Pipelines and other similar structures transport fluids and other materials, such as oil, water, and sewage, over long distances and through various medium, e.g., above ground, below ground, underwater, through marshes, etc. Pipelines are typically exposed to all types of climates, weather, and temperatures. For example, some pipelines may be exposed to extreme climates in which the temperature may reach −65 degrees Fahrenheit or lower. In order to control heat loss from the materials carried within structures such as pipelines, the structures may be insulated.
A method of adding insulation to a pipeline, a pipeline, and an insulation panel for a pipeline are disclosed by the present application.
In one exemplary embodiment, a method of adding insulation to a pipeline having an existing insulation system is disclosed. The existing insulation system comprises insulation disposed around a pipe of the pipeline and a hard shell that encases the insulation disposed around the pipe. The method of adding insulation includes delivering an insulation panel to the pipeline. The insulation panel includes one or more pieces of compressible fiberglass insulation material having an R value per inch of thickness from about 2 to about 13 hr-sq ft-deg F/Btu measured at 75 degrees Fahrenheit. The insulation material is configured to return substantially back to its original thickness and density after being compressed. The insulation panel also includes a substantially rectangular coated fabric cover encasing the one or more pieces of insulation material. The coated fabric cover has a weight from about 5 to about 40 oz/sq yd. A first row of spaced apart apertures is disposed along a first side of the coated fabric cover. A second row of spaced apart apertures is connected to the coated fabric cover. The second row of spaced apart apertures is generally parallel to the first row of spaced apart apertures.
The method of adding insulation also includes attaching one or more elongated flexible members to at least one of the apertures. The one or more elongated flexible members are tossed over the top of the existing insulation system. The insulation panel is pulled over the top of the hard shell of the existing insulation system using the one or more elongated flexible members such that the insulation panel is draped over the top of the hard shell of the existing insulation system. Apertures of the first row of spaced apart apertures are attached to apertures of the second row of spaced apart apertures to secure the coated fabric cover around the existing insulation system.
In another exemplary embodiment, a pipeline is disclosed. The pipeline includes a pipe, insulation disposed around the pipe, a hard outer shell that encases the insulation disposed around the pipe, and a plurality of insulation panels secured around the hard outer shell that encases the insulation disposed around the pipe. At least one of the plurality of insulation panels includes one or more pieces of compressible fiberglass insulation material having an R value per inch of thickness from about 2 to about 13 hr-sq ft-deg F/Btu measured at 75 degrees Fahrenheit. The insulation material is configured to return substantially back to its original thickness and density after being compressed. At least one of the plurality of insulation panels also includes a substantially rectangular coated fabric cover encasing the one or more pieces of insulation material. The coated fabric cover has a weight from about 5 to about 40 oz/sq yd. At least one vent is disposed in the coated fabric cover.
In another exemplary embodiment, an insulation panel for adding insulation to a pipeline having an existing insulation system is disclosed. The existing insulation system includes insulation disposed around a pipe of the pipeline and a hard shell that encases the insulation disposed around the pipe. The insulation panel includes one or more pieces of compressible fiberglass insulation material having an R value per inch of thickness from about 2 to about 13 hr-sq ft-deg F/Btu measured at 75 degrees Fahrenheit. The insulation material is configured to return substantially back to its original thickness and density after being compressed. The insulation panel also includes a substantially rectangular coated fabric cover encasing the one or more pieces of insulation material. The coated fabric cover has a weight from about 5 to about 40 oz/sq yd. A first row of spaced apart apertures is disposed along a first side of the coated fabric cover. A second row of spaced apart apertures is connected to the coated fabric cover. The second row of spaced apart apertures is generally parallel to the first row of spaced apart apertures. The first and second rows of spaced apart apertures are configured such that attachment of apertures of the first row of apertures to apertures of the second row of apertures secures the coated fabric cover around the pipeline. At least one vent that permits air to escape from inside the cover when the insulation panel is compressed is disposed in the coated fabric cover.
In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to example the principles of the inventions.
As described herein, when one or more components are described as being connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be in direct such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements.
Insulation and methods of insulating an object are disclosed in the present application. In many exemplary embodiments disclosed herein, insulation panels are described as being used to insulate a pipeline. However, the insulation panels of the present application may be used to insulate any pipe, tube, duct, and/or conduit and are not limited to only pipelines. The insulation panels may also be used to insulate a variety of other objects, such as tanks, vessels, trailers, or railroad cars. The insulation panels of the present application may include thermal and/or acoustical insulation.
The insulation panels may be configured for use in cold weather climates and inclement weather conditions. For example, the insulation panels may be flexible at low temperatures (e.g., −65 degrees F.) such that the panels may be wrapped around a pipeline in cold weather regions. The insulation panels may also be made from a tough, durable, weatherproof material to prohibit damage to the panel from various weather conditions, such as high winds, rain, snow, and ice. As such, the insulation panels may be waterproof and capable of being secured to a pipeline or other object in such a way as to prohibit removal or damage from environmental elements. The insulation panels may also be resistant to ultraviolet light (UV) or sunlight to prohibit degradation of the panel over a period of time (e.g., 10-20 years or longer).
The insulation panels may also be configured to withstand impacts and prohibit damage to the panel from potential hazards, such as animals, vehicles, humans, and various projectiles (e.g., gunshots). The insulation panels may be configured to prohibit tampering, theft, or sabotage of the panel. Further, the insulation panels may be compressible and lightweight to facilitate transportation and installation of the panel on pipelines or other objects in remote regions of the world. The insulation panels may also be capable of being easily repaired if damaged.
An insulation panel generally includes a cover or jacket encasing an insulation material. The cover provides structure to the insulation panel and protects the insulation material from the elements and other potential hazards. The cover is also configured to facilitate installation of the insulation panel on a pipeline or other similar structure.
The cover of the insulation panel of the present application may include an outer portion for fastening the insulation panel to a pipeline or other structure. As illustrated in
In some embodiments, the insulation panel may or may not include a cover having an outer portion. Further, the outer portion of the cover may extend along less than all the sides of the insulation panel, e.g., only along two opposing sides of the insulation panel. One or more sections of the outer portion may be larger than other sections of the outer portion, e.g., the outer portion may be wider in some sections than others. Further, one or more outer portions may extend only partially along a side of the insulation panel, e.g., one or more flaps may extend from a side of the insulation panel. The outer portion may also extend from a side of the insulation panel at the top, bottom, or anywhere in between. The outer portion may be any thickness, e.g., the thickness of the outer portion may be more or less than the thickness of the insulation material.
The cover 104 of the insulation panel 100 may be made from a variety of flexible materials capable of withstanding inclement weather conditions. The material of the cover 104 may be strong, tough, durable, lightweight, flexible (even at low temperatures), weather resistant, and/or waterproof. The material of the cover 104 may also be UV or sunlight resistant, tear/puncture resistant, chemical resistant, mildew resistant, insect/rodent resistant, and/or biodegradable. The cover 104 may also be repaired if punctured, torn, or otherwise damaged, such as with a heat sealable patch.
A fabric may be used for the cover 104 of the insulation panel 100. The fabric may be a coated fabric, such as the geo-membrane material used as pond or pit liners. The fabric material may be made, for example, of a medium or high density polyethylene, various polyesters, reinforced polyethylene, ethylene propylene diene monomer (EPDM), polyvinyl chloride (PVC), and/or polypropylene material. The fabric may be knitted, woven or nonwoven. The material may be a variety of weights, such as from about 5 to about 40 oz/sq yd. Other materials, such as Kevlar, may also be used for the cover 104 of the insulation panel 100.
As shown, the cover 104 of the insulation panel 100 is made from a geo-membrane material known as 8218 LTA Low Temperature Use Geomembrane, manufactured by Seaman Corporation. Test method details about this material can be found in Table 1 below and at http://www.xr-5.com/products/8218_LTA.html. The This material may be supplied in sheets, or rolls, with a nominal weight of 18 oz/sq yd. This material is capable of withstanding inclement weather conditions and is flexible at temperatures as low as −67 degrees F. This material is also waterproof, weather resistant, durable, tough, UV or sunlight resistant, and tear/puncture resistant.
The cover 104 of the insulation panel 100 may be a variety of colors. The color of the cover 104 may affect the UV resistance and thermal properties of the insulation panel 100. For example, a black cover will tend to absorb more thermal radiation during the day than a lighter color. However, a lighter colored cover (e.g., white or light grey) may have better UV resistance than a darker colored cover.
The insulation material 102 of the insulation panel 100 may be a variety of flexible insulation materials capable of reducing heat loss from the pipeline or other structure. For example, the insulation material 102 may be selected to prohibit fluids (e.g., water) in a pipeline from freezing when the pipeline is exposed to low temperatures (e.g., −65 degrees F.). The insulation material 102 may be lightweight and have a uniform thickness and/or density, though this does not have to be the case. The thickness and/or density of the insulation material 102 preferably remains substantially unchanged over a period of time (e.g., 10-20 years). The insulation material 102 may be configured such that it does not slide or move within the cover 104 (e.g., downward) when wrapped around a pipeline. The insulation material 102 may also be flexible at low temperatures (e.g., −65 degrees F.) such that the insulation panel 100 may be wrapped around a pipeline in cold weather regions of the world. The insulation material 102 may be capable of being compressed (e.g., for packaging and/or transport) and then return substantially back to its original thickness and density when decompressed or released (e.g., for installation). In this form, insulation material 102 preferably includes the ability to be compressed, densified or otherwise deformed under pressure and the ability to return to its original density, state or form upon removal of the compressing force or pressure.
The insulation material 102 may include one or more pieces of fiberglass insulation or other insulation having an R-value per inch of thickness from about 2 to about 13 hr-sq ft-deg F/Btu or a K-value from about 0.08 to about 0.5 Btu-in/hr-sq ft-deg F, measured at 75 deg F. The R value of the insulation material 102 may be increased or decreased depending on the thickness of the insulation material. For example, doubling the thickness of the insulation material 102 may double the R value of the insulation material, tripling the thickness of the insulation material may triple the R value, and so forth. A wide variety of different types of insulation materials and combinations of different types of insulation materials may be used. Examples of suitable insulation materials include, but are not limited to foam, rock wool, and/or aerogels. In addition, the insulation material 102 may also comprise mineral, organic, cellulose, and/or polymer based insulation. Further, the insulation material 102 may comprise “blown-in” or loosefill insulation, such as AttiCat® Expanding Blown-In Fiberglass insulation manufactured by Owens Corning. Combinations of any of the aforementioned materials may also be used.
The insulation material 102 can be, in one embodiment, a unitary piece of TRS-40 fiberglass manufactured by Owens Corning. This insulation material has a nominal density of about 2.5 lb/cu ft. A 4 inch thick piece of this insulation material has an R-value from about 18.0 to about 18.4 hr-sq ft-deg F/Btu and a K-value from about 0.21 to about 0.23 Btu-in/hr-sq ft-deg F, measured at 75 deg F. This insulation material is flexible at low temperatures (e.g., −65 degrees F.). This insulation material is capable of being compressed and then return substantially back to its original thickness and density when decompressed or released. In other embodiments, multiple pieces of insulation having the same or different properties and shapes can be used inside cover 102 to form insulation material 102.
The insulation panel 100 may be manufactured in a variety of different ways. For example, one or more pieces of cover material may be wrapped around the insulation material. One or more sides of the cover material may then be fastened or sealed together to encase the insulation material. The sides of the cover material may be sealed or fastened in a variety of ways, e.g., with fasteners, adhesives, heat sealed, or the like. Further, one or more sides of the cover material may be fastened or sealed to form an outer portion along the sides of the cover.
In one embodiment, a single piece of cover material is wrapped around the top, bottom, and one side of the insulation material. The cover material is then sealed with heat around the remaining sides of the insulation material to form an outer portion of the cover. In another embodiment, the insulation material is sandwiched between two pieces of cover material. The two pieces of cover material are then fastened or sealed together to encase the insulation material. In yet another embodiment, one or more sides of the cover material are fastened or sealed together like a pouch or bag and then the insulation material is inserted into the cover. One or more openings may be placed in the cover material before or after the cover material is applied to the insulation material, e.g., openings may be punched in outer portion of the cover after the cover material is applied to the insulation material. In one embodiment, the cover material is heat shrunk onto a piece of insulation material to form the insulation panel.
When the insulation panel 200 is installed on a pipeline having existing insulation, the insulation panel may be installed over the existing insulation to provide additional insulation to the pipeline. As such, the insulation panel 200 may be used to increase the overall R value of the pipeline insulation, such as, for example, doubling or tripling the overall R value of the existing insulation. Other exemplary applications of the insulation panel 200 include insulating pipelines having no existing insulation or re-insulating pipelines in which the existing insulation is removed and replaced by one or more insulation panels.
In the embodiment shown, insulation panel 200 is wrapped around the circumference or outer surface of the pipeline 206 and about a longitudinal axis 208 of the pipeline. When installed, the bottom surface 218 of the insulation panel 200 contacts the outer surface of the pipeline 206 (see
Further, the insulation panel 200 is dimensioned such that the third and fourth sides 226 and 228 of the panel intersect or can overlap when the panel is wrapped around the pipeline 206. The intersection of the third and fourth sides 226 and 228 is shown at the bottom of the pipeline 206 in
As discussed in more detail below in reference to
The insulation panel of the present application may include membranes that form pockets inside the panel configured to hold pieces of insulation material or “blown-in” insulation material in place within the panel.
However, the insulation panel of the present application may have a variety of other configurations of pockets within the panel to hold pieces of insulation material or “blown-in” insulation material in place within the panel. Further, the insulation material within the insulation panel may be secured to the cover such that the insulation material is held in place relative to the cover. The insulation material may be secured to the cover in a variety of ways, such as with one or more fasteners, adhesives, or the like.
The insulation panel of the present application may be shaped and configured in a variety of ways. For example, the insulation panel may be shaped and configured such that it may be installed around components of a pipeline, e.g., pipe junctions or support structures. The insulation panel may also be shaped and configured to insulate a pipeline of varying diameter (e.g., the transition area between pipes of different diameters). Further, the insulation panel may be shaped and configured to insulate the transition area between an above ground pipeline and below ground pipeline (e.g., the intersection of the pipeline and the surface) and bends in pipelines. The insulation panel may also be shaped and configured to insulate a bend in a pipeline or a non-straight section of a pipeline.
An insulation panel 404 of
An insulation panel 406 of
The insulation panel may include one or more openings or slots in the cover. For example, an insulation panel 500 illustrated in
The insulation panel may be secured to a pipeline or other structure in a variety of ways. One exemplary method includes securing two sides of the insulation panel together when the panel is wrapped around the pipeline.
The insulation panel of the present application may include flanges or flaps on one or more sides of the panel for securing the panel to a pipeline. One or more of the flanges or flaps may be positioned along the length of a side or a single flange or flap may run the entire length of the side.
Another exemplary method of securing the insulation panel of the present application to a pipeline includes securing one or more sides of the panel to the pipeline or component of the pipeline. This exemplary method may prohibit the insulation panel from moving longitudinally relative to the pipeline.
As described above, the insulation panel of the present application may secured to the pipeline such that the fastening means is located at any location about the circumference or outer surface of the pipeline, e.g., towards the bottom, on either side, or on top of the pipeline. With the fastening means located near the bottom of the pipeline, any moisture that builds up between the pipeline and the insulation panel may be permitted to drain out between the sides of the panel located towards the bottom of the pipeline. For example, as shown in
The insulation panels of the present application may also include features that discourage tampering, theft, or sabotage of the panel. For example, one or more of the fasteners used to secure the insulation panel to the pipeline may be tamper proof. One exemplary tamper proof fastener includes a bolt with a unique head requiring a special tool to remove the fastener (e.g., a bolt with a pentagonal head having a pin in the middle). The cover of the insulation panel may also be made of tear or cut resistant material to discourage cutting the panel around one more of the openings used to secure the panel to the pipeline. Further, a fence or cage may be placed or wrapped around the insulated panels of the pipeline in populated areas to discourage access to the pipeline.
The insulation panels may be connected to one or more adjacent insulation panels on the pipeline to form a long continuous insulated pipeline or other structure. The adjacent insulation panels may also be configured to prohibit insulation gaps between the panels when installed on a pipeline. For example,
Adjacent insulation panels may also be shingled to prohibit insulation gaps between the panels when installed on a pipeline. For example,
The insulation panels may be used with a heat source, such as a point or distributed heat source. The heat source may be positioned between the insulation panel and the outer surface of the pipeline. The heat source may be configured to keep the space between the outer surface of the pipeline and the inner surface of the insulation panel at a selected temperature. With the outer surface of the pipeline held at a substantially constant and known temperature by use of the heat source, the insulation panel may require less insulation material to prohibit the fluid in the pipeline from freezing.
The amount of energy required by a heat source to maintain the outer surface of the pipeline at a selected temperature varies based on a variety of factors, e.g., the selected temperature maintained, the outside temperature, and the amount of insulation material in the insulation panel. For example, less energy is required to maintain the outer surface of the pipeline at a low temperature than at a higher temperature; however, the insulation panel may require more insulation material to prohibit the material in the pipeline from freezing. Further, the additional heat provided by the heat source may not be required when the outside temperature is above the selected temperature, e.g., during the summer months. Thus, the heat source may be turned on or off depending on the outside temperature. The heat source may be controlled automatically through the use of temperature sensors and switches. In some embodiments, the heat source may be at least be partially powered by solar energy.
One exemplary heat source is an electrical heat source that includes one or more wires positioned between the outer surface of the pipeline and the inner surface of the insulation panel. The electrical heat source may be integrated with the insulation panel and include one or more of the wires printed on the inner surface of the cover. The electrical heat source may also be separate from the insulation panel. For example,
One exemplary method of installing an insulation panel of the present application on a pipeline is described below and illustrated in
Once the insulation panel 1100 is delivered to the installation site, the panel is positioned on one side of the pipeline 1118 and unrolled. The insulation panel 1100 is allowed to decompress and return substantially to its original shape, thickness, and density (i.e., original uncompressed state). The insulation panel may return to its original state naturally over a period of time. Further, a compressor may be used to blow air into the insulation panel to assist with decompression of the panel. As illustrated in
The insulation panels of the present application are generally of a size and weight that they can be installed on the pipeline or similar structure by two people. As illustrated in
The insulation panel 1100 is positioned such that panel may be secured to the pipeline 1118, pipeline component, or adjacent insulation panel by any means disclosed in the present application. For example, the two hanging ends or sides 1140 and 1142 of the insulation panel 1100 may be positioned such that they can be fastened together. The insulation panel 1100 is fastened or secured to the pipeline 1118, pipeline component, or adjacent insulation panel by any means disclosed in the present application. For example, one or more elongated flexible members may be used to fasten the hanging ends or sides 1140 and 1142 of the panel 1100 together. One or more elongated flexible members may also be used to secure the insulation panel 1100 around the outer surface of the pipeline 1118.
A second insulation panel may be installed on the pipeline 1118 adjacent to the first insulation panel 1100 by repeating the steps outlined above. The second insulation panel may be positioned relative to the first insulation panel 1100. For example, the second insulation panel may be positioned to butt up against or overlap the first insulation panel 1100. The second insulation panel may be secured to the pipeline 1118, pipeline component, or first insulation panel 1100 by any means disclosed in the present application.
A heat source may be installed on the pipeline 1118 prior to installation of the insulation panel 1100. For example, the wires of an electrical heat source may be wrapped around the pipeline 1118 prior to installation of the insulation panel 1100. The wires may be connected to the electrical heat source. Further, if the wires of the electrical heat source are printed on the inner surface of the insulation panel 1100, installation of the panel may require connecting the wires to an electrical heat source.
As mentioned above, the insulation panel of the present application may be used to insulate a variety of objects, such as tanks, vessels, trailers, or railroad tank cars. Application to these objects is illustrated in
The insulation panels 1200 may be similar to the insulation panel 100 described above. In one embodiment, the insulation panels 1200 include insulation material encased within a cover or jacket. The cover of the insulation panels 1200 may be lightweight and configured to protect the insulation material during shipment and installation. The cover may also be configured such that the panel 1200 may be vacuum sealed. As such, the insulation panels 1200 may be compressed for shipping by evacuating the air within the panel, as described above. In another embodiment, the insulation panels 1200 do not include a jacket or cover. Instead, only the insulation material of the panel 1200 is installed on the pipeline 1206.
The seal rings 1250 positioned at each end of the insulation panels 1200 installed on the pipeline 1206 may be made of a variety of materials. For example, in one embodiment, the seal ring 1250 is made of an insulating foam, such as polystyrene or polyurethane. In another embodiment, the sealing ring 1250 is made of a fiberglass composite. The seal ring 1250 may also include one or more gasketed sealing surfaces to seal the ring relative to the pipeline 1206, panels 1200, and/or overwrap 1260.
As illustrated in
While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the invention to such details. Additional advantages and modifications will readily appear to those skilled in the art. For example, where components are releasably or removably connected or attached together, any type of releasable connection may be suitable including for example, locking connections, fastened connections, tongue and groove connections, etc. Still further, component geometries, shapes, and dimensions can be modified without changing the overall role or function of the components. Therefore, the inventive concept, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.
This application claims priority to U.S. Provisional Patent Application No. 61/466,165, filed Mar. 22, 2011, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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61466165 | Mar 2011 | US |