FOR PIPE LINING APPLICATIONS

BACKGROUND OF THE INVENTION

This invention relates broadly to the field of linings for internal pipe surfaces and methods of applying these linings, and more particularly relates to such linings adapted and adaptable for use in the structural repair or remediation of degraded, damaged or leaking pipes. In particular, the invention relates to Sprayed-In-Place-Pipe (SIPP) lining methods, systems and technologies. The invention most particularly relates in general to methods and apparatuses for temporarily blocking the openings of service laterals, i.e., smaller diameter lateral pipes connected to the wall of a larger mainline pipe, when the SIPP process is performed, such that the lining material does not negatively impact the openings of the smaller lateral pipes, i.e., produce a permanent blockage, or such that liquid flow from the service laterals is stopped during application and curing of the SIPP liner material.

SIPP lining technology encompasses many different market sectors such as municipal water, industrial as well as governmental. In most of these markets the pipe systems will consist of mainlines that intersect with numerous smaller diameter pipe for feed lines, drains, monitoring instrumentation etc. Typically, the municipal water market - potable water transmission to homes - will always have these smaller pipe intrusions termed as service laterals or service leads or just services. Usually, these services have pipe diameters ranging from 0.5" to 1". Fluid conveyance systems rely on the structural integrity of the pipe to safely and efficiently operate. In the municipal and industrial sectors, there are pipe systems that are degrading such that they fall below standards due to corrosion or crack propagation. These systems include for example the potable water transmission lines to residential areas which can range in sizes of 6 to 48 inches and will typically have complex networks that were installed and modified over many years as the neighborhoods were developed.

There are currently only a few methods to rehabilitate a pipe system to full structural integrity without excavating and replacing pipe segments. The current methods include Cast-In- Place-Pipe (CIPP) and Spray-In-Place-Pipe (SIPP). In the current SIPP methods, a SIPP spraying apparatus traverses the pipe by being pulled by an electrical and resin-supplying tether, known as the umbilical, or through robotic armatures. The spraying apparatus comprises a spinner member that ejects the lining material, such as an uncured or partially cured polymer resin, onto the inner diameter of the pipe, effectively creating a new pipe with a known thickness and structural properties inside the pre-existing pipe.

Currently in the SIPP industry the lining application method for class I and class II systems is to simply apply the lining across or over the service laterals during the lining process. The coating/lining is typically not intrusive to the performance of the service, i.e., the lining does not block the opening, however one can still have issues with liquid flow leaking from these service laterals. This water or moisture negatively affects the surface of the mainline pipe being lined, and may cause adhesion and/or foaming issues, and may impede complete curing of the coating. Therefore, temporary blockage of flow from the service laterals is desirable in the SIPP process. This would also hold true for Class III and IV or 'structural' lining applications.

A current issue when installing a semi-structural (Class III) or fully structural (Class IV) system, which is becoming more prevalent in the industry, is that the services laterals do get either partially or fully blocked, since the liner volume/ thickness in this case is significantly greater than that needed in remediation of a Class I or II system. If the service laterals are blocked upon completion of mainline lining, it is necessary to expend the time and resources to insert a remote cutter unit to first locate the filled service laterals and once located, cut the lining out to reinstate the service.

It is an objective of this invention to provide an apparatus, system and method that addresses the problems described above regarding service laterals and their openings when using SIPP technology to remediate, rehabilitate or repair a mainline pipe. Such apparatus, system and method address these problems by providing an apparatus which inserts a plug into the service lateral openings prior to application of the liner material in the mainline pipe, the plug being removed to re-establish fluid communication between the service lateral and the mainline pipe. It is a further objective to provide such an apparatus, system and method wherein the plug is liquid- soluble such that it is self-destructive in service laterals conducting water or other liquids, or wherein the plug is composed of a material having a low melt temperature so as to be self- destructive in the ambient environment or upon the direct application of heat. SUMMARY OF THE INVENTION

The purpose of the apparatus, system and method of the invention in various embodiments is to automatically or easily reinstate the service laterals after lining the mainline pipes with the SIPP process during pipe remediation, rehabilitation or repair. The apparatus, being either semi- autonomous or fully autonomous, self-powered or pushed/pulled, navigates in the mainline pipe to locate the opening of the service laterals and upon detection of a service lateral, inserts a plug or insert member to block the service lateral opening. These plug members preclude any flow or leakage from the service lateral, which in turn eradicates the issues of adhesion, foaming and curability of the lining material. The plug members also block the service lateral opening so that when the pipe is lined the service lateral does become sealed over by the polymeric material. In a preferred embodiment, the plug member is liquid-soluble, eliminating the need to relocate and uninstall the plug members, and is provided with a hydrophobic coating to repel the lining material, such that the plug member dissolves when liquid is again passed through the service lateral or mainline pipe to contact the non-coated surfaces of the plug members.

The plugger apparatus is either self-powered or adapted to be pulled or pushed by a separate powered drive member or by retrieval of an umbilical cable, the plugger apparatus having wheels, rollers, treads or the like for movement through the pipe. The plugger apparatus comprises a plug storage compartment that retains a plurality of plug or insert members, a robotic arm assembly compartment, a plug feeder mechanism for delivering individual plug members from the plug storage compartment to the robotic arm assembly compartment, and an extendable/retractable robotic arm assembly to receive and insert the plug members into the service openings.

The robotic arm assembly comprises an extension mechanism and a gripping mechanism adapted to receive a plug member from the plug feeder mechanism, radially extend and press the plug member into a service lateral opening, release the plug member, and retract into the robotic arm assembly compartment to receive the next plug member. The robotic arm assembly compartment is adapted to rotate about the longitudinal axis of the plugger apparatus to properly align the robotic arm assembly with a service lateral opening. One or more alignment control systems, such as for example cameras, laser pointers or the like, are provided on the plugger apparatus to locate a service lateral opening and properly align the robotic assembly for delivery of the plug member into the service lateral opening.

In alternate language, the invention may be summarized as a plugging apparatus adapted to plug service lateral openings in the interior of a pipe, the plugging apparatus comprising: a housing; transport mechanisms mounted to said housing, said transport mechanisms adapted to move said housing through a pipe having service lateral openings; a rotatable manipulator compartment mounted to said housing, said manipulator compartment containing a robotic arm assembly, said robotic arm assembly comprising a plug gripping assembly and an extension assembly; said housing retaining plugs and one or more plug loading actuators adapted to individually advance each of said plugs into said manipulator compartment and said plug gripping assembly; said extension assembly being adapted to extend each of said plugs positioned in said plug gripping assembly radially from said manipulator compartment and into one of the service lateral openings in the pipe. Furthermore, said plug gripping assembly comprising a receiver base, clamp members and a clamp actuator, said clamp actuator adapted to close said clamp members to retain and open said clamp members to release one of said plugs positioned on said receiver base; said extension assembly comprising an extension shaft connected to said gripping assembly and an extension actuator adapted to extend and retract said extension shaft; said housing further retaining a plurality of chutes, said chutes retaining said plugs in rows, one of said plug loading actuators being associated with each of said chutes; said manipulator compartment comprising a feed opening, wherein said manipulator compartment is rotatable to align said feed opening with one of said chutes such that each of said plugs is advanced through said feed opening into said manipulator compartment and said plug gripping assembly; said plugs comprising an insertion portion and a head portion; said plugs formed of a liquid- soluble material;, said plugs having a hydrophobic coating; said transport mechanisms comprising treads, rollers or wheels, and/or further comprising alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation.

In alternate language, the invention may be summarized as a method of plugging service lateral openings in a pipe comprising the steps of: providing a plugging apparatus comprising a housing; transport mechanisms mounted to said housing, said transport mechanisms adapted to move said housing through a pipe having service lateral openings; a rotatable manipulator compartment mounted to said housing, said manipulator compartment containing a robotic arm assembly, said robotic arm assembly comprising a plug gripping assembly and an extension assembly; said housing retaining plugs and one or more plug loading actuators adapted to individually advance each of said plugs into said manipulator compartment and said plug gripping assembly; said extension assembly being adapted to extend each of said plugs positioned in said plug gripping assembly radially from said manipulator compartment and into one of the service lateral openings in the pipe; navigating said plugging apparatus said plugging apparatus through a pipe; locating a service lateral opening; aligning said manipulator compartment and said robotic arm assembly with the service lateral opening; extending said robotic arm assembly and inserting one of said plugs into said service lateral opening; and releasing said one of said plugs and retracting said robotic arm assembly. Furthermore, wherein said plugging apparatus further comprises alignment control systems adapted to navigate the apparatus through the pipe, locate service lateral openings, properly position the apparatus relative to the openings, properly align said manipulator compartment and said robotic arm assembly, or confirm a successful plugging operation; and/or wherein said steps of navigating, locating, and aligning are controlled by said alignment control systems.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a perspective view of an embodiment of the plugging apparatus, shown in the non-loaded state. Figure 2 is an end view as seen from the longitudinal or transport axis of the plugging apparatus of Figure 1.

Figure 3 is a top view, relative to the orientation shown in Figures 1 and 2, of the plugging apparatus of Figure 1.

Figure 4 is a side view, relative to the orientation shown in Figures 1 and 2, of the plugging apparatus of Figure 1.

Figure 5 is a cross-sectional view of the plugging apparatus of Figure 1 , taken along line B-B of Figure 4.

Figure 6 is a cross-sectional view of the plugging apparatus of Figure 1, taken along line A- A of Figure 4. Figure 7 is an exposed perspective view of an alternative embodiment of the plugging apparatus, shown from the end opposite the manipulator compartment and in the non-loaded state.

Figure 8 is an exposed perspective view of the embodiment of the Figure 7, shown from the manipulator compartment end.

Figure 9 is an exposed end view of the embodiment of Figure 7. Figure 10 is an exposed perspective view of the embodiment of Figure 7, shown from the manipulator end with a plug in the loaded state.

Figure 1 1 is an exposed perspective view of the embodiment of Figure 7, shown from the manipulator end with a plug in the extended state. DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, which are meant to be non-limiting as to the scope of the invention and are not to scale, the invention is shown and described in various embodiments. In a broad sense, the invention is a plugging apparatus, system and method of plugging circular service lateral openings in a pipe prior to its undergoing rehabilitation by a SIPP process or similar process, such that the with the plugs inserted into the service lateral openings, polymer material sprayed to coat the inner wall of the pipe will not block the service openings.

After cleaning the pipe using conventional methods, such as blasting, pigging, etc. all the service lateral openings need to be covered. To achieve the task a plugging apparatus or robot is sent into the pipe. This apparatus can be semi-autonomous or fully automated. In the semi- autonomous configuration, the apparatus is connected to an umbilical cord which provides it with the required power and wired data communication protocol. In a fully-automated configuration, the plugging apparatus is powered using batteries and uses wireless communication protocol for data transmission. A semi -autonomous system will require an operator to navigate and execute various task of the robot in contrast to the fully-automated system, which may be self-sufficient.

Alignment control systems 19, such as cameras and sensors, are mounted on the plugging apparatus for navigation, locating service lateral openings, proper positioning of the apparatus relative to the openings, and confirmation of a successful plugging operation. The cameras 19 mounted on the apparatus guide the apparatus through the pipe and transmit HD quality data to the end user so that the operator can have real time images of the pipe. The cameras 19 are preferably surrounded with a ring of LEDs to provide clear images even in dark environment. A secondary camera 19 in addition to the primary navigating camera 19 may be provided on each apparatus to provide concentrated images of the service lateral opening being plugged. Alternatively and preferably, the alignment control devices 19 automatically navigate, locate service lateral openings, properly position the apparatus relative to the openings, and confirm a successful plugging operation.

Transport mechanisms 11 mounted at spaced locations on the plugging apparatus main housing 10 move and support the apparatus within the pipe. The transport mechanisms 11, which are preferably powered, comprise reads, rollers, wheels or similar members preferably mounted on extendable and retractable assemblies such that the transport mechanisms can be extended or retracted as required for proper fit within the pipe. The transport mechanisms 11 are oriented such that the plugging apparatus moves longitudinally through the pipe. A manipulator compartment 12 is rotationally mounted to the main housing 11 with the rotational axis of the manipulator compartment 12 aligned to be coaxial with or parallel to the central longitudinal axis of the pipe as the plugging apparatus moves through the pipe. The rotating manipulator compartment 12 is mounted in a manner allowing it to rotate relative to the non- rotating main housing 10. This may be accomplished in various ways, one of which is illustrated wherein the manipulator compartment 12 is mounted on a shaft 13 extending from a powered rotator actuator 14. Bearings and seals are provided at the junction of the manipulator compartment 12 and main housing 10.

The main housing 10 acts as a storage compartment for a plurality of cylindrical plug or insert members 90. Each plug 90 is composed of a compressible or resilient material, such as a rubber or polymer, and is configured for ease of insertion in to the circular service lateral openings as well as suitable retention within the opening. For example, in the embodiment shown in the drawings, each plug 90 comprises a head portion 92 and an insertion portion 91, the insertion portion being provided with annular grooves 93 to reduce friction during insertion while creating an effective seal within the service lateral opening. Alternatively, the insertion portion 91 could be tapered or otherwise configured.

In a preferred embodiment, the plug 90 is made of a liquid-soluble material comprising of a low molecular weight polymer and a surfactant, the material being chosen such that it readily dissolves in water or upon application of heat. The plug head portion 92 may be encapsulated or coated with hydrophobic or similar material which repels or prevents adhesion of the lining material later applied to the pipe, thereby precluding the lining material from encasing or trapping the plug 90 such that it cannot be readily, dissolved, removed or expelled from the service lateral opening once the pipe is put back into service.

The plugs 90 are stored in longitudinally-oriented rows on or in chutes or rails 16. A plug loading actuator 17associated with each chute 17, powered by a servo motor or similar means, pushes the row of plugs 90 in the direction of the manipulator compartment 12 as required to load a plug 90 onto the robotic arm assembly 20, the manipulator compartment having a feed opening 15 in its interior-facing wall that allows a plug 90 to be moved into the receiver base 22 of the robotic arm assembly 20 when the feed opening 15 is rotated into alignment with a chute 17. The robotic arm assembly 20 is housed within the manipulator compartment 12, and is the mechanism that inserts a plug 90 into a service lateral opening. The robotic arm assembly 20 comprises a plug gripping assembly 21 to retain and release the plug 90 during the insertion operation and an extension assembly 25 to extend and retract the gripping assembly 21 through an insertion window or opening 18 during the insertion operation. A first embodiment of the plug gripping assembly 21 is shown in Figures 1 through 6 and a second embodiment is shown in Figures 7 through 1 1. In both embodiments the gripping assembly 21 comprises a receiver base 22 adapted to receive the plug 90 when delivered from the main housing 10. The receiver base 22 preferably provides a floor or similar structure that enables pressure to be applied against the plug head portion 92 when the plug 90 is extended radially, relative to the longitudinal axis, into a service lateral opening. The gripping assembly 21 further comprises clamp members 23 controlled by a powered clamp actuator 24, the clamp members 23 being articulated, hinged or otherwise manipulatable so as to be able to be opened or spread laterally to allow a plug 90 to be fed from a chute 17 into the receiver base 22, closed to securely grasp and retain the plug 90 during the insertion operation, and again opened to release the plug 90 once it is inserted into the service lateral opening. The extension assembly 25 extends and retracts the gripping assembly 21 and comprises an extension shaft 26 connected to the gripping assembly, preferably to the receiver base 22, and an extension actuator 27 adapted to extend and retract the extension shaft 26.

In operation, the plugging apparatus advances or is advanced through the pipe until the alignment control systems 19, sensors and/or cameras, provide signals or visuals that a service lateral opening has been found. Although manual alignment is possible, it is preferred that the plugging apparatus automatically align itself with the service lateral opening in the longitudinal direction relying on information from the alignment devices 19 and that the manipulator compartment 12 automatically rotate about its axis to properly orient the robotic arm assembly 20 with the service lateral opening. If in the non-loaded state, as shown in Figures 1 through 9, the manipulator compartment 12 is rotated to align the feed opening 15 with a chute 17 containing a plug 90. The plug loading actuator 17 is then activated, by an operator or preferably automatically, and a plug 90 is advanced into the receiver base 22 of the gripping assembly, as shown in Figure 10. The clamp members 23, opened to allow passage of the plug 90, are now closed by the clamp actuator, manually or preferably automatically, to securely retain the plug 90 within the receiver base 22. The manipulator compartment is then rotated manually or preferably automatically to align the plug 90 concentrically with the service lateral opening.

Once properly aligned, the extension actuator is manually or preferably automatically activated to radially advance the plug 90 through the insertion window 18 of the manipulator compartment 12 and toward the service lateral opening, as shown in Figure 11, the plug 90 being loaded into the receiver base 22 such that the insertion portion 91 extends outward. Activation of the extension actuator 27 radially advances or extends the extension shaft 26 until the insertion portion 91 of the plug 90 is seated in the service lateral opening, the receiver base 22 pushing against the plug head portion 92. Once seated, the clamp members 23 are opened, manually or preferably automatically, by the clamp actuator 24 to release the plug 90, and the extension shaft 26 is retracted, manually or preferably automatically, by the extension actuator 27 to retract the gripping assembly 21 through the insertion window 18 and into the manipulator compartment 12. The plugging apparatus is then advanced to the next service lateral opening and the process is repeated until the supply of plugs 90 has been exhausted. It is understood that equivalents and substitutions for certain elements and steps described above may be obvious to those of skill in the art, and therefore the true scope and definition of the invention is to be as set forth in the following claims.