PIPE CONNECTION REPAIR APPARATUS
FIELD OF THE INVENTION
The present invention relates to repairing connections of pipes and, in particular, to an apparatus and method of repairing the lateral or branch connection joints of sewer pipes where the house service pipe connects to the sewer main.
BACKGROUND OF THE INVENTION
In domestic sewage collection systems, the house service pipes usually connect to the sewer main which has access chambers in order that maintenance or inspection of the pipes can be carried out. These access chambers are generally located at spaced apart intervals along the sewer main and the house service pipes are connected to the sewer main along its length. The access chambers are generally located adjacent the house service pipe connections but the distance and direction from the nearest house service pipe connections can vary. These access chambers in the sewer main are relatively easy to locate and enter as manhole covers provide ease of access. The house service pipe can have, but do not always have, access openings thereto. However, such access openings can be difficult to locate and can be difficult or complicated to access as digging may be required.
Using existing techniques, to repair the lateral or branch connection joints of the house service pipe and the sewer main, it is necessary to have access to both the house service pipe access opening and the access chamber of the sewer main. The need to access the house service pipe access opening adds to the costs of the repair as well as causing inconvenience in that access to the access opening may require digging into soil or breaking up concrete and the like.
It is therefore seen that it would be advantageous to have a method and apparatus to repair lateral connection joints of sewer mains and house service pipes by accessing only one of the access chambers or inspection openings of the sewer main.
While the following description refers primarily to a method and apparatus associated with repairing lateral connection joints between sewer main pipes and house service pipes, it should be understood that the method and apparatus are applicable to repairing or relining connection joints of pipes in general.
It is an object of the present invention to provide a method and apparatus of repairing connection joints of pipes which requires access to only one access chamber of the pipes.
At the very least, it is an object of the invention to provide an alternative to previously known methods and apparatus.
SUMMARY OF THE INVENTION
According to a first aspect of the invention there is provided a pipe liner installation apparatus for installing a flexible liner into an internal connecting region between a main pipe and a target branch pipe, the apparatus deployable from within the main pipe and including: an elongate body; a flexible lateral arm having a proximal and a distal end, the proximal end of the arm connected to the body; a guide means connected to the distal end of the arm, the guide means having a proximal end connected the to distal end of the lateral arm and a free end; and an inflatable sleeve assembly extending at least partially over the body and the arm, wherein, in use, the free end of the guide means provides a lead-in for the
distal end of the lateral arm into the target branch pipe solely under the external action of pushing or pulling of the body longitudinally with respect to the main pipe.
Preferably the free end of the guide means is reliantly moveable with respect to the body such that, in use within the main pipe, the free end presses against the inside wall of the main pipe.
Preferably the guide means includes a pivot joint to allow pivotal movement of the free end of the guide means with respect to the distal end of the lateral arm.
Preferably the guide means further comprises a coil spring operably mounted across the pivot joint, wherein the spring pulls the free end of the guide means into contact with the inside wall of the main pipe.
Preferably the free end of the guide is adapted to slide along the inside wall of the main pipe.
Preferably the guide includes at least one wheel arranged to roll along the inside wall of the main pipe.
Preferably the apparatus further includes a cradle means integral with or depending from the body, the cradle means arranged and constructed to restrict relative circumferential movement between the guide means and the body when the distal end of the arm is adjacent the body, whereby, in use within the main pipe, the guide means can be circumferentially positioned with respect to the main pipe by rotation of the body,
thereby allowing the guide means to be aligned with the target branch pipe.
Preferably the cradle means is changeable from a deployed condition in which a cradle is formed on an external surface of the sleeve to a non-deployed condition.
Preferably the body includes a hollow pipe, the hollow pipe allowing transmission of fluid through the apparatus while in use.
According to a second aspect of the invention there is provided a flexible liner for lining an internal connecting region between a main pipe and a branch pipe, the liner comprising: a main passage having opposed first and second open ends; a branch passage having an open distal end and a proximal end communicating with the main passage; at least one tension member attached to the distal end of the branch passage; a connection means attaching the tension member to the distal end of the branch passage, characterised in that the connection means holds when the tension member is tensioned by pulling in a direction outwards of the branch passage and away from the distal end and self-releases when tensioned by pulling in a direction inwards to the branch passage and away from the distal end.
Preferably the connection means comprises a thread sewn through the tension member and the distal end of the branch passage.
Preferably the liner comprises textile material, the textile impregnable with resin.
Preferably the thread is sewn in a plan machine loose stitch.
According to a third aspect of the invention there is provided a method of installing a flexible liner into a junction between a main pipe and a branch pipe, the method including the steps of: fitting the flexible liner over an installation apparatus, the apparatus including an elongate body; a flexible lateral arm having a proximal and a distal end, the proximal end of the arm connected to the body; a guide means connected to the distal end of the arm, the guide means having a proximal end connected to the distal end of the lateral arm and a free end; and an inflatable sleeve assembly extending at least partially over the body and the arm; inserting the installation apparatus and fitted liner into the main pipe via an access opening; pushing or pulling the installation apparatus and fitted liner along the main pipe towards an entrance to the branch pipe; further pushing or pulling the installation apparatus and fitted liner along the main pipe so that the arm is driven through the entrance of the branch pipe into the branch pipe; inflating the sleeve so as to press the fitted liner against the inner walls of both the main pipe and the branch pipe until the liner is fixed in place; deflating the sleeve; and withdrawing the installation apparatus from within the liner fixed within the branch and main pipes.
Preferably the method further includes the step of: impregnating the liner with a resin, the resin curable to form a bond between the liner and the inner walls of both the main pipe and the branch pipe, wherein the impregnating step occurs before said inserting step.
Preferably the method further includes the step of: rotating the main body thereby rotating the guide means so as to align it with
an entrance to the branch pipe, wherein the rotating step occurs before said further pushing or pulling step.
Preferably the apparatus further comprises: a pair of circumferentially spaced apart raised portions depending from the main body and preferably the method further includes the step of: applying a vacuum to a cavity bounded by the sleeve and the body such that the sleeve conforms over the raised portions so as to form a cradle; and the step of applying a vacuum occurring before the step of pushing or pulling.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described with reference to the accompanying drawings in which:
Fig. 1 is a perspective view of a packer assembly apparatus of the preferred embodiment shown in position within a main pipe and a branch pipe;
Fig. 2 is a perspective view of the packer assembly apparatus of Fig. 1 shown with the line and the inflatable sleeve removed;
Figs. 3a and 3b are detailed perspective views of the launcher mounted at the end of the arm of the packer assembly apparatus as shown in Fig. 2; Fi s. 4a and 4b are successive diagramatic schematic views of the packer assembly of Fig. 1 being used to repair a connection joint between a sewer main and a house service line;
Fig. 5a shows a cross-sectional view of the packer assembly of Fig. 1 in position within a main pipe (with the liner omitted for clarity); Fig. 5b is a similar view to that of Fig. 5a but shows an alternative embodiment of the invention.
Fig. 6 is a similar view to that of Fig. 5 but is an end view rather than a cross- sectional view;
Fig.7 is similar to the view of Fig.6, but shows the packer assembly rotated into alignment with a lateral pipe;
Fig. 8 is a perspective view of the packer assembly of Fig. 1 with the sleeve inflated; Fig. 9 is a similar view to that of Fig 8, but shows the sleeve deflated and the launcher being extracted from the liner;
Fig. 10 is a perspective view of a liner according to another embodiment of the invention; and
Fig. 11 is a perspective view of a liner according to another embodiment of the invention.
BEST MODE OF CARRYING OUT THE INVENTION
A pipe line installation apparatus in the form of a packer assembly 10 is used to apply a textile liner 60 impregnated with resin to an internal connecting region 11 between a sewer main 12 and a house service line 13 as seen in Figs. 1, 4a and 4b of the drawings.
Referring to Fig 1, the packer assembly 10 includes a main body 14 and a lateral arm 15 which extends outwardly from the main body portion 14 intermediate its ends. The main body 14 has end ring flanges 16 located at both ends. The lateral arm 15 has at its distal end a guide means in the form of a launcher 17 which acts as a guide for positioning of the lateral arm 15. The launcher 17 is pivotally attached to the lateral arm 15. An inflatable sleeve 18 forms the outer surface of the main body 14 and lateral arm 15.
Referring to Fig. 2, it can be seen that the main body 14 is formed from a flexible tubular hose 19 with the end ring flanges 16 attached to its ends. A saddle 20 is fitted to the hose 19 and a hose restrainer cable 21 connects between the end ring flanges 16 to prevent the flanges 16 from detaching from the hose 19.
The lateral arm 15 is formed from a flexible rod 22 fixed to one of the end ring flanges 16 with the launcher 17 pivotally connected to its free end. The pivotal connection is by means of a hinge 23 most clearly shown in figure 3a and 3b. The launcher 17 has a pair of rollers 26 applied to it to assist in its movement. A lateral arm restrainer cable 27 is connected between the launcher 17 and end ring flange 16 to prevent the launcher from becoming detached.
The sleeve 18 is fitted over the hose 19 and the rod 22 with the configuration as seen in Fig. 1 with the sleeve 18 being secured thereto by bands 28.
Air hose connectors 29 are located at both the ends of the end ring flanges 16 and are adapted to be used to input air from an air hose (not illustrated) into the cavity between the hose 19 and the sleeve 18 in the main body 14 and within the lateral arm 15. The air supply can be input from either end as required.
The guide means in the form of the launcher 17 has a proximal end connected to a proximal end of the lateral arm 15 and a free end. The free end in the preferred embodiment shown in Figs. 3a and 3b comprises a wheel or a pair of wheels 26 arranged to roll on the inside wall 12' of the main pipe as is best illustrated in Fig. 4a. Extra wheels 26' shown in Figs 1 and 2 only are optional.
The free end 26 of the launcher 17 is resiliently moveable with respect to the main body 14 such that, in use within the main pipe, the wheels 26 press against the inside wall 12' of the main pipe 12 as shown in Fig.4a to provide a lead-in into the target branch pipe 13.
The provision of a launcher 17 that provides an automatic lead-in into the target branch pipe 13 as described above allows the operator to insert the liner 60 into
position solely by pushing or pulling push rods 34 as shown in Figs.4a and 4b. There is no need for complicated hydraulic, electric or pneumatic actuators requiring manual actuation when the packer assembly 10 is in a particular longitudinal position within the main serve pipe 12.
While various means may be employed to provide resilient movement of the wheels 26 with respect to the main body 14, with the preferred embodiment of the invention as illustrated in the drawings, a spring means is employed. More specifically a tension spring in the form of a coil spring 24 is provided as is clearly shown in Figures 3a and 3b. Figures 3a and 3b show that the launcher 17comprises a steel plate 25 pivotally mounted to a ring flange 16' by a hinge 23. The plate 25 supports a pair of rollers 26. The rollers 26 form the free end of the launcher 17. The coil spring 24 is arranged to pull the free end 26 of the launcher 17 into contact with the inside wall of the main pipe, as shown in Figs. 6 and 4a.
A cradle means depending from the body 14 is provided to allow the launcher 17 to be manoeuvred into the correct angular position for "launching" into the appropriate lateral or branch pipe 13. The cradle means is constructed to restrict relative circumferential movement between the launcher 17 and the body 14 when the distal end of the arm 15 is adjacent the body 14 as is shown in Figs. 4a, 5a and 5b.
Referring to Figs 5a and 6 it can be seen that the cradle means of one embodiment of the invention includes a pair of spaced apart raised portions in the form of saddle 20. A vacuum is applied to the cavity 41 bounded by the inflatable sleeve 18 and the tubular hose 19 causing the sleeve 18 to conform over the raised portions of the saddle to form the cradle 40. The cradle restrains the launcher 17 such that it can be rotated as is illustrated by arrow 50 in Fig. 6. This allows an operator within an access chamber 33 to circumferentially position the launcher 17 appropriately such that it enters the correct lateral or branch pipe 13.
In another embodiment of the invention, the cross section of which is shown in Figure. 5b, the cradle means is simplified. This embodiment, suitable for smaller diameter pipes, the main body 19 comprises a hose that has been partially crushed so that a flat area 20' is formed 'to cradle' the lateral arm 15.
A stiffening rod 30 is adapted to be secured to the inside of the hose 19 to assist in rigidity and a rod connector adaptor 31 secured to the end ring flanges 16 is used to connect push rods 34 (illustrated in Figs. 4a and 4b) to the packer assembly to allow it to be manoeuvred into position and subsequently be removed. Cameras (not illustrated) are used to assist in the movement of the assembly and an electric power lead 32 is used to power the cameras and light source required.
Two alternative liners 60, for use with a launcher 17 of the type shown in Figure 5b are illustrated in Figures 10 and 11. The liner illustrated in Figure 10 can be used to repair the internal connecting region between a main pipe and a branch pipe having the same nominal diameter and where the branch pipe is angled with respect to the main pipe.
Figs 10 and 11 show the liners 60 inside out with a liquid impervious outer surface and a resin absorbing inner surface. In use, the resin absorbing surface is on the outside and is covered with a resin that cures to bond the liner 60 to the inner surfaces of the lateral pipe 13 and the main pipe 12. Various resins may be used. For instance, resins that cure under ambient conditions may be used or resins that are heat cured by steam or other means may be used.
Various diameters can be constructed, for instance the liner 60 can be constructed for a main pipe having a nominal diameter of 6 inches or 150 millimetres and a branch or lateral pipe of the same diameter.
The liner 60 shown in Figure 10 is similar to that shown in Figure 9, however it is designed for repairing a joint between a lateral and a main pipe where the lateral is angled at 90 degrees with respect to the main pipe. Such a liner may be required to repair a lateral pipe coming off a deeply buried sewer main.
Both Figures 10 and 11 show a liner 60 having a main passage 62 and a branch passage 63. The main passage 62 has opposed opened first and second ends 66 and 67. The branch passage 63 has an open distal end 69 and a proximal end of the branch passage 63 communicating with the main passage 62.
Tension members in the form of tags 70 are connected to the distal end of the branch passage 63 by means of thread sewn through the tag 70 and distal end of the branch passage 63. The ends of the tag 70 are provided to enable attachment to the lateral arm 15 as illustrated in Figures 1, 8 and 9.
Use of the packer assembly 10 to install a flexible liner 60 into a junction between a main pipe 12 and a branch pipe 13 will now be described. The textile liner 60 is fitted to the packer assembly 10 which is uninflated at that time. A resin is applied to the liner 60. Preferably a sheet layer of plastics material 82 is positioned between the textile liner 60 and the sleeve 18 to assist in the dislodgement of the liner from the sleeve. For clarity, this is shown in Figure 1 on one end of the main body 14 only.
In order to obtain access to the sewer main 12, the installing staff typically gain access to the sewer main 12 through an access chamber 33 of the type illustrated in Figures 4a and 4b.
The packer assembly 10 is inserted into the sewer main 12 with the lateral arm 15 . being adjacent or substantially side by side with the main body 14 in order that the
assembly 10 can travel along the inside of the sewer main 12. A vacuum is applied to the cavity 41 to ensure that a cradle 40 is formed to constrain the arm 15 and launcher 17 as shown in Figs. 5 and 6. Rods 34 or the like are used to push the assembly closer to the joint and the cameras are used to assist the staff in the manoeuvring of the assembly.
As the launcher 17 is pushed and/or pulled along within the sewer pipe 12, rollers 26 remain in contact with the inside wall of the main pipe 12. The combination of the rollers 26 and the tension spring 24 allow the launcher 17 to remain in contact with the inside wall of the main pipe even where cracks or other defects are present within the pipe. The tension in the spring 16 ensures that the roller 26 continues to follow the internal contours of the pipe and has the effect of providing a lead-in to any laterals or branch pipes encountered. Once the launcher has commenced entering a lateral, the underside of the plate 25 typically contacts internal surfaces within the lateral. An optional wheel 26', shown in Figures 1 and 2, may be used to reduce rolling friction. However, it has been found that this wheel 26' is not essential.
Figs. 4a and 4b show only one lateral or branch pipe 13 extending from the main pipe 12. In practice, there are often a number of lateral pipes extending from the main pipe at different longitudinal positions and also at different circumferential positions. The cradle described above allows the operator to rotate the main body 14 as he moves the launcher longitudinally along the main pipe 12. Thus, by rotating the launcher 17 so as to align it with the entrance of the correct branch pipe 13, the operator can ensure that the launcher 17 enters the correct lateral or branch pipe 13.
The flexibility of the lateral arm 15 ensures that it then takes up the direction and the angle of the house service line 13. Typically, the angle is 45° or 90° from the direction of the main 12 even though angles of 30° or 60° are also known.
Once in position, the packer assembly 10 is inflated and the liner is forced against the interior of the main 12, the house service line 13 and the connection joint 11. Figure 8 shows the packer assembly 10 and liner 60 with the sleeve 18 inflated. While the inflatable sleeve 18 is expanded to the size of the main 12 and the house service line 13, the resin is allowed to cure. After curing, the assembly 10 is deflated and can be dislodged from the liner and retrieved from the main 12, as is shown in Figure 9.
Figure. 9 shows that as the lateral arm 15 of the assembly 10 is progressively withdrawn from the lateral pipe by pulling or pushing, tension in the tags 70 is released, and then reapplied in an opposite direction. By the time the lateral arm 15 has reached the position shown in Figure. 9, the tag 70 has folded back and as it is retensioned by further withdrawal of lateral arm 15, the stitching (shown in Figure. 10) unravels. Unravelling occurs automatically with a stitching known as plan machine loose stitch. Other stitching that unravels when pulled in one direction, but holds firm when pulled in the opposite direction may, also be used.
The packer assembly 10 allows operators repairing a connection joint 11 between a main 12 and a house service line 13 to access the connection joint 11 from a single access chamber 33 of the sewer main 12. The assembly 10 can be either pushed or pulled into position with the launcher 17 enabling the lateral arm to be manoeuvred into position in the house service line 13.
When the term "vacuum" is used in this specification and in the associated claims, it is to be understood to mean a pressure below the ambient atmospheric pressure. Its meaning encompasses a partial vacuum and is not limited to a complete vacuum.
Throughout the specification, the word "comprise" and its derivatives are intended to have an inclusive rather than an exclusive meaning unless the context requires otherwise.
The foregoing describes only some embodiments of the present invention, and modifications obvious to those skilled in the art can be made thereto without departing from the scope of the present invention.