Note: Descriptions are shown in the official language in which they were submitted.
CA 2965568 2017-04-28
NS-536A
POLYMER-LINED PIPES AND FITTINGS WITH REPLACEABLE
COMPONENTS
Inventors: Soon Won MOON; Stefano CHIOVELLI; Shane D. RYAN
Assignee: Syncrude Canada Ltd. In Trust for the Owners of the Syncrude Project
Field of the Invention
[0001] The present invention relates generally to pipes and fittings having a
polymer liner,
and having replaceable inlet and/or outlet components.
Background
[0002] Due to superior wear and corrosion resistance, polymer-lined pipes and
fittings have
been used in many aggressive slurry services in the oil sands mining industry.
Rubbers and
polyurethanes are the main polymeric liner materials currently being used.
Liner thickness is
commensurate with length of the pipe run, and can exceed 1 inch in very long
pipe runs.
However, liner wear still occurs, and in particular, the inlets and outlets
often experience the
most serious liner wear. This is mainly due to pipe misalignment where the
resultant step
change in pipe inside diameter (ID) can cause so-called 'liner wash-out' due
to either direct
impingement from the slurry particles (prior art Fig. 1A) or slurry
turbulence. The wash-out
area is localized, normally less than a foot from the pipe connection between
the upstream
pipe (UP) and the downstream pipe (DP). Liner wear is often accelerated in
that localized
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wear zone, resulting in early retirement of the spool even though most areas
are in serviceable
condition.
[0003] When two different piping materials having significantly different wear
rates are
connected side by side, ID mismatch can develop during pipe operation and this
can also lead
to accelerated liner wear near the pipe connection. Piping components can have
different
geometries (i.e. elbows vs. straight spools) having different wear profiles
and rotation
strategies and in this case, step change in ID can appear after pipe rotation.
It is challenging to
achieve ID match throughout the pipeline during operation.
[0004] Currently, field repair kits are used to address the localized liner
wear. Repair kits are
composed of two-part mixing components: once they are mixed together and
applied onto the
damage area, solid repair patch is formed after curing. Proper surface
preparation (solvent
cleaning, mechanical buffing on the liner adjacent to the damage area), good
environmental
control (temperature, humidity), and skillsets of the applicators are key to
success. Since
repairs are conducted in the field during outages where limited time and
resources are
available, it is challenging to achieve consistent repair quality.
Accordingly, there remains a
need for more efficient and reliable technologies to achieve smooth ID
transition in polymer-
lined pipeline.
[0005] When there is step-change in inside diameter at pipe connection due to
different inside
diameters (IDs) of mating pipes (prior art Fig. 1B), transition rings can be
used for smooth ID
transition. Transition rings use abrasion and wear resistant alloy linings
such as tungsten
carbide, which introduces significant cost increase. Also, transition rings
are flange-
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connected, thereby incorporating more pipe connection points with a resulting
increase in the
possibility of ID mismatch.
Summary Of The Invention
[0006] In one aspect, the invention may comprise a polymer-lined pipe or
fitting having
replaceable components, wherein the inlet and/or the outlet of the polymer-
lined pipe or
fitting is adapted to receive a replaceable component to form a continuous
bore. The
replaceable component may comprise:
a. an outer ring having at least a portion with an outside diameter matching
an
inside diameter of the pipe or fitting; and
b. a polymer liner bonded to the outer ring and having an inside diameter
matching the inside diameter of the polymer liner of the pipe or fitting.
100071 In some embodiments, the outer ring may comprise two or more rings,
separated by
the polymer liner, or may comprise a spirally wound ring, or may be elongated
and tapered to
be a portion of a truncated cone, wherein a first end of the outer ring
contacts an inside
surface of the pipe and a second end does not.
Brief Description of the Drawings
[0008] The following drawings form part of the specification and are included
to further
demonstrate certain embodiments or various aspects of the invention. In some
instances,
embodiments of the invention can be best understood by referring to the
accompanying
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drawings in combination with the detailed description presented herein. The
description and
accompanying drawings may highlight a certain specific example, or a certain
aspect of the
invention. However, one skilled in the art will understand that portions of
the example or
aspect may be used in combination with other examples or aspects of the
invention.
[0009] Figures IA and 1B are cross-sectional views of prior art pipes
assembled with an
adjacent pipe or fitting, or a transition ring.
[0010] Figure 2 is a longitudinal cross-sectional view of one embodiment of a
pipe, with
perspective views of replaceable components at both ends of the pipe.
[0011] Figure 3 is a longitudinal cross-sectional view of the embodiment shown
in Figure 2,
showing the replaceable components with a square cut end.
[0012] Figure 4 is a longitudinal cross-sectional view of the embodiment shown
in Figure 2,
showing the replaceable components with an angle cut end,
[0013] Figure 5 is a longitudinal cross-sectional view of an alternative
embodiment of Figure
2, showing outer ring of the replaceable components is lined, coated, or
encapsulated for
corrosion protection,
[0014] Figure 6 is a longitudinal cross-sectional view of pipe connection,
showing the
replaceable component being interlocked between parent and mating pipes.
[0015] Figure 7 is a cross-sectional view of replaceable components, showing
the polymer
liner protruding beyond two ends of the outer ring. When interlocked between
parent and
mating pipes, the protruded polymer is compressed to make compression fit,
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[0016] Figure 8 is a longitudinal cross-sectional view of pipe connection,
showing
replaceable components with tapered liner to achieve smooth ID transition.
[0017] Figure 9 is a longitudinal cross-sectional view of pipe connection,
showing
replaceable components with tapered liner to achieve smooth ID transition.
[0018] Figure 10 shows cross-sectional views of a replaceable component, each
showing a
replaceable component assembled from multiple sections.
100191 Figure 11 shows a longitudinal cross-sectional view of an alternative
embodiment,
where the outer ring comprises a plurality of narrow rings, gapped with the
polymer liner.
[0020] Figure 12 shows a longitudinal cross-sectional view of an alternative
embodiment,
where the outer ring is tapered to reduce surface area contact with the pipe.
100211 Figure 13 shows a longitudinal cross-sectional view of an alternative
embodiment,
where the outer ring comprises a plurality of narrow rings, gapped with the
polymer liner, and
having smaller diameters.
[0022] Figure 14 shows a longitudinal cross-sectional view of an alternative
embodiment,
where the outer ring is tapered, and an end ring.
[0023] Figure 15 shows a longitudinal cross-sectional view of an alternative
embodiment,
where the outer ring comprises a plurality of narrow rings, gapped with the
polymer liner, and
an end ring.
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Detailed Description
[0024] This invention relates to polymer-lined pipes and fittings with
replaceable inlet/outlet
components (10). The replaceable component (10) comprises an outer ring or
sleeve (12) and
an inner polymer liner (14).
[0025] The outer ring (12) is preferably a metal ring, such as steel, but may
be made from any
suitable rigid material which can provide structural integrity to support the
replaceable
component in place. The outer ring may be made of a non-metallic material such
as fiberglass
reinforced plastic.
[0026] The polymer liner (L) of the parent (P) pipe or fitting, and the
polymer liner (14) of
the replaceable component, may comprise any polymer suitable for lining pipes
used for
mining slurry transport, and are well known in the art. Especially, elastomers
have
demonstrated excellent wear performance in many slurry applications. An
elastomer is a
polymer having the property of elasticity, whereby the polymer deforms in
response to the
application of stress, and substantially recovers its original foul" when the
stress is removed.
Elastomers typically have a low Young's modulus and a high yield strain, as is
well known in
the art. Suitable elastomers include, without limitation, natural or synthetic
rubbers,
polyurethanes, thermoplastic polymers, and other thermoset polymers. Polymer
liner can
have fillers such as carbon black, Kevlar fibers or nano-fillers for higher
wear and tear
resistance, as is well known in the art.
[0027] It is preferable for the polymer liner (14) of the replaceable
component to be the same
or similar material as the polymer liner (L) of the pipe (P) or fitting it is
installed into, to
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mitigate uneven wear performance throughout the pipe. In one embodiment, the
polymer liner
(14) is fully bonded onto the outer ring (12) such as through a molding,
casting or vulcanizing
process.
[0028] The inlet and/or the outlet of the polymer-lined pipe or fitting is
configured to receive
the replaceable components as shown in Fig. 2. Essentially, the metallic shell
of the pipe (P)
extends beyond the polymer liner (L) by a distance substantially equal to the
length of the
replaceable component. In one embodiment, the outer diameter of the outer ring
(12) should
closely match the inside diameter of the pipe (P) in the groove, while the
inside diameter of
the polymer liner (14) of the replaceable components should closely match the
inside diameter
of the polymer liner (L) of the pipe (P).
[0029] The end of the replaceable components can be square-cut as shown in
Figure 3 or
angle-cut to make the mating interface between the replaceable component and
the parent
pipe away from the direction of the incoming slurry stream, as shown in Figure
4.
[0030] In one embodiment, the outer ring (12) can be encapsulated by the
polymer liner (14)
to prevent any possible corrosion on the metallic component (Figure 5).
Alternatively, the
exposed metallic surfaces in the replaceable components can be separately
lined or coated.
The exposed metallic surfaces of the parent pipe (P) in the groove can be
lined or coated to
prevent possible corrosion on the parent pipe. The replaceable components (10)
can be glued
to the pipe (P) or fitting for additional stability. The adhesive should have
sufficient strength
to provide proper stability during operation, however still allow separation
when required for
replacement. Sealing agents compatible with the polymer liner (L, 14), such as
those found in
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field repair kits may also be used to fill any gaps, seams, and rough surface
profiles to achieve
smooth bore.
[0031] The replaceable component (10) can be interlocked between the parent
pipe (P) and a
mating pipe (P'), as shown in Figure 6. A tight seal between pipes (P, P') may
be achieved
with tight tolerance control and a compression-fit design. For example, the
polymer liner (14)
in the replaceable components (10) may be slightly oversized in the axial
direction, so as for
polymer liner to protrude slightly beyond two ends of the outer ring (Figure
7). Thus, when
interlocked between parent and mating pipes, the protruded polymer can be
compressed to
make compression fit.
[0032] The polymer-lined pipes and fittings with replaceable inlet/outlet
components of this
invention disclosure can be used as an alternative to transition rings to
accommodate mating
between pipes with different inside diameters. The polymer liner (14) in the
replaceable
component (10) may be tapered with increasing diameter (Figure 8) or
decreasing diameter
(Figure 9) so as to form a conically shaped inner bore. In each case, the
smooth transition in
inside diameter can be achieved at the pipe connection. The polymer liner (14)
may be
tapered by molding or casting in the desired shape, or by machining flat-faced
liner.
[0033] For easy rotation or replacement, the replaceable components can be
sectioned into
multiple pieces (i.e. two, three or four pieces) as shown by the dashed lines
in Figure 10.
[0034] In an alternative embodiment, the replaceable component may comprise
two or more
outer rings (20), which may be of narrower width than if a single outer ring
is used. As
shown in Figure 11, the multiple rings (20) may be uniformly spaced, with the
polymer liner
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(14) disposed in the gaps between adjacent rings. In another embodiment, the
replaceable
component may comprise an outer ring which is a spirally wound ring, leading
to increased
flexibility of the replaceable ring and the resultant benefits in
assembly/disassembly during
installation.
[0035] In another alternative embodiment, as shown in Figure 12, the outer
ring (30) may be
elongated and have a slight taper, to have a smaller diameter at one end. As a
result, the outer
ring may have the shape of a portion of a truncated cone. The polymer liner
(14) may wrap
around the reduced diameter end, to form a lip (16) which seals against the
inside of the pipe
(P). This configuration reduces the contact area between replaceable component
(10) and the
pipe (P), which may make insertion and removal more convenient. In another
variation, as
shown in Figure 13, two or more outer rings (20) with a slightly diminishing
diameter may be
provided, which also has the effect of reducing contact area between the
replaceable
component (10) and the pipe.
[0036] In a further alternative example, as shown in Figure 14, a combination
of a truncated
cone ring (30) together with a single end ring (22) disposed within the lip
(16) may provide
the combination of easy installation or removal, and enhanced structural
integrity.
[0037] In yet another alternative, a combination of multiple rings (20) with
slightly
diminishing diameters, and an end ring (22) disposed within the lip may be
used, as shown in
Figure 15.
[0038] Once the replaceable component has serious liner wear on the bottom,
only the
replaceable component can be rotated. This can bring significant benefits in
maintenance
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compared to rotating the entire pipe or fitting. Once the replaceable
component is seriously
worn out around the circumference, only the replaceable component can be
replaced. This can
bring significant benefits in maintenance compared to replacing the entire
pipe or fitting. This
is similar to replacing ink cartridge in printers, not requiring significant
time, environmental
control, and skillsets as being required for repair kits.
[0039] It is believed by using the replaceable inlet/outlet components (10)
described herein,
the lifecycle of the polymer-lined pipes or fittings can be extended. Also, it
is hoped that by
using the replaceable components with a tapered liner, significant cost
benefit can be achieved
by avoiding use of expensive transition rings.
[0040] Definitions and Interpretation
[0041] The singular forms "a," "an," and "the" include plural reference unless
the context
clearly dictates otherwise. It is further noted that the claims may be drafted
to exclude any
optional element. As such, this statement is intended to serve as antecedent
basis for the use
of exclusive terminology, such as "solely," "only," and the like, in
connection with the
recitation of claim elements or use of a "negative" limitation. The terms
"preferably,"
"preferred," "prefer," "optionally," "may," and similar terms are used to
indicate that an item,
condition or step being referred to is an optional (not required) feature of
the invention.
[0042] The term "and/or" means any one of the items, any combination of the
items, or all of
the items with which this term is associated. The phrase "one or more" is
readily understood
by one of skill in the art, particularly when read in context of its usage.
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[00431 As will be understood by one skilled in the art, for any and all
purposes, particularly in
terms of providing a written description, all ranges recited herein also
encompass any and all
possible sub-ranges and combinations of sub-ranges thereof, as well as the
individual values
making up the range, particularly integer values. A recited range of values
includes each
specific value, integer, decimal, or identity within the range. Any listed
range can be easily
recognized as sufficiently describing and enabling the same range being broken
down into at
least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting
example, each range
discussed herein can be readily broken down into a lower third, middle third
and upper third,
etc.
100441 As will also be understood by one skilled in the art, all language such
as "up to", "at
least", "greater than", "less than", "more than", "or more", and the like,
include the number
recited and such terms refer to ranges that can be subsequently broken down
into sub-ranges
as discussed above. In the same manner, all ratios recited herein also include
all sub-ratios
falling within the broader ratio. Accordingly, specific values recited for
radicals, substituents,
and ranges, are for illustration only; they do not exclude other defined
values or other values
within defined ranges for radicals and substituents.
100451 One skilled in the art will also readily recognize that where members
are grouped
together in a common manner, such as in a Markush group, the invention
encompasses not
only the entire group listed as a whole, but each member of the group
individually and all
possible subgroups of the main group. Additionally, for all purposes, the
invention
encompasses not only the main group, but also the main group absent one or
more of the
group members. The invention therefore envisages the explicit exclusion of any
one or more
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of members of a recited group. Accordingly, provisos may apply to any of the
disclosed
categories or embodiments whereby any one or more of the recited elements,
species, or
embodiments, may be excluded from such categories or embodiments, for example,
as used in
an explicit negative limitation.
[0046] As will be apparent to those skilled in the art, various modifications,
adaptations and
variations of the foregoing specific disclosure can be made without departing
from the scope
of the invention claimed herein. The various features and elements of the
invention described
herein may be combined in a manner different than the specific examples
described or
claimed herein without departing from the scope of the invention. In other
words, any
element or feature may be combined with any other element or feature in
different
embodiments, unless there is an obvious or inherent incompatibility between
the two, or it is
specifically excluded.
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