
coating and sealant.
Step Four¨Piping System Profiling ¨ Step 2 of Method of Corrosion Control and
Leak
Sealant 40
For step four, 40, the piping system is to be profiled, and can include:
(a) Dried pipes can be profiled using an abrasive agent in varying quantities
and
types. The abrasive medium can be introduced into the piping system by the use
of the moisture and oil free heated compressed air using varying quantities of
air
and varying air pressures. The amount of the abrading agent is controlled by
the
use of a pressure generator. The abrading agent is introduced into the air
stream
using a burst technique wherein small amounts of the abrasive are introduced
into
the air stream, travel through the pipe and exit, wherein the next amount or
shot
of abrasive is introduced.
(b) The simultaneous use of the air filter vacuum at the exit end, drawing air
to assist
the compressor, reducing the effects of friction loss in the piping system,
enhancing the effects of the sanding and debris removal.
(c) The abraded pipe, when viewed without magnification, must be generally
free of
all visible oil, grease, dirt, mill scale, and rust. Generally, evenly
dispersed, very light
shadows, streaks, and discolorations caused by stains of mill scale, rust and
old
coatings can remain on no more than approximately 33 percent of the surface.
Also,
slight residues of rust and old coatings can be left in the craters of pits if
the original
surface is pitted.
(d) Pipe profiling is completed to ready the pipe for the application of the
barrier
coating leak sealant material.
(e) Visual inspections can be made at connection points and other random
access
areas of the piping system to assure proper cleaning and profiling standards
are
achieved.
(f) An air flushing sequence is completed to the piping system to remove any
residuals left in the piping system from the profiling stage.
22
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
Step Five¨Corrosion Control Epoxy Sealing Leak Repair and Protection of the
Piping -
Step 3 of the Method of Corrosion Control and Leak Repair 50
For step five, 50, the piping system is protected with a barrier coating and
leaks
sealed and can include:
(a) Piping system can be heated with hot, pre-filtered, moisture and oil free
compressed air to an appropriate standard for an epoxy coating application.
Pipes
can be heated to approximately 25 to approximately 40 degrees Celsius
(b) Piping system can be checked for leaks.
(c) If leaks are identified or are suspect and the approximate size determined
the
operator can choose to apply the coating material without fillers, if the leak
is determined
to be >approximately 30 mils in width the operator can decide to add fillers
to the coating
material, prior to injection into the piping system.
(d) Coating and leak sealing material can be prepared and metered to
manufacturer's specifications using a proportionator.
= (e) The barrier coating leak sealant and fillers are placed into the epoxy
carrying tube or injection device.
(f) The coating and leak sealant material can be injected into the piping
system
using hot, pre-filtered, moisture and oil free compressed air at temperatures,
air
volume and pressure levels to distribute the epoxy barrier coating leak
sealant
throughout the pipe segment, in sufficient amounts to eliminate the water to
pipe
contact in order to create an epoxy barrier coating on the inside of the pipe
and
seal the leak in a single operation. During this wetting out stage a vacuum
filter
can be used in conjunction with the compressor to assist the wetting out of
the
coating material. At all times, a neutral or positive pressure must be
maintained on
the inside of the pipe.
(g) The coating can be applied to achieve a coating of at least approximately
4
mils and sealing leaks up to approximately 125 mils in size.
(h) Once the epoxy barrier coating leak sealant is injected and the piping
segment
is wetted out warm, pre-filtered, moisture and oil free compressed air can be
applied to create a positive pressure inside the pipe with a continuous
positive
pressure maintained of at least approximately 1.5 P.S.I. over the internal
surface
of the pipe to achieve the initial set of the epoxy barrier coating sealant
takes
= place. After initial set and still maintaining positive pressure confirm
that all
valves and pipe segments support appropriate air flow indicating clear passage
of
the air through the pipe i.e.: no areas of blockage. Allow the barrier coating
leak
sealant to cure to manufacturer's standards.
Step Six¨System Evaluation and Re-Assembly 60
The final step six, 60 allows for restoring the piping system to operation and
can
include:
(a) Remove all process application fittings.
(b) Examine pipe segments to assure appropriate coating standards, checks to
ensure all leaks are sealed.
(c) Re-confirm that all valves and pipe segments support appropriate air flow.
(d) Install original valves, fittings/fixtures, or any other fittings/fixtures
as
specified by building owner representative.
23
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
(e) Reconnect water system, and water supply.
(f) Complete system checks, testing and evaluation of the integrity of the
piping
system.
(g) Complete a water flush of system, according to manufacturer's
specifications.
(h) Evaluate water flow and quality.
(i) Document piping layout schedule, and complete pipe labeling.
Figures 2A, 2B, 2C and 2D show a detailed process flowchart using the steps of
Fig. 1 for cleaning the interior walls of the pipes and for providing the
barrier coating leak
sealant. These flow chart figures show a preferred method of applying a novel
barrier
coating leak sealant for the interior of small diameter piping systems
following a specific
breakdown of a preferred application of the invention.
Components in Fig. 3 will now be identified as follows:
IDENTIFIER EQUIPMENT
100 Compressors Outfitted with Aftercooler, Water separator, Fine
Filter and Reheater (if required)
200 Main Air Header and Distributor (Main Header)
300 Floor (Mini) Manifold (optional)
400 Sander
500 Pre-Filter
600 Dust Collector System (Air Filter Vacuum)
700 Portable Epoxy Metering and Dispensing Unit (Epoxy Mixer)
800 Epoxy Barrier Coating and Sealant
900 Epoxy Carrying Tube - Injection Device
Referring to Fig. 3, components 100-900 can be located and used at different
locations in or around a building. The invention allows for an entire isolated
building
piping system to be cleaned in one single pass through run without having to
dismantle
24
CA 02707023 2012-08-27
either the entire or multiple sections of the piping system. The piping system
can include
pipes having diameters of up to approximately 2 inches in diameter with the
piping
including bends up to approximately ninety degrees or more throughout the
building and
include at t-branches in the piping systems. The invention allows for an
entire isolated
building piping system to have the interior surfaces of the pipes cleaned,
coated and leaks
sealed in one single pass through run without having to dismantle either the
entire or
multiple parts of the piping system. Each of the 'components will now be
defined.
100 AIR COMPRESSOR
The air compressors 100 can provide filtered and heated compressed air. The
filtered and heated compressed air employed in various quantities is used, to
dry the
interior of the piping system, as the propellant to drive the abrasive
material used in
cleaning of the piping system and is used as the propellant in the application
of the epoxy
barrier coating leak sealant and the drying of the epoxy barrier coating leak
sealant once it
has been applied. The compressors 100 also provide compressed air used to
propel
ancillary air driven equipment.
200 MAIN AIR HEADER AND DISTRIBUTOR
A main header and distributor 200 referred to in Figures 3 can be one
Manufactured By: Media BIastTM & Abrasives, Inc. 591 W. Apollo Street Brea, CA
92821.
The Main Header 200 provides safe air management capability from the air
compressor for both regulated and unregulated air distribution (or any
combination
thereof) to the various other equipment components and to both the piping
system risers
and fixture outlets for a range of piping configurations in residential and/or
commercial
buildings that can range from a single family home to a multi-story building.
25
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
300 FLOOR (Mini) MANIFOLD
A floor or mini manifold 300 can be one Manufactured By: M & H Machinery
45790 Airport Road, Chilliwack, BC, Canada
As part of the general air distribution system set up, the floor manifolds 300
can
be pressure rated vessels designed to evenly and quietly distribute the
compressed air to at
least 5 other points of connection, typically being the connections to the
piping system.
Airflow from each connection at the manifold is controlled by the use of
individual full
port ball valves.
400 PRESSURE GENERATOR SYSTEM-SANDER
A pressure generator sander 400 that can be used with the invention can be one
Manufactured By: Media Blast & Abrasives, Inc.591 W. Apollo Street Brea, CA
92821.
The pressure generating sander system 400 can provide easy loading and
controlled dispensing of a wide variety of abrasive medium. The pressure
generator
sander can include operational controls that allow the operator to easily
control the
amount of air pressure and control the quantity of the abrasive medium to be
dispersed in
a single or multiple application. The abrasive medium can be controlled in
quantity and
type and is introduced into a moving air steam, using small bursts of
material, that is
connected to a pipe or piping systems that are to be sand blasted clean by the
abrasive
medium. The abrasive medium can be introduced by the pressure generator sander
system 400 by being connected to and be located outside of the piping system
depicted in
Fig. 3. The novel application of the sander system 400 allows for cleaning
small pipes
having diameters up to approximately 2 inches.
26
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
Table 1 shows a list of preferred dry particulate materials with their
hardness
ratings from 1 to 10 (being the hardest), and grain shapes that can be used
with the sand
generator 400, and Table 2 shows a list of preferred dry particulate particle
sieve sizes
that can be used with the invention.
TABLE 1. PARTICULATES
Material Moh Rating Grain Shape
Silicon Carbide 10 Cubical
Aluminium Oxide 9 Cubical
Silica 5 Rounded
Garnet 5 Rounded
Table 1 shows the hardness and shapes of the typical types of particulates
used in
the cleaning and sanding process. Based on the Moh scale of hardness, it is
found that a 5
or higher hardness particulate can be used in this process. A particulate such
as silicon
carbide is recommended over a softer garnet particulate when used to clean and
profile
harder metal pipes, such as steel, where the metal is a softer, such as copper
it can be
cleaned and profiled with a less hard particulate such as garnet.
Silica, Garnet and Aluminum Oxide can be used to clean copper, preferably
Garnet and Aluminum Oxide are most preferable since Aluminum Oxide is hard and
Garnet is readily available and is environmentally desirable. The mesh size
for
particulates for copper pipes can be a range between 12 to 45 mesh sizes.
For cleaning steel pipes, Silica, Garnett, Silicon Carbide and Aluminum Oxide
can be used. Preferably Silica, Silicon Carbide and Aluminum would be most
preferable
in view of the their hardness for steel pipes. The mesh size for particulates
for steel pipes
can be a range between 12 to 60 mesh sizes.
27
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
TABLE 2. PARTICULATE SIZE
SIEVE SIZE OPENING
U.S. Mesh Inches Microns Millimeters
4 .187 4760 4.76
8 .0937 2380 2.41
16 .0469 1190 1.20
25 .0280 710 .70
45 .0138 350 .35
Table 2 describes the various standards for measuring particulate size. In the
cleaning and profiling stage an operator will decide to use particulate of
various sizes
depending on the size of pipe, the type of piping material i.e. steel or
copper and the
degree and type of build up inside the pipe. In a copper pipe situation it is
common to use
a 24 mesh size. When cleaning a heavily encrusted steel pipe an operator might
use a
small particulate such as a 45 or 60 mesh to bore a hole through the build up
without
getting clogged or plugged up inside the pipe. As the opening inside the pipe
increases by
the abrasive cleaning, larger particulate sizes can be used.
The following table 3 illustrates the approximate amount of pushing air volume
and pressure ranges required for adequate cleaning of pipes in various
diameters up to 2"
when used in conjunction with a vacuum assist at the exit.
TABLE 3
Pipe Size (inches) Air Volume (CFM) Pressure Ranges (bar)
0.5 80 1.5 ¨ 7.0
0.75 80
1.00 80
1.25 125
1.50 175
1.75 225
2.00 275
The following Table 4 illustrates the amount of abrasive material introduced
into a
metal piping system in the form of a shot or intermittent bursts to adequately
profile the
28
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
pipe for the barrier coating. Note: the number of shots depends on pressure
applied,
actual conditions of the pipe, degree of any existing buildup inside the pipe,
length of
pipe, # of angles ie: bends, hardness and type and size of abrasive. For this
illustration the
abrasive was aluminum oxide and the length of pipe was 30 meters for 25 mesh.
TABLE 4
25 mesh ( .70mm) Aluminum Oxide 9 Moh scale
Pipe Size/type Air Pressure Abrasive per shot # shots
0.5" type/Cu 2-3 bar 25-80 grams 6
0.5" type/galvanized 3-6 bar 25-80 grams 12-16
0.5" type/CPVC, PEX 3-6 bar 25-80 grams 12-16
0.75" type/Cu 2-3 bar 40-120 grams 6
0.75" type/Galvanized 3-6 bar 40-120 grams 12-16
0.75" type/CPVC, PEX 3-6 bar 40-120 grams 12-16
1.00" type/Cu 2-3 bar 60-160 grams 6
1.00" type/Galvanized 3-6 bar 60-160 grams 14-16
1.00" type/CPVC, PEX 3-6 bar 60-160 grams 14-16
1.5" type/Cu 3-4 bar 75-200 grams 8
1.5" type/Galvanized 4-7 bar 75-200 grams 16-20
1.5" type/CPVC, PEX 4-7 bar 75-200 grams 16-20
1.75" type/Cu 3-4 bar 75-200 grams 8
1.75" type/Galvanized 4-7 bar 75-200 grams 16-20
1.75" type/CPVC, PEX 4-7 bar 75-200 grams 16-20
Table 5 shows results for 16 mesh using Aluminum Oxide.
TABLE 5
16 mesh (1.20m) Aluminum Oxide 9 Moh scale
Pipe Size/type Air pressure Abrasive per shot # of shots
0.5" type Cu 2-3 bar 25-80 grams 5
0.5" type/Galvanized 3-6 bar 25-80 grams 10-12
0.5" type/CPVC, PEX 3-6 bar 25-80 grams 10-12
0.75" type/Cu 2-3 bar 40-120 grams 5
0.75" type/Galvanized 3-6 bar 40-120 grams 10-12
0.75" type/CPVC, PEX 3-6 bar 40-120 grams 10-12
1.00" type/Cu 2-3 bar 60-160 grams 5
1.00" type/Galvanized 3-6 bar 60-160 grams 14-16
1.00" type/CPVC, PEX 3-6 bar 60-160 grams 14-16
1.5" type/Cu 3-4 bar 75-200 grams 8
1.5" type/Galvanized 4-7 bar 75-200 grams 16-20
1.5" type/CPVC, PEX 4-7 bar 75-200 grams 16-20
1.75" type/Cu 3-4 bar 75-200 grams 8
1.75" type/Galvanized 4-7 bar 75-200 grams 16-20
1.75" type/CPVC, PEX 4-7 bar 75-200 grams 16-20
29
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
Table 6 shows 12 mesh with Aluminum Oxide.
TABLE 6
12 mesh (1.68mm) Aluminum Oxide 9 Moh scale
Pipe Size/type Air pressure Abrasive per shot # of shots
0.5" type/Cu 2-3 bar 25-80 grams 5
0.5" type/Galvanized 3-6 bar 25-80 grams 10-12
0.5" type/CPVC,PEX 3-6 bar 25-80 grams 10-12
0.75" type/Cu 2-3 bar 40-120 grams 5
0.75" type/Galvanized 3-6 bar 40-120 grams 10-12
0.75" type/CPVC, PEX 3-6 bar 40-120 grams 10-12
1.00" type/Cu 2-3 bar 60-160 grams 5
1.00" type/Galvanized 3-6 bar 60-160 grams 14-16
1.00" type/CPVC, PEX 3-6 bar 60-160 grams 14-16
1.5" type/Cu 3-4 bar 75-200 grams 8
1.5" type/Galvanized 4-7 bar 75-200 grams 16-20
1.5" type/CPVC, PEX 4-7 bar 75-200 grams 16-20
1.75" type/Cu 3-4 bar 75-200 grams 8
1.75" type/Galvanized 4-7 bar 75-200 grams 16-20
1.75" type/CPVC, PEX 4-7 bar 75-200 grams 16-20
500 ABRASIVE RECLAIM SEPARATOR MODULE (PRE-FILTER)
A pre-filter that can be used with the invention can be one Manufactured By:
Media Blast & Abrasives, Inc. 591 W. Apollo Street Brea, CA 92821
During the pipe profiling stage, the Pre-Filter 500 allows the filtering of
air and
debris from the piping system. When used in conjunction with the dust
collection
equipment 600, fine dust particles and air are captured and filtered
600 DUST COLLECTION FILTER - AIR FILTER VACUUM
An example of an air filter vacuum 600 used with the invention can be one
Manufactured By: Media Blast & Abrasives, Inc. 591 W. Apollo Street, Brea, CA
92821.
During the pipe profiling stage, the air filter vacuum or dust collector 600
is the
final stage of the air filtration process. The dust collector 600 filters the
passing air of
30
WO 2009/070135 CA 02707023 2010-05-27PCT/US2007/024504
fine dust and debris from the piping system after the contaminated air first
passes through
the pre-filter 500 (abrasive reclaim separator module).
During the drying stage the filter 600 can be used simultaneously with
compressor
100 which aids in drawing air through the piping system. During the sanding or
cleaning
stage the filter 600 can be used with compressor 100 the filter 600 which
assists by
drawing air through the piping system. The filter 600 can be used
simultaneously with
the compressor 100 to create a pressure differential in the piping system
which is used to
reduce the effects of friction loss and assists in a pulling action within the
pipe during the
drying and sanding or cleaning stages as well as the coating stage.
700 PORTABLE EPDXY METERING AND DISPENSING UNIT
A metering and dispensing unit 700 used with the invention can be one
Manufactured by: Lily Corporation, 240 South Broadway, Aurora, Illinois 60505-
4205.
The unit 700 can be very mobile and can be used both indoors and outdoors. The
unit 700 requires only a single operator.
The epoxy 800 can be metered to control the amount of epoxy being dispensed.
800 EPDXY BARRIER COATING LEAK SEALANT
A preferred epoxy barrier coating that can be used with the invention can be
one
Manufactured by: CJH, Inc. 2211 Navy Drive, Stockton, CA 95206. The barrier
coating
product used in this process can be a 2-part thermo set resin with a base
resin and a base-
curing agent.
The preferred thermo set resin is mixed as a two-part epoxy that is used in
the
invention. When mixed and applied, it forms a durable barrier coating leak
sealant on
31
CA 02707023 2010-05-27
WO 2009/070135 PCT/US2007/024504
pipe interior surfaces and other substrates. The barrier coating leak sealant
provides a
barrier coating that protects those coated surfaces from the effects caused by
the corrosive
activities associated with the chemistry of water and other reactive materials
on the metal
and other substrates and seal leaks in the pipe.
The epoxy barrier coating sealant can be applied to create a protective
barrier
coating and leak sealant to pipes ranging in size up to approximately 6"and
greater. The
barrier coating can be applied around bends intersections, elbows, tees, to
pipes having
different diameters and make up. The barrier coating leak sealant can be
applied to pipes
in any position e.g.: vertical or horizontal and can be applied as a
protective coating leak
sealant to metal and plastic type pipes used in fire sprinkler systems and
natural gas
systems. At least an approximately 4 mils coating layer can be formed on the
interior
walls of the pipes. The barrier coating leak sealant protects the existing
interior walls and
can also stop leaks in existing pipes which have small openings and cracks,
and the like,
of up to approximately 125 mils in size.
Although the process of application described in this invention includes
application of thermo set resins other types of thermo set resins can be used.
For example, other thermo set resins can be applied in the process, and can
vary
depending upon viscosity, conditions for application including temperature,
diameter of
pipe, length of pipe, type of material pipe comprised of, application
conditions, potable
and non potable water carrying pipes, and based on other conditions and
parameters of
the piping system being cleaned, coated and leaks sealed by the invention.
Other thermo set type resins that can be used include but are not limited to
and
can be one of many that can be obtained by numerous suppliers such as but not
limited to:
32
WO 2009/070135 CA 02707023 2010-05-27PCT/US2007/024504
Dow Chemical, Huntsmans Advances Material, formerly Ciba Giegy and Resolution
Polymers, formerly Shell Chemical.
Fillers used in the process preferably can contain a mixture of low and high
aspect
ratio particles, acicular shaped particles, and plate like particles. The
fillers can be inert
material comprised of any one of the group of epoxy, glass, plastic foam
parts, cork, clay.
Although the novel invention can be applied to all types of metal pipes such
as but
not limited to copper pipes, steel pipes, galvanized pipes, and cast iron
pipes, the
invention can be applied to pipes made of other materials such as but not
limited to
plastics, PEX(cross-linked polyethylene) type pipes, CPVC(Chlorinated
Polyvinyl
Chloride) type pipes, PVC(polyvinyl chloride), composite materials,
polybutidylene, and
the like.
Additionally, small cracks and holes in plastic type and metal pipes can also
be
fixed "in place" by the barrier coating leak sealant. A coating of at least
approximately 4
mils on the interior pipe walls, can be used for sealing leaks up to
approximately 125 mils
in size.
Fig. 4 shows an illustration of the effects of deburring and water turbulence,
before and after the cleaning and coating process is used. Before the cleaning
process,
water turbulence can be created by water flowing against and over an unburred
joint or
excess solder at a joint, which can become further clogged and/or damaged as
described
above. With the subject invention cleaning operation, the burr or excess
solder is reduced
or eliminated in place, substantially improving water flow, flow of coating
material and
reducing effects of water turbulence, that can include excessive wear and
damage.
The abrasive technique in the subject invention greatly reduces or eliminates
the lip(s)
associated with undreamed or improperly reamed pipes.
33
CA 02707023 2010-05-27
WO 2009/070135
PCT/US2007/024504
Table 7 shows a comparison of prior art techniques(Japanese A-S Method Table
4-3 and NAF patent 5,007,461) compared to the novel ACE method described in
the
subject invention.
TABLE 7
Material Diameter Length
A-S Method NAF Amount of Abrasive Used ACE Method
Steel Pipe .5" _ 1" 10-20m
5-10 kg .84-2.56 kg
Steel Pipe 1.25"-1.75" 20-30m
20-30 kg 1.2-4.0 kg
Steel Pipe 1.00 ¨ 1.5" 70m
200 kg 1.2 ¨ 4.0 kg
The kg amounts are cumulative for the total amount of abrasive used.
In the subject invention, the unique combination of using small bursts of
abrasive
material combined with compressed air pushing and a vacuum pulling the
material greatly
improved the overall sanding performance. In the case of pipes having a
diameter of .5"
to 1" diameter, the same (similar) cleaning results were achieved using about
74 to
about 83% less abrasive material. In the case of 1.25"to 1.75" diameter pipes
approximately 80 to approximately 92% efficiencies were noted.
In addition the push/pull method also reduced the overall impact on the inside
walls of the piping system. The operator noted that they were able to clean
pipes using
this method that had thinner side walls, resulting in less damage to the
interior of the pipe
when compared to the conventional streaming of larger qualities of abrasive
into the one
directional pushing air stream.
The use of burst sanding in which the abrasive material is sent through the
pipe in
smaller quantities and is allowed to exit before introducing the next burst
makes the
34
CA 02707023 2012-08-27
process more efficient, reduces the negative effects of simply adding a stream
of material
which in turn reduces the air flow and pressure inside the pipe which and
reduces the
impact associated with the abrasive material striking the inside walls of the
pipe. The
vacuum assists by reducing friction loss in the run of the pipe, assist as
well by drawing
debris and the abrasive out of the pipe.
The prior art NAF used 1 Bar, and A-S Method used 2.5-3 kg/cm2 or 2.45-2.94
Bar. The subject invention's (ACE's) lower end of the scale air pressures were
within
the average range when compared to the A-S Method for respective pipe
diameters i.e.: 3
bar on average, but the subject invention(ACE) used a vacuum drawing air to
assist.
Although the preferred applications for the invention are described with
building
piping systems, the invention can have other applications such as but not
limited to
include piping systems for swimming pools, underground pipes, in-slab piping
systems,
piping under driveways, various liquid transmission lines, tubes contained in
heating and
cooling units, tubing in radiators, radiant in floor heaters, chillers and
heat exchange
units, and the like.
The scope of the claims should not be limited by the preferred embodiments set
forth in the examples, but should be given the broadest interpretation
consistent with the
description as a whole.
35
