SYSTEMS, COMPOSITIONS, AND METHODS FOR CURING LEAKAGES IN PIPES

Abstract

The present invention provides leakage plugging devices and methods for sealing a leakage at a remote site in a pipe, the device including a porous carrier plug of a deformable material including pores and at least one sealant composition disposed in the pores, wherein the porous carrier plug is adapted to transport the at least one sealant composition from a first site to a remote site and to plug the leakage at the remote site.

Claims

1. A leakage plugging device for sealing a leakage at a remote site in a pipe, the device comprising: a. a porous carrier plug of a deformable material comprising pores carrying a first density enhancing dried composition; and b. at least one sealant composition disposed in said pores, said at least one sealant composition comprising at least one filler, a premixed hardening agent, at least one surfactant, and at least one resinous agent, wherein said porous carrier plug is adapted to transport said at least one sealant composition from a first site to a remote site and to plug said leakage at said remote site.

2. A leakage plugging device according to claim 1, wherein said device is of a first dimension and said leakage is of a second dimension.

3. A leakage plugging device according to claim 2, wherein said first dimension is in a range of 0.1 mm to 100 mm.

4. A leakage plugging device according to claim 3, wherein said first dimension is in a range of 1 mm to 60 mm.

5. A leakage plugging device according to claim 5, wherein said first dimension is in a range of 2 mm to 15 mm.

6. A leakage plugging device according to claim 1, wherein said porous carrier plug or a multiplicity of porous carrier plug filled with at least one sealant composition adapted to penetrate said remote site.

7. A leakage plugging device according to claim 6, wherein said porous carrier plug or a multiplicity of porous carrier plug are adapted to fill at least one of a hole, a crack and breakage causing said leakage at said remote site.

8. A leakage plugging device according to claim 7, wherein said porous carrier plug or a multiplicity of porous carrier plug are adapted to be condensed at said remote site to form a condensed carrier plug.

9. A leakage plugging device according to claim 8, wherein said at least one sealant composition resides within said condensed carrier plug or plugs to fill said at least one of a hole, a crack and breakage causing leakage at said remote site.

10. A leakage plugging device according to claim 1, wherein said porous carrier plug or plugs are of a shape selected from the group consisting of wedge-shaped, rhomboid, cubic, polygon, spherical, ovular, egg-shaped, diamond-shaped and pyramid-shaped.

11. A leakage plugging device according to claim 1, wherein said porous carrier plug or plugs comprise a polymer selected from the group consisting of a foamed material, a polyurethane material, an expanded material, a natural material and a biodegradable porous material.

12. A leakage plugging device according to claim 1, wherein said at least one sealant composition comprises two sealant compositions.

13. A leakage plugging device according to claim 12, wherein said deformable material comprises polyurethane of a density of 15-30 kg/m.sup.3, and said at least one sealant composition further comprises a fatty acid liquid composition.

14. A leakage plugging device according to claim 13, wherein said fatty acid liquid composition comprises a vegetable oil.

15. A leakage plugging device according to claim 13, wherein said vegetable oil is selected from the group consisting of sunflower oil, safflower oil, corn oil, soybean oil, olive oil, canola oil and rapeseed oil.

16. A leakage plugging device according to claim 7, wherein said porous carrier plug is adapted to form a narrow head part and wider tail part, wherein said head part is lodged within said remote site.

17. A leakage plugging device according to claim 16, wherein an average density of said device is increased at least twofold after plugging said site.

18. A leakage plugging device according to claim 17, wherein an average density of said narrow head part is increased at least threefold after plugging said site.

19. A leakage plugging device according to claim 1, wherein said first density enhancing dried composition comprises at least one polymer, at least one filler and at least one gelling agent.

20-43. (canceled)

44. A leakage plugging device according to claim 3, wherein said third dimension is in a range of 0.1 mm to 30 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The invention will now be described in connection with certain preferred embodiments with reference to the following illustrative figures so that it may be more fully understood.

[0051] With specific reference now to the figures in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of the preferred embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the invention. In this regard, no attempt is made to show structural details of the invention in more detail than is necessary for a fundamental understanding of the invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the invention may be embodied in practice.

[0052] In the drawings:

[0053] FIGS. 1A-1C show simplified images of a leakage plugging device for in situ repair of a pipe, in accordance with an embodiment of the present invention;

[0054] FIG. 2 shows a simplified image of a leakage plugging device for in situ repair of a pipe, in accordance with an embodiment of the present invention;

[0055] FIG. 3 shows a simplified schematic diagram of the end product of repair—the pipe from the outside after repair with a sealant plug, in accordance with an embodiment of the present invention;

[0056] FIG. 4 shows a simplified schematic diagram of the end product of repair—the pipe from the inside after repair with a sealant plug, in accordance with an embodiment of the present invention; and

[0057] FIG. 5 shows a simplified flowchart of a method for the preparation of a sealant plug in accordance with an embodiment of the present invention.

[0058] In all the figures similar reference numerals identify similar parts.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0059] In the detailed description, numerous specific details are set forth in order to provide a thorough understanding of the invention. However, it will be understood by those skilled in the art that these are specific embodiments and that the present invention may be practiced also in different ways that embody the characterizing features of the invention as described and claimed herein.

[0060] The present invention provides systems and methods for repairing leaking pipes in situ, apparatus and systems for method implementation, materials and sealant compositions.

[0061] The present invention provides leakage plugging devices and methods for sealing a leakage at a remote site in a pipe, the device including a polymeric carrier plug of a deformable material including pores and at least one sealant composition disposed in the pores, wherein the polymeric carrier plug is adapted to transport the at least one sealant composition from a first site to a remote site and to plug the leakage at the remote site.

[0062] Prior art systems often have the following drawback, namely that hardening material which is not in the optimal ratio is fed into the pipeline. Additionally, after exposure of the material in the hole in the pipe, it can remain and may also exit pressure pipe.

[0063] One of the aims of the present invention is to eliminate the drawbacks of the prior art, that is, the development of a reliable pipe repair process from the inside, as well as development of basic devices, materials and other items needed for reliable pipe repair in real conditions.

[0064] When the carrier plugs that are suspended in a composite sealant composition approach the holes in the pipe, they go into the holes and plug them. The remaining plugs and composition are ejected from the pipe and disposed of. Carrier plugs, which have come through the holes in the pipe after the specified time harden and form strong plug, termed herein leakage plugging devices. The pipe is cleaned from residues of the additional material/sealant compositions and plugs. This leaves the final pipeline repaired with in situ leakage plugging device(s) and no/negligible leakage.

[0065] Reference is now made to FIGS. 1A-1C, which show simplified images of a leakage plugging device 100, 110, 120, for in situ repair of a pipe, in accordance with an embodiment of the present invention.

[0066] Device 100 is comprises a polymer carrier plug 102 of general three-dimensional shape before use and at least one sealant composition carried therein (not seen). The carrier plug has a height h.sub.1, width, l.sub.1 and thickness w, before use. After use its shape is changed 110 and forms a head section 112 and tail section 114. The head section is of a length h.sub.2 and diameter d. The head section is often of a cylindrical shape if it stoppers a circular hole or often termed pinhole. The tail section may be of a regular or irregular shape of height h.sub.3 and width l.sub.2. The dimensions after curing (use) depend on the degree of compacting/increasing density thereof. The density may typically increase 1-10 fold and dimensions decrease respectively. The density is typically non-uniform, being greater in the head section and lower in the tail section.

[0067] FIG. 2 shows further simplified images of a leakage plugging device for in situ repair of a pipe before use 210, during the curing process 210 and after the curing process 220.

[0068] FIG. 3 shows a simplified schematic diagram of the end product of repair—a pipe from the outside after repair 302 with a sealant plug 300 showing part of head section 112.

[0069] FIG. 4 shows a simplified schematic diagram 400 of the end product of repair—the pipe from the inside after repair 402 with a sealant plug tail (partial view) 114, in accordance with an embodiment of the present invention.

[0070] Sealant compositions are introduced into carrier plugs. The unloaded carrier plugs are constructed and configured to: [0071] a. receive at least one sealant composition thereby forming a loaded carrier plug; [0072] b. transport the at least one sealant composition along the pipe; [0073] c. enable the at least one sealant composition to harden and/or expand/and or polymerize and/or be retained in situ at the leakage site (hole/crack/other) thereby forming a leakage plugging device.

[0074] The carrier plugs thus form a novel system for plugging/sealing leakage sites in pipes.

[0075] The sealant compositions of the present invention may further comprise other particles/solids which remain in the leakage site outside the carrier plugs.

[0076] A composite sealant composition may comprise: [0077] a. one or more sealant compositions; [0078] b. one or more type of loaded or unloaded carrier plugs; [0079] c. optionally, at least one filler or particulate; and [0080] d. other optional additives.

[0081] The composite sealant composition comprising some or all of the above, are adapted to be introduced into a pipeline by the help of special devices.

[0082] Reference is now made to FIG. 5, which shows a simplified flowchart 500 of a method for the preparation of a sealant plug in accordance with an embodiment of the present invention.

[0083] In a first mixing step 502, a polymeric condensable material 501 is introduced into a first solution or suspension 503. The polymeric condensable material, may be, for example, polyurethane of a density of 15-30 kg/m.sup.3. According to some embodiments, the density is 15-18 kg/m.sup.3.

[0084] According to some embodiments, the first solution (solution 1, FIG. 5) is in accordance with that described in U.S. Pat. No. 6,057,378 (FIG. 3 and example 1), incorporated herein by reference.

[0085] According to some other embodiments, solution 503 comprises: [0086] a) At least one polymer, selected from polyurethane, polyacrylate, rubber, plastic, cellulose and combinations thereof in a weight ratio of 5-20% wt/wt. [0087] b) At least one organic or inorganic filler selected from carbon ash, aluminum hydroxide, calcium carbonate, calcium hydroxide, magnesium hydroxide, magnesium carbonate, titanium hydroxide, silica, similar fillers and combinations thereof in a weight ratio of 40-90% wt/wt. [0088] c) At least one surfactant selected from an ionic surfactant, an anionic surfactant, a detergent, an edible oil, an inedible oil and combinations thereof in a weight ratio of 0.01 to 4% wt/wt. [0089] d) At least one gelling agent selected from carrageenan, agar agar, hydroxymethylcellulose, hydroxyethyl cellulose, hydroxypropyl cellulose and combinations thereof in a weight ratio of 0.01 to 4% wt/wt. [0090] e) An antifoam in a weight ratio of 0.01 to 4% wt/wt. [0091] f) A coloring agent selected from a water soluble dye, a water insoluble dye, a paint, an oxide, a metal oxide and combinations thereof in a weight ratio of 0.01 to 1% wt/wt.

[0092] The resultant wet impregnated material 507 is typically of a density of 30-150 kg/m.sup.3.

[0093] The wet impregnated material 507 is then dried in a drying step 504. The drying step may be conducted in a belt dryer, tray drier, oven or any other commercially available drying method, known in the art. The resultant product is a dried impregnated material 509.

[0094] In parallel, a second solution or suspension 515 is prepared from a first composition 511 and a second composition 513 in a second mixing step 508. The first composition acts as a hardener.

[0095] Some non-limiting examples of the first composition 511 (A) are:— [0096] a) A premixed hardening agent comprising polyoxypropylene triamine in a weight ratio of 50 to 90% wt/wt. [0097] b) At least one organic or inorganic filler selected from carbon ash, aluminum hydroxide, calcium carbonate, calcium hydroxide, magnesium hydroxide, magnesium carbonate, titanium hydroxide, silica, similar fillers and combinations thereof in a weight ratio of 2-20% wt/wt. [0098] c) A coloring agent selected from a water soluble dye, a water insoluble dye, a paint, an oxide, a metal oxide and combinations thereof in a weight ratio of 0.01 to 1% wt/wt. [0099] d) At least one surfactant selected from an ionic surfactant, an anionic surfactant, a detergent, an edible oil, an inedible oil and combinations thereof in a weight ratio of 0.01 to 15% wt/wt. [0100] e) At least one aqueous agent selected from sea water, tap water, distilled water, ice and combinations thereof in a weight ratio of 0.01 to 15% wt/wt.

[0101] The second composition (B) 513, FIG. 5 acts as a resinous composition. Some examples of the second composition (B) are:— [0102] a) At least one resinous agent selected from bisphenol A, glycidyl ether, bisphenol S, EPI-001 and combinations thereof in a weight ratio of 20 to 90% wt/wt. [0103] b) At least one organic or inorganic filler selected from carbon ash, aluminum hydroxide, calcium carbonate, calcium hydroxide, magnesium hydroxide, magnesium carbonate, titanium hydroxide, silica, similar fillers and combinations thereof in a weight ratio of 2-20% wt/wt. [0104] c) A coloring agent selected from a water soluble dye, a water insoluble dye, a paint, an oxide, a metal oxide and combinations thereof in a weight ratio of 0.01 to 1% wt/wt. [0105] d) At least one surfactant selected from an ionic surfactant, an anionic surfactant, a detergent, an edible oil, an inedible oil and combinations thereof in a weight ratio of 0.01 to 15% wt/wt. [0106] e) At least one aqueous agent selected from sea water, tap water, distilled water, ice and combinations thereof in a weight ratio of 0.01 to 15% wt/wt.

[0107] Thereafter, in a cutting step 506, the dried impregnated material 509 is cut either manually or by machine into little chips in a cutting step 506 to form chips 517.

[0108] The chips are typically wedge-shaped having dimensions, such as 0.1-8 cm height, 0.1-6 cm width and 1-30 mm thickness. Additionally or alternatively, the chips may be arrow-shaped, cylindrical, cubic or any other suitable shape.

[0109] The chips are mixed with second solution or suspension 515 in a third mixing step 510 to form a plug product 519. According to some embodiments, the chips may be placed under pressure, and upon release, they will suck up some of the second solution or suspension. The plug product 519 may be used for plugging a hole or crack in a pipe.

[0110] Some examples of the sealant compositions are provided in the following examples.

Example 1

[0111] In this example, the values percent of the fundamental materials A1 and B1, and exemplary weight concentration ranges outside elements.

[0112] Composition of material A1(%):

[0113] Bisphenol A 50.0-70.0(%)

[0114] Glycidyl Ether 7.0-20.0(%)

[0115] Inert powdered filler 10.0-20.0(%)

[0116] Clay 0-2.0(%)

[0117] A detergent precursor 0-5.0(%)

[0118] A corrosion resistance provider 0-3.0(%)

[0119] Hydrophobic liquid filler 2.0-5.0(%)

[0120] Inert liquid filler 4.0-7.0(%)

[0121] Silicon dioxide 0.5-1.0(%)

[0122] Iron oxide hydroxyl 0.1-0.5(%)

[0123] Composition of material B1(%):

[0124] Diethylene thiamine 0-23.0(%)

[0125] 4.4-isopropylidenediphenol 0-16.0(%)

[0126] Isophorondiamine 0-31.0(%)

[0127] Benzyl alcohol 0-31.0(%)

[0128] A surfactant 0-1.0(%)

[0129] Detergent precursor 0-5.0(%)

[0130] Inert powdered filler 5-15.0(%)

[0131] Polyoxypropylene thiamine 0-70.0(%)

[0132] A corrosion resistance provider 0-5.0(%)

[0133] Clay 0-4.0(%)

[0134] 4-nonylphenol, branched 0-15.0(%)

[0135] Silicon dioxide 0.2-2.0(%)

[0136] Iron oxide hydroxyl 0-0.6(%)

[0137] Inert liquid filler 1-6.0(%)

[0138] Hydrophobic liquid filler 1.0-6.0(%)

These materials once cured serve to provide robust long term plugging of the leakage with a longevity of similar order of magnitude to the remaining useful life of the host pipe. They also serve to withstand changing environmental conditions. The cured product having a similar thermal coefficient in order of magnitude to the host pipe typically expands and contracts under changing temperatures in unison with the host pipe so as not to create a secondary leak under these conditions.

Example 2

[0139] This example shows the composition of the sealant plug covering the hole in the pipe and the pipe remains in the field of repair of.

TABLE-US-00001 CAS # Name component material Content, % 80-05-7 Bisphenol A 39 668609-97-2 Glycidyl ether 11 21645-51-2 Inert powder filler 20 (synthetic aluminum 67-53-0 A corrosion resistance provider 3 120962-03 Rapeseed oil 6.1 112945-52 Silicon dioxide 1 20344-49 Iron oxide hydroxyl 0.3 1140-40-0 Diethylene thiamine 3.5 80-05-74.4 Isopropylidenediphenol 2.5 2855-13-2 Isophorondiamine 4 100-51-6 Benzyl alcohol 4 9009-54-5 Polyurethane 2 9003-04-7 Polyacrylate (Tamcril-15) 3 9004-62-9 Berol NP-10 ( 9) 0.4 9004-62-0 Hydroxyethyl cellulose 0.1 8050-81-5 Antifoam APRU DF-7010 0.1

[0140] The references cited herein teach many principles that are applicable to the present invention. Therefore the full contents of these publications are incorporated by reference herein where appropriate for teachings of additional or alternative details, features and/or technical background. It is to be understood that the invention is not limited in its application to the details set forth in the description contained herein or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Those skilled in the art will readily appreciate that various modifications and changes can be applied to the embodiments of the invention as hereinbefore described without departing from its scope, defined in and by the appended claims.