TECHNICAL FIELD

[0001] The present invention relates generally to the field of pipe support system. More specifically, the present invention relates to a composite pipe support system including an insulation member and a load bearing member such that the composite pipe support system possesses the desired insulating properties and load bearing capacity.

BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] In today's times of high energy costs, an effective thermal insulation system that reduces energy loss, possesses sufficient strength, and load-bearing capacity is increasingly important. Particularly, in oil refineries and petrochemical complexes, high temperature media such as steam, process chemicals and distillates/finished products are transported and/or conveyed via pipelines. The operating temperatures typically vary from the ambient temperature (above 35°C) to 1000°C. Traditionally, hot supports using bulky load bearing and insulating materials such as calcium silicate and the likes have been used that suffers from several disadvantages including, but not limited to, occupancy of large amount of space on the pipe rack, immense weight, need of special handling as they are breakable, prone to water vapour ingress and consequent damage, and being expensive.

[0004] Composite pipe support systems are now being utilized which comprise an insulation layer, preferably in the form of boards or flexible blankets, which are usually adhesively bonded to the insulated surface. Layers of render may be applied to the insulation layer in order to protect the insulation layer against weathering influences. It is usual to apply a base render which is reinforced with a woven fabric layer and is covered by a layer of covering render.

[0005] Many insulation materials have been used in the past for the insulation layer of a composite thermal insulation system. In particular, polymeric foams, e.g. foams based on polyurethanes or polystyrene, mineral wool, glass fibres, and also natural materials such as hemp, cork or perlites and more particularly Calcium Silicate are used as insulation materials. [0006] There is, therefore, a need in the art to develop a pipe-support system for pipelines that possesses not only the desired insulating properties but also sufficient load bearing capacity such that these support systems can be used efficiently under maximum operating temperatures.

OBJECTS OF THE INVENTION

[0007] An object of the present disclosure is to provide a composite pipe support system that satisfies the existing needs, as well as emerging ones, and generally overcomes the deficiencies found in the prior art.

[0008] Another object of the present disclosure is to provide a composite pipe support system that uses aerogel as an insulating material, which is up to 10 times more thermally efficient than the conventionally used calcium silicate.

[0009] Another object of the present disclosure is to provide a composite pipe support system that can be used efficiently under enhanced operating temperatures of ranging from 450 Deg C to 1000 Deg C.

[0010] Another object of the present disclosure is to provide a composite pipe support system that is thinner by up to 4-5 times as compared to the conventional pipe support systems and gives better thermal performance than the conventional pipe support systems.

[0011] Another object of the present disclosure is to provide a composite pipe support system that does not easily crack or break during shipping, handling and installation, more particularly, exhibits attributes such as superior bend strength and compressive strength.

[0012] Another object of the present disclosure is to provide a composite pipe support system that matches the insulation thickness of the mother pipe to provide a seamless transition from support structure to line insulation.

[0013] Another object of the present disclosure is to provide a composite pipe support system that is hydrophobic yet provides for evacuation of trapped water vapor.

[0014] Another object of the present disclosure is to provide a composite pipe support system whose thermal performance remains consistent throughout the lifecycle of the support system and does not reduce with age.

[0015] Another object of the present disclosure is to provide a composite pipe support system that is robust and resists damage while handling, transportation and installation and remains maintenance free throughout its life. SUMMARY

[0016] The present invention relates generally to the field of pipe support system. More specifically, the present invention relates to a composite pipe support system including an insulation member and a load bearing member such that the composite pipe support system possesses the desired insulating properties and load bearing capacity.

[0017] An aspect of the present disclosure relates to a composite pipe support system including: an opening for a pipe; an insulating member configured to prevent heat transfer to and from the pipe; and a load bearing member configured to confer load bearing capacity to the composite pipe support system, wherein the insulation member is not in admixture with the load bearing member and wherein the load bearing member covers at least 10% circumference of said composite pipe support system along a length of said composite pipe support system.

[0018] In an embodiment, the load bearing member has bend strength of at least 60MP and a compressive strength of at least lOOMPa. In an embodiment, the insulation member has thermal conductivity of at least 0.03 W/(m K) at 35°C. In an embodiment, the insulation member includes one or a plurality of layers of the aerogel. In an embodiment, the one or a plurality of aerogel layer is configured as any or a combination of blanket, boards, particulate and preformed bag filled with aerogel. In an embodiment, the one or a plurality of aerogel layer is based on any or a combination of silica, alumina and titanium based material. In an embodiment, the load bearing member is in form of any or a combination of (a) concentric ring and (b) a pair of articulate members to match/form a concentric ring. In an embodiment, the load bearing member covers about 30% circumference of said composite pipe support system along a length of said composite pipe support system. In an embodiment, the composite pipe support system exhibits combined thermal conductivity of at least 0.07 W/(m K) at 35°C.

[0019] Another aspect of the present disclosure provides a composite pipe support system including: an opening for a pipe; at least two load bearing members, each configured independently in shape of any of (a) a concentric ring and (b) a pair of articulate members to match/form a concentric ring to be detachably and concentrically coupled to the pipe; an insulation member configured to fill an annular space between the at least two load bearing members; and a pipe support member configured to encase at least a part of both of the load bearing member and the insulation member. In an embodiment, the load bearing member covers at least 10% circumference of said composite pipe support system along a length of said composite pipe support system. [0020] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiment/s, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0022] FIG. 1 illustrates an exemplary assembled view of a conventional pipe support system.

[0023] FIG. 2 illustrates an exemplary perspective view of the composite pipe support system in accordance with an embodiment of the present disclosure.

[0024] FIG. 3 illustrates an exemplary sectional view (along the plane A-A depicted in FIG. 2) of the composite pipe support system in accordance with an embodiment of the present disclosure.

[0025] FIG. 4 illustrates an exemplary sectional view of a variant of composite pipe support system in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0026] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0027] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims. [0028] As used in the description herein and throughout the claims that follow, the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.

[0029] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0030] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0031] The present invention relates generally to the field of pipe support system. More specifically, the present invention relates to a composite pipe support system including an insulation member and a load bearing member such that the composite pipe support system possesses the desired insulating properties and load bearing capacity.

[0032] An aspect of the present disclosure relates to a composite pipe support system including: an opening for a pipe; an insulating member configured to prevent heat transfer to and from the pipe; and a load bearing member configured to confer load bearing capacity to the composite pipe support system, wherein the insulation member is not in admixture with the load bearing member and wherein the load bearing member covers at least 10% circumference of the composite pipe support system along a length of the composite pipe support system.

[0033] In an embodiment, the load bearing member has bend strength of at least 60MPa and a compressive strength of at least lOOMPa. In an embodiment, the insulation member has thermal conductivity of at least 0.03 W/m K at 35°C. In an embodiment, the insulation member includes one or a plurality of layers of the aerogel. In an embodiment, the one or a plurality of aerogel layer is configured as any or a combination of blanket, particulate and performed bag filled with aerogel. In an embodiment, the one or a plurality of aerogel layer is based on any or a combination of silica, alumina and titanium based material. In an embodiment, the load bearing member is in form of any or a combination of (a) concentric ring and (b) a pair of articulate members to match/form a concentric ring. In an embodiment, the load bearing member covers about 30% circumference of said composite pipe support system along a length of said composite pipe support system. In an embodiment, the composite pipe support system exhibits combined thermal conductivity of at least 0.07 W/(m K) at 35 °C.

[0034] Another aspect of the present disclosure provides a composite pipe support system including: an opening for a pipe; at least two load bearing members, each configured independently in shape of any of (a) a concentric ring and (b) a pair of arcuate members to matingly form a concentric ring to be detachably and concentrically coupled to the pipe; an insulation member configured to fill an annular space between the at least two load bearing members; and a pipe support member configured to encase at least a part of both of the load bearing member and the insulation member. In an embodiment, the load bearing member covers at least 10% circumference of said composite pipe support system along a length of said composite pipe support system.

[0035] FIG. 1 illustrates an exemplary assembled view of a conventional pipe support system. The conventional pipe support system, as can be observed from FIG. 1, includes: (a) a circular hole through which a pipe passes, (b) one or more thick layers of insulating member(s) to provide insulation to the pipe (as can be seen in the FIG. 1 in light and heavy grey shades), (c) a protective render covering the insulating member(s) to prevent any damage to the insulating member(s), and (d) a supporting/securing structure having plurality of securing members/features (screws and the like), to support the pipe and establish a direct engagement with the ground/earth or any other member to which the pipe along with the insulating member need to be affixed. A person skilled in the art would immediately realize that such conventional pipe support system suffers from multitude of shortcomings, including but not limited to, occupancy of large amount of space on the pipe rack, immense weight, need of special handling as they are breakable, prone to water vapor ingress and consequent damage, being expensive and most importantly, lack of load bearing capacity.

[0036] FIG. 2 illustrates an exemplary perspective view of the composite pipe support system in accordance with an embodiment of the present disclosure. FIG. 3 illustrates an exemplary sectional view (along the plane A-A depicted in FIG. 2) of the composite pipe support system, realized in accordance with an embodiment of the present disclosure. As illustrated, the composite pipe support system includes (a) an opening 102 for a pipe, (b) an insulating member 104 (can be seen in FIG. 3), (c) a protective render 106 (optional) to prevent any damage to the insulating member 104 surrounding the pipe 102, during service/operating conditions, (d) a load bearing member 110 to confer load bearing capacity to the composite pipe support system and (e) a pipe support member 108, optionally having one or more ground/earth securing member(s) (screws and the like), covering (encasing) at least a part of both the load bearing member 110 and the protective render 106 (or insulation member 104 in case no protective render is utilized/present), to support the pipe and establish a direct engagement with the ground/earth or any other member to which the pipe along with the insulating member need to be affixed. As can be realized from FIG. 2 and 3, the load bearing member is not in physical/chemical admixture with the insulation member. In an embodiment, the pipe support member 108 covers (encases) substantial part of both the load bearing member 110 and a protective render 106 (or insulation member 104 in case no protective render is utilized/present).

[0037] In an embodiment, the insulating member 104 includes one or more layers of aerogel. In an embodiment, said one or more layers of aerogel is in the form of any or a combination of blanket(s), particulate(s) and performed bag(s) filled with the aerogel. In an embodiment, said insulation member is an aerogel based insulation material having thermal conductivity ranging of at least 0.03 W/(m K) at 35 °C. In an embodiment, protective render 106 can be made up of any suitable protective material. In an embodiment, the composite pipe support system does not include a protective render 106. In an embodiment, said load bearing member 110 can be made up of any suitable material, as known to or appreciated by a person skilled in the art to confer desired load bearing capacity to the composite pipe support system. In an embodiment, the load bearing material is made of a ceramic based material. In an embodiment, the pipe support member 108 can have any or a combination of designs selected from resting, guided, anchor, and clamp hanger, as known to a person skilled in the pertinent art. In an embodiment, the securing member(s) include any or a combination of screws, rivets, bolts, and the likes.

[0038] In an embodiment, the load bearing member 110 covers at least 10% circumference of the composite pipe support system along a length of the composite pipe support system. Preferably, the load bearing member 110 covers about 20% to about 40% circumference of the composite pipe support system along a length of the composite pipe support system (alternatively and synonymously referred to as surface area). Most preferably, the load bearing member 110 covers about 30% circumference of the composite pipe support system along a length of the composite pipe support system. In an embodiment, the insulating member 104 fills an annular space between the load bearing members. In an embodiment, the load bearing member 110 covers about 20% to about 40% surface area and the insulating member 104 covers about 60% to about 80% of the surface area of the pipe 102. In an embodiment, the load bearing member 110 covers about 20% surface area and the insulating member 104 covers about 80% of the surface area of the pipe 102. In another embodiment, the load bearing member 110 covers about 10% surface area and the insulating member 104 covers about 90% of the surface area of the pipe 102. However, a person skilled in the art should appreciate that the load bearing member 110 can cover surface area extending over the substantially whole composite pipe support area without departing from the scope and spirit of the present invention. In an embodiment, the insulating member 104 fills an annular space between the load bearing members. In an embodiment, the load bearing member 110 covers at least 10% of the surface area and the insulating member 104 covers the rest of the surface area of the pipe 102. In an embodiment, the composite pipe support system exhibits combined thermal conductivity of at least 0.07 W/(m K) at 35 °C. Inventor of the present disclosure has realized that such an arrangement of the insulating member along with load bearing member confers a unique combination of insulating properties and load bearing properties to the pipe support system, which could not be achieved with the conventional arrangements and/or pipe support systems.

[0039] In an embodiment, the aerogel is made of metal oxides, including but not limited to, silica, alumina, titania, zirconia, polymeric material such as phenol-formaldehyde, or combination of them. In an embodiment, the aerogel is reinforced with material(s), as known to or appreciated by a person skilled in the art, to confer sufficient strength thereto. In an embodiment, aerogel is produced by sol-gel process followed by drying in such a way that the original volume, particulate network in the gel is retained to the maximum extent to form aerogel. The processes suitable for the drying includes freeze drying, sub critical drying, ambient pressure drying and super critical drying, but not limited thereto. The process of aerogel production by sol-gel process followed by its supercritical drying is well known to a person skilled in the art (Kistler et al, Nature, volume 127, page 741, 1931). The aerogel can be produced in the form of monoliths, beads, granules, powder, particles and the likes. Various conditions of sol-gel processing are well established (Jones, W. et al, Fundamental principles of Sol-Gel technology, Institute of Metals Communications, 1990). The sol-gel process that can be followed to make aerogel can include any suitable process utilizing suitable chemical composition(s) including additives, if any, to give any functionality such as infrared opacifier, fire or flame retardant, EMI opacifier and the likes. In an embodiment, aerogel can be of hydrophilic or hydrophobic nature prepared by using suitable precursors and surface modification process. [0040] In an embodiment, said aerogel layer(s) can be in the form of one or a plurality of aerogel blanket(s). In an embodiment, aerogel blanket is made from a composite of fibers and aerogel. The fibers used in preparation of aerogel blanket can be in any form including, but not limited to, mats, blankets, batting, bulk fibers and the likes. The fibers used in aerogel blanket can be of inorganic or organic in nature, including but not limited to, mineral wool, fiber glass, ceramic, carbon, acrylic, polyester, aramide, polyimide and the likes.

[0041] In an embodiment, aerogel blanket can be prepared by soaking the aerogel precursor solution or sol in the fiberous mat (alternatively, also referred as blanket and batting) followed by supercritical drying as known to a person skilled in the art and disclosed, at least in part, in US5306555, US5789075, US6068882 and WO2017009858. In an embodiment, aerogel blanket can be prepared by making an aerogel sheet by mixing preformed aerogel and fibers as disclosed in US20070222116A1, US7560062B2 and the likes. However, a person skilled in the art would appreciate that any other method, as known to or appreciated by a person skilled in the art, for preparation of aerogel and/or aerogel composite can be utilized to serve the intended purpose as laid down in the present disclosure without departing from the scope and spirit of the present invention. In an embodiment, the composite aerogel/fiber blanket can then be wrapped tightly around the pipe in a series of layers. In an embodiment, aerogel is wrapped around the pipe using existing machinery for applying Multi-Layer Insulation.

[0042] In an embodiment, said aerogel layer can be in a particulate form. Various powders, granules and beads are available in size ranges from 0.5 to 5.0 mm. To fill an insulating space with particulate, it is generally desirable to orient the pipe vertically so the annular space fills from the bottom upwards. This ensures that there are no void spaces which can adversely affect performance. Numerous methods are available for handling powders. An exemplary method for conveying the aerogel is to use a vacuum conveyor.

[0043] In an embodiment, said aerogel can be packaged in preformed bags. Each bag can be filled with aerogel and purged with a condensable gas, preferably carbon dioxide. The bag can then be evacuated, ideally to a pressure in the range of between 1000 to 10,000 microns, and sealed. Under ambient pressure, the volume of the bag can be reduced, so it can fit easily in the insulation space. For large insulation spaces, such as tanks, trailers and the likes, multiple bags can be used to fill the insulation space. For smaller insulation spaces, such as conduits the bag can be pre-formed to a clamshell shape which conforms to the contours of the insulation space. If aerogels are packed in this way, the insulation space should still be purged with condensable gas, and will be evacuated to a pressure similar to the internal pressure of each bag. Suitable bag materials are polymeric materials with a permeability low enough to allow vacuum to be maintained for the duration of the assembly process. With this system it is necessary to ensure that a sufficient fraction of the insulation volume is filled with the aerogel containing bags such that when the bags expand there are no void spaces.

[0044] In another embodiment, aerogel blankets can be combined with aerogel particulates. In all cases it is possible to use either a hydrophilic or hydrophobic form of aerogel. The hydrophobic aerogel particulate can be compressed without losing its structure, and has a low water content. The hydrophilic aerogel is less compressible and has a high affinity for water. Moreover, the hydrophilic aerogel is non-flammable in pure oxygen and is therefore more suitable for this service.

[0045] In an embodiment, the load bearing member is a ceramic based load bearing member. However, it should appreciate that any ceramic based material as known to or appreciated by a person skilled in the pertinent art can be utilized without departing from the scope and spirit of the present invention. In an embodiment, said the bearing member has bend strength of at least 60MPa and a compressive strength of at least lOOMPa so as to confer desired load bearing capacity to the composite pipe support system. However, a person skilled in the art would appreciate that any other material (other than ceramic based material) can be utilized to serve its intended purpose as laid down in the present disclosure without departing from the scope and spirit of the present invention.

[0046] In an embodiment, the load bearing member covers surface area of at least 10% and said insulation member covers the rest of the surface area of the pipe (at least 50%). In a preferred embodiment, the load bearing member covering at least 10% surface area of a pipe support system and the insulation member covers at least 50% surface area of the pipe support system.

[0047] FIG. 4 illustrates an exemplary sectional view of a variant of the composite pipe support system, realized in accordance with an embodiment of the present disclosure. As illustrated, the composite pipe support system includes (a) an opening for a pipe 102, (b) an insulating member 104, (c) a protective render 106 (optional) to prevent any damage to the insulating member 104 surrounding the pipe 102, during service/operating conditions, (d) a load bearing member 1 10 to confer load bearing capacity to the composite pipe support system and (e) a pipe support member 108 having one or more ground/earth securing member(s) (screws and the like), covering, at least a part of, both the load bearing member 110 and the protective render 106 (or insulation member 104 in case no protective render is utilized/present), to support the pipe and establish a direct engagement with the ground/earth or any other member to which the pipe along with the insulating member need to be affixed. In an embodiment, the pipe support member 108 covers substantial part of both the load bearing member 110 and a protective render 106 (or insulation member 104 in case no protective render is utilized/present). As can be observed, the pipe is substantially covered with the insulating member 104 with load bearing member 110 secured thereon at both ends, such that, effectively, the insulating member 104 covers at least 50% of the surface area of the pipe 102 (circumference of the composite pipe support system along a length of the composite pipe support system) and the load bearing member 110 cover up the rest of the surface area of the pipe 102.

[0048] In an alternate embodiment, the load bearing member is provided in the form of discrete spacers along the circumference of the pipe. In still another embodiment, the load bearing member is provided in the form of spirally wound spacer running along the circumference of the pipe. In still further embodiment, the load bearing member is provided in the form of spikes, radially outwardly projecting from the pipe. In still further embodiment, the load bearing member is provided in the form defining alternative peaks and troughs. It should be appreciated that the load bearing member can be configured in any other shape, as known to or appreciated by a person skilled in the art, and the rest of the surface/support area (circumference of the composite pipe support system along the length of the composite pipe support system) can be covered with the insulation member to serve its intended purpose as laid down in embodiments of the present disclosure without departing from the scope and spirit of the present invention.

[0049] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION

[0050] The present disclosure provides for a composite pipe support system that satisfies the existing needs, as well as others, and generally overcomes the deficiencies found in the prior art. [0051] The present disclosure provides for a composite pipe support system that effectively accommodates the use of aerogel as the insulating member to achieve very low thermal conductivity/high thermal performance of the pipe support system.

[0052] The present disclosure provides for a composite pipe support system that can be used efficiently under enhanced operating temperatures.

[0053] The present disclosure provides for a composite pipe support system that is thinner than the conventional pipe support systems.

[0054] The present disclosure provides for a composite pipe support system that does not easily crack or break during shipping, handling and installation.

[0055] The present disclosure provides for a composite pipe support system that matches the insulation thickness to provide a seamless transition from support structure to line insulation.

[0056] The present disclosure provides for a composite pipe support system that is hydrophobic yet provides for evacuation of water vapor.

[0057] The present disclosure provides for a composite pipe support system that is resistant to high temperatures and in cases of fire events such as petrochemical pool fires, the pipe support system is resistant to temperature of about 1000°C.

[0058] The present disclosure provides for a composite pipe support system whose thermal conductivity remains consistent throughout the lifecycle of the composite pipe support system and does not age.