Patent Description:
Piping systems, including municipal water systems, can develop breaks in pipe walls that can cause leaking. Example of breaks in a pipe wall can include radial cracks, longitudinal cracks, point cracks, etc. Leaking also commonly occurs at joints in the piping system. Locating and repairing a leak in a pipe wall often requires the piping system to be shut off, which can be inconvenient for customers and costly for providers. Furthermore, depressurizing the pipeline can increase of the risk of undesirable foreign objects (e.g., bacteria, dirt, etc.) entering the pipeline at the location of the leak. Additionally, locating the break site and repairing the break can necessitate grandiose construction, including the digging up of streets, sidewalks, and the like, which can be costly and time-consuming.

<CIT> provides a system for pipeline rehabilitation. The system includes repairing a leak in a pipe using a pair of substantially semi-cylindrical parts connected through a compliant j oint. When the parts are compressed, the semi-cylindrical parts form a cylinder whose outside diameter is less than the inside diameter of a pipe with a defect thereby allowing the cylinder to be inserted into the pipe at a location of a leak. Once in place, the parts engage the inside surface of the pipe when the compression is released thereby to seal the leak.

<CIT> relates to a method of maintaining a sealing element within a leak site in a vessel, particularly a pipe. The method comprises the steps of introducing a radially compressible hollow elastic tube, held under axial tension or radial compression into the vessel, the tube being radially compressed from an at rest condition to a contracted condition, releasing the tension or compressive force on the tube such that the tube expands radially from the contracted towards the at rest condition against the wall of the vessel to trap the sealing element within the leak site between the outer surface of the tube and the inner wall of the vessel. Where a tool such as an applicator is utilised to deploy the tube within a pipe, the tool may comprise means to locate the tube at the required location within the pipe, adjacent the leak. For example, the tool may comprise one or more hydrophones, sonar or camera positioning systems such that the progress of the tool along the pipe towards the leak can be closely monitored to ensure that the tube is deployed from the tool most efficiently and at the optimum location.

<CIT> provides a connector for tubulars, particularly for connecting expandable tubulars formed of bistable cells, including a number of extending insertion portions which engage with corresponding extending receiving portions.

Disclosed is a pipe repair device according to claim <NUM>.

Also disclosed is a method for repairing a pipeline according to claim <NUM>.

The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures may be designated by matching reference characters for the sake of consistency and clarity.

The present disclosure can be understood more readily by reference to the following detailed description, examples, drawings, and claims, and the previous and following description. However, before the present devices, systems, and/or methods are disclosed and described, it is to be understood that this disclosure is not limited to the specific devices, systems, and/or methods disclosed unless otherwise specified, and, as such, can, of course, vary.

The following description is provided as an enabling teaching of the present devices, systems, and/or methods in its best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects of the present devices, systems, and/or methods described herein, while still obtaining the beneficial results of the present disclosure. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used throughout, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "an element" can include two or more such elements unless the context indicates otherwise.

For purposes of the current disclosure, a material property or dimension measuring about X or substantially X on a particular measurement scale measures within a range between X plus an industry-standard upper tolerance for the specified measurement and X minus an industry-standard lower tolerance for the specified measurement. Because tolerances can vary between different materials, processes and between different models, the tolerance for a particular measurement of a particular component can fall within a range of tolerances.

As used herein, the terms "optional" or "optionally" mean that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

The word "or" as used herein means any one member of a particular list and also includes any combination of members of that list. Further, one should note that conditional language, such as, among others, "can," "could," "might," or "may," unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain aspects include, while other aspects do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more particular aspects or that one or more particular aspects necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular aspect.

<FIG> illustrates a first aspect of a leak detection and pipe repair device <NUM> (hereinafter, the "pipe repair device <NUM>"), according to the present disclosure. Example aspects of the pipe repair device <NUM> can drive through a pressurized pipeline <NUM> (shown in <FIG>), detect a leak <NUM> (shown in <FIG>) in a pipe <NUM> (shown in <FIG>) of the pipeline <NUM>, and repair the damage to the pipe <NUM> at the location of the leak <NUM> (e.g., the leak region <NUM>, shown in <FIG>). Referring to the block diagram of <FIG>, these functions can be performed by various subsystems of the pipe repair device <NUM>. Example aspects of the pipe repair device <NUM> can comprise a locomotion subsystem <NUM>, a leak detection subsystem <NUM>, and a pipe repair subsystem <NUM>, as will be described in further detail below. The pipe repair device <NUM> further can comprise a power subsystem <NUM> and a communications subsystem <NUM>. In some aspects, the pipe repair device <NUM> can also comprise a leak region preparation subsystem <NUM> and/or a repair evaluation subsystem <NUM>. According to the example aspects, the various subsystems of the pipe repair device <NUM> can be controlled by a control module <NUM>. In some aspects, the pipe repair device <NUM> can be used in municipal drinking water systems, while other aspects, the pipe repair device <NUM> can be used in other pipeline <NUM> systems, such as oil pipelines, gas pipelines, etc..

Example aspects of the control module <NUM> can function to provide control instructions to the various subsystems of the pipe repair device <NUM>. The control module <NUM> can also function to generate control instructions in response to and/or based on sensor inputs. In example aspects, the control module <NUM> can be self-contained within the pipe repair device <NUM> and can comprise a processor (not shown) attached to the pipe repair device <NUM>. In a second aspect, the control module <NUM> can be implemented at a remote computing system (not shown) and can be connected to the pipe repair device <NUM> by a data link (e.g., a wired tether <NUM> (shown in <FIG>), a wireless link, etc.). However, the control module <NUM> can be otherwise suitably implemented in other aspects.

The power subsystem <NUM> can function to provide power to the various subsystems of the pipe repair device <NUM> in order to facilitate operation of the subsystems. In a first aspect, the power subsystem <NUM> can comprise the tether <NUM> that can carry electrical power from a surface generator (not shown) to the pipe repair device <NUM> within the pipeline <NUM>. In a second aspect, the power subsystem <NUM> can comprise a battery module (not shown) onboard the pipe repair device <NUM>. However, in other aspects, the power subsystem <NUM> can comprise any suitable energy storing and/or generating components.

The pipe repair device <NUM> can also comprise the communications subsystem <NUM> in various aspects. The communications subsystem <NUM> can function to transmit and receive control instructions and sensor inputs. In one aspect, the communications subsystem <NUM> can comprise a serial data bus (not shown) connected to the tether <NUM> that directly connects the pipe repair device <NUM> to a computing system (not shown) outside of the pipeline <NUM> (e.g., providing a serial data connection). In another example, the communications subsystem <NUM> can comprise a wireless radio (not shown) that can be connected to the computing system by a wireless data link. In yet another example, the communications subsystem <NUM> can comprise an acoustic-data transducer (not shown) that can send and receive signals transmitted as vibrations through a wall of the pipeline <NUM> and/or the water within the pipeline <NUM>. In other aspects, the communications subsystem <NUM> can comprise any other suitable components for communicating between the pipe repair device <NUM> and the computing system.

As shown in <FIG>, the pipe repair device <NUM> can comprise a body <NUM> defining a first end <NUM>, an opposite second end <NUM>, and a middle section <NUM> therebetween. Optionally, the body <NUM> can be formed from an NSF/ANSI <NUM> certified material that is approved as safe for use in drinking-water applications, such as, for example, stainless steel. In other aspects, the body <NUM> can be formed from another suitable material, such as, for example, aluminum, other metals, plastic, etc. As best seen in <FIG>, the tether <NUM> can be attached to the second end <NUM> of the body <NUM>, such that the tether <NUM> trails behind the pipe repair device <NUM> as it moves in a forward direction through the pipeline <NUM>.

The locomotion subsystem <NUM> can function to transport the pipe repair device <NUM> within the pipeline <NUM> to the leak region <NUM>. As shown in <FIG>, the locomotion subsystem <NUM> can comprise a transport mechanism <NUM> for transporting the pipe repair device <NUM> along an inner surface <NUM> (shown in <FIG>) of the pipeline <NUM>. In a specific example aspect, the transport mechanism <NUM> can comprise radially-repositionable continuous tracks <NUM> attached to the body <NUM> (e.g., six continuous tracks <NUM> positioned equidistant azimuthally about the pipe repair device <NUM>, as shown) that can be biased against the inner surface <NUM> of the pipeline <NUM>. In one aspect, each of the tracks <NUM> substantially spans a length of the middle region of the body <NUM>, from the first end <NUM> to the second end <NUM>.

In one aspect, as depicted, each the tracks <NUM> can be biased against the inner surface <NUM> of the pipeline <NUM> by a hydraulic cylinder (not shown). For example, an onboard pump <NUM> can pump fluid to the hydraulic cylinders, and the fluid can apply pressure to a piston <NUM> (shown in <FIG>) of the hydraulic cylinder. The piston <NUM> can force the respective track <NUM> outward against the inner surface <NUM> of the pipeline <NUM>. According to example aspects, the hydraulic cylinders can allow the pipe repair device <NUM> to accommodate for pipes of varying interior diameters because the tracks <NUM> can be radially repositionable relative to the body <NUM>. For example, in the depicted aspect, the pistons <NUM> can move into and out of the body <NUM> to adjust the distance between the tracks <NUM> and the body <NUM>. Furthermore, example aspects of the tracks <NUM> can have a certain degree of compliance, which can provide for improved maneuverability of the pipe repair device <NUM> around turns in the pipeline <NUM>. In some aspects, the locomotion subsystem <NUM> further can comprise a pressure sensor (not shown) in each of the hydraulic cylinders. The pressure sensors can be configured to measure the pressure applied by the fluid to the pistons <NUM>. The pressure data can be communicated to the control module <NUM>, and the control module can control adjustments to the pressure, as necessary, for improved maneuverability.

In another aspect, the tracks <NUM> can be biased against the inner surface <NUM> of the pipeline <NUM> by pneumatic cylinders. In such an aspect, compressed air can be used to force the tracks <NUM> outward against the inner surface <NUM> of the pipeline <NUM>. In still other aspects, the tracks <NUM> can be biased against the inner surface <NUM> of the pipeline <NUM> by other suitable biasing means, such as, for example, a compression spring or by a controllable scissor-jack mechanism. Moreover, in other aspects, the pipe repair device <NUM> can comprise alternative or additional mechanisms for rolling, sliding, gliding, or otherwise moving along the inner surface <NUM> of the pipeline <NUM>, such as, for example, wheels.

For example, <FIG> illustrate additional example aspects of the pipe repair device <NUM> and locomotion subsystem <NUM>. Each aspect of the pipe repair device <NUM> can comprise the body <NUM> and one or more wheels <NUM> for engaging the inner surface <NUM> of the pipeline <NUM> (shown in <FIG>). As shown, the wheels <NUM> can be connected to one or more pivotable arms <NUM> that can allow the wheels <NUM> to be radially repositioned to accommodate for varying pipe diameters. In some aspects, the pivotable arms <NUM> can be biased outward by springs <NUM>. Furthermore, as shown in <FIG>, example aspects of the pipe repair device <NUM> can comprise a connector <NUM> for physically connecting the pipe repair device <NUM> to the environment outside of the pipeline <NUM> (shown in <FIG>). For example, as shown, the connector <NUM> can be a pushrod <NUM> for pushing the pipe repair device <NUM> through the pipeline <NUM>. In other aspects, the connector <NUM> can be a tether, wire, or any other suitable connection mechanism.

Referring back to <FIG>, example aspects of the tracks <NUM> can be driven by one or more electric motors (not shown) that are operable while the pipe repair device <NUM> is submerged in fluid flowing through the pipeline <NUM>. Optionally, the pipe repair device <NUM> can comprise at least two motors that can be differentially driven to facilitate maneuvering the pipe repair device <NUM> around turns in the pipeline <NUM>. For example, in one aspect, the pipe repair device <NUM> can comprise a first motor and a second motor (first and second motors not shown). When approaching a turn in the pipeline, the speed of the first motor can be slowed in order to slow the tracks <NUM> driving on the inside of the turn, to facilitate navigation around the turn. In other aspects, the locomotion subsystem <NUM> can additionally or alternatively comprise one or more impellers, propellers, synthetic flagella, and/or any other suitable mechanisms for locomotion within the pipeline <NUM>. In example aspects, the locomotion of the pipe repair device <NUM> can be remotely operated by a remote operator (e.g. a technician) outside of the pipeline <NUM> (e.g., above ground).

Example aspects of the locomotion subsystem <NUM> can comprise a steering rod <NUM> extending from the first end <NUM> of the body <NUM>. The steering rod <NUM> can be movable relative to the body <NUM> of the pipe repair device <NUM> and can serve to guide the pipe repair device <NUM> in a preferred direction at an intersection in the pipeline <NUM>. In one example aspect, the intersection can be a tee fitting (not shown) in the pipeline <NUM>, and the pipe repair device <NUM> can move in either a left direction into a left-side pipe segment or a right direction into a right-side pipe segment. The steering rod <NUM> can be pointed in the preferred direction (e.g., left or right) and the pipe repair device <NUM> can be driven forward. As the pipe repair device <NUM> is driven forward, the steering rod <NUM> can engage the inner surface <NUM> of the preferred pipe segment (e.g. the left-side segment or right-side segment), and the pipe repair device <NUM> will turn in the preferred direction. In example aspects, the steering rod <NUM> can be actuated mechanically or electronically by the remote operator.

Example aspects of the locomotion subsystem <NUM> can be configured to navigate bends, tees, and vertical sections of the pipeline <NUM>. The locomotion subsystem <NUM> can also allow for both forward and reverse movement through the pipeline <NUM>. For example, the pipe repair device <NUM> can drive in a forward direction through the pipeline <NUM> to the leak region <NUM>, and then drive in a reverse direction out of the pipeline <NUM> upon completion of repairs to the leak region <NUM>. In example aspects, the tether <NUM> can also allow a remote operator to manually pull the pipe repair device <NUM> out of the pipeline <NUM> in an instance where the pipe repair device <NUM> is unable to drive itself out of the pipeline <NUM>. Examples of such instances can include malfunctioning of the locomotion subsystem <NUM>, power subsystem <NUM>, or control module <NUM>.

Example aspects of the pipe repair device <NUM> can further comprise the leak detection subsystem <NUM>, which can function to identify the presence of the leak <NUM> and the position of the leak region <NUM> requiring repair relative to the pipe repair device <NUM>, in order to enable the pipe repair device <NUM> to suitably position itself relative to the leak region <NUM> for a repair. In a first aspect, the pipe repair device <NUM> can comprise an image sensor <NUM> (e.g., a camera <NUM>) for visually identifying the leak region <NUM>. In an example of this aspect, the pipe repair device <NUM> can stream video data collected via the image sensor <NUM> to a remote operator in order to manually identify the leak region <NUM> based on the visibility of damage to the pipe <NUM>. As shown, the camera <NUM> can be disposed within a protective housing <NUM>. Some aspects of the pipe repair device <NUM> can also comprising a lighting mechanism (not shown) for illuminating the interior of the pipeline <NUM> for improved visibility. In a second aspect, the pipe repair device <NUM> can comprise an acoustic microphone <NUM> (e.g., a hydrophone <NUM>) for aurally identifying the leak region <NUM>. For example, the pipe repair device <NUM> can comprise one or more hydrophones <NUM> that can identify the axial and azimuthal position of the leak region <NUM> based on triangulation of hydrophone-derived audio signatures corresponding to leakage out of the pipeline <NUM>. In some aspects, as shown in <FIG>, the leak detection subsystem <NUM> can comprise both the image sensor <NUM> and the acoustic microphone <NUM> for improved detection of the leak region <NUM> and positioning of the pipe repair device <NUM> for repairing the leak region <NUM>.

Other example aspects of the pipe repair device <NUM> can comprise additional or alternative technologies for detecting a leak <NUM> within the pipeline <NUM>. For example, other technologies can include, but are not limited to, ultrasound, magnetic flux, lidar, sonar, laser, spectral aerial imaging, and light/infrared technologies. Yet another technology for detecting a leak <NUM> can include inserting dyes or gasses into the pipeline <NUM> and measuring for seepage through the leak <NUM>.

Upon detection of the leak <NUM>, the locomotion subsystem <NUM> can transport the pipe repair device <NUM> within the pipeline <NUM> to the leak region <NUM> and, using the leak detection subsystem <NUM>, position the pipe repair device <NUM> at an ideal location for repairing the leak region <NUM>. The locomotion subsystem <NUM> can transport the pipe repair device <NUM> to the leak region <NUM> after the leak <NUM> is identified, or can transport the pipe repair device <NUM> contemporaneously with locating the leak region <NUM> (e.g., transport the pipe repair device <NUM> though the pipeline <NUM> and identify the leak region <NUM> as the pipe repair device <NUM> traverses the pipeline <NUM>). Moreover, in some aspects, other factors or mechanisms can additionally or alternatively aid in the movement of the pipe repair device <NUM> axially through the pipeline <NUM> to the leak region <NUM>. For example, a current of the fluid in the pipeline <NUM>, a water hammer introduced into the pipeline <NUM> to generate a pressure force, or, as noted above, a propulsion mechanism, such as an impeller, propeller, and/or any other suitable submersible propulsion mechanism can assist in moving the pipe repair device <NUM> to the leak region <NUM>. According to example aspects, the leak detection subsystem <NUM> can be used to locate additional leak regions <NUM> requiring repair before, during, or after repair of the first leak region <NUM>.

<FIG> illustrates an example aspect of the pipe <NUM> of the pipeline <NUM> comprising the leak <NUM>. Example aspects of the leak <NUM> can be caused by a crack <NUM> in the pipe <NUM>. The crack <NUM>, and in some aspects the surrounding area, can define the leak region <NUM>. As shown in <FIG>, some example aspects of the pipe repair device <NUM> can comprise the leak region preparation subsystem <NUM>. The leak region preparation subsystem <NUM> can comprise a resurfacing mechanism <NUM> that can, in variations, function to grind, ablate, scour, and/or otherwise suitably remove material from the inner surface <NUM> of the pipe <NUM> in the leak region <NUM>. In additional or alternative aspects, the resurfacing mechanism <NUM> can overlay additional material on the inner surface <NUM> (e.g., fill in uneven areas of the inner surface <NUM> with additional material to prepare a substantially smooth inner surface <NUM> at the leak region <NUM>). In some aspects, the leak region preparation subsystem <NUM> can comprise a volume control mechanism (not shown) that functions to control a controlled preparation volume of the pipe <NUM> proximal the leak region <NUM>. Example aspects of the volume control mechanism can isolate the controlled preparation volume. The volume control mechanism can provide a suction force to the controlled preparation volume proximal the leak region <NUM> (e.g., to prevent removed pipe material and/or resurfacing material from being entrained in fluid flowing through the pipe <NUM> and carried downstream), a barrier to temporarily block and/or limit fluid flow passed the barrier (e.g., an inflatable bladder and/or balloon that can be expanded downstream of the leak region <NUM>), or any other suitable mechanism for regulating the conditions of the controlled preparation volume proximal the leak region <NUM>. Other example aspects of the pipe repair device <NUM> may not comprise the leak region preparation subsystem <NUM>.

The pipe repair device <NUM> can also comprise the pipe repair subsystem <NUM> for repairing the leak region <NUM> in the pipeline <NUM> detected by the leak detection subsystem <NUM> described above. The pipe repair subsystem <NUM> can function to reduce the leak rate through the leak region <NUM> of the pipe <NUM> to and/or below a leak rate threshold by applying a repair material to the leak region <NUM>. Applying the repair material functions to provide an impermeable mechanical barrier between the fluid (e.g., water) within the pipeline <NUM> and the environment external to the walls of the pipe <NUM> in order to repair the leak <NUM>. Example aspects of the repair material can be a NSF/ANSI <NUM> certified material that is approved as safe for use in drinking-water applications.

The leak rate threshold can be a zero-leakage rate (e.g., completely reducing the leak rate), less than a known lowest leak rate of the piping system (e.g., to reduce the minimum leak rate of the piping system), less than a known average leak rate of the piping system (e.g., to reduce the average leak rate of the piping system), and/or any other suitable leak rate threshold.

In a first aspect, as shown in <FIG>, the repair material can comprise a liquid-phase repair material. Specifically, the repair material can be epoxy reagents <NUM>. The epoxy reagents <NUM> can be, for example, an acrylic-based mixture, a polyester-based mixture, a resin-based mixture, or any other suitable epoxy mixture. In aspects wherein the repair material is a liquid-phase repair material, the repair material can comprise a binder. The binder can be an organic binder, an inorganic binder, a combination thereof, and/or any suitable binder. In examples, the repair material can comprise a water-insoluble cement, plaster, polymer compound (e.g., epoxy, thermoplastic, foam filler material, resin, etc.), and/or any other suitable material that can be applied to the leak region <NUM> in a liquid or semi-liquid phase. The repair material and/or components thereof can optionally comprise curable compounds (e.g., compounds that solidify upon curing). Such compounds can be curable via heat application, exposure to water, exposure to other compounds (e.g., a reagent that causes a phase-change in the curable compound), exposure to electromagnetic radiation (e.g., ultraviolet light), and/or curable in any other suitable manner.

As shown in <FIG>, the pipe repair device <NUM> can comprise a flexible cap <NUM>. The flexible cap <NUM> can be pressed against the inner surface <NUM> of the pipe <NUM> at the leak region <NUM> to isolate a controlled volume <NUM> around the leak region <NUM>. The pressing force can be generated by the pipe repair subsystem <NUM>, be generated by the surrounding water pressure within the pipe <NUM> (e.g., leveraging the low-pressure region proximal the leak <NUM> to drive cap attachment), or be otherwise generated and applied. In example aspects, the flexible cap <NUM> can also function as the volume control mechanism of the leak region preparation subsystem <NUM>, such that the controlled volume <NUM> can also be the controlled preparation volume. However, in other aspects, the flexible cap <NUM> can be separate from the volume control mechanism. The flexible cap <NUM> can create a fluid-impermeable seal around the leak region <NUM>, such that fluid flowing through the pipe <NUM> cannot enter the controlled volume <NUM>, and such that the repair material cannot escape the controlled volume <NUM>.

The pipe repair subsystem <NUM> can pump the epoxy reagents <NUM> into the controlled volume <NUM> defined within the flexible cap <NUM> through an opening <NUM> in the flexible cap <NUM> In example aspect, the epoxy reagents <NUM> can be mixed within the controlled volume <NUM> (e.g., using an agitator, by modulating the in-flow of the reagents <NUM> to layer the reagents <NUM> within the controlled volume <NUM> such that passive diffusion processes result in mixing, etc.). Some aspects of the pipe repair subsystem <NUM> can comprise a mixing nozzle (not shown) for mixing the epoxy reagents <NUM>.

The injected volume of binder can be a predetermined amount, a dynamically determined amount (e.g., a small amount if the leak <NUM> is proximal the bottom or nadir of the pipe; the controlled volume <NUM> if the leak <NUM> is proximal the top or apex of the pipe), or be any suitable volume. In an example aspect, injecting the epoxy reagents <NUM> can displace fluid (not shown) that is isolated within the controlled volume <NUM> (e.g., through a one-way check valve embedded in the flexible cap <NUM>). In another aspect, the epoxy can be injected through a nozzle that emerges into the controlled volume <NUM>. A bubble can be injected into the epoxy flow such that when the controlled volume <NUM> has been filled with the injected epoxy, the bubble can be liminal to the boundary between the controlled volume <NUM> and the nozzle (e.g., to create a discontinuous region between the epoxy inside the controlled volume <NUM> and the source of the epoxy). In still another aspect, ultraviolet light can be transmitted into the controlled volume <NUM> (e.g., via fiber-optic cabling, transparent walls of the flexible cap <NUM>, etc.) and can cure the epoxy.

In another aspect, the flexible cap <NUM> can be attached to the inner surface <NUM> of the pipe <NUM> by the epoxy (e.g., after curing and/or solidification of the epoxy), and can be left at the repaired leak region <NUM> (e.g., detached from the pipe repair device <NUM>) after repairing the leak <NUM>. In a similar aspect, the epoxy reagents <NUM> can be contained within sub-compartments attached to an outside of the flexible cap <NUM>, and repairing the leak <NUM> can comprise compressing the cap <NUM> against the leak region <NUM> to simultaneously inject the epoxy reagents <NUM> from the sub-compartments into the controlled volume <NUM>, mixing the reagents <NUM> within the controlled volume <NUM>, and biasing the epoxy mixture against the leak region <NUM> to fill the leak <NUM> and repair the leak <NUM> upon solidification of the epoxy mixture. However, in other aspects, the flexible cap <NUM> can be reusable (e.g., withdrawn from the inner surface <NUM> of the pipe <NUM> after epoxy solidification and/or curing).

Some example aspects of the pipe repair subsystem <NUM> can further comprise a separating mechanism (not shown) for mechanically separating the solidified epoxy from the source of the epoxy (e.g., the nozzle). For example, the separating mechanism can be a blade, a scissor-like mechanism, or any other suitable mechanism for cutting the epoxy away from the source.

In a second aspect, as shown in <FIG>, the pipe repair subsystem <NUM> comprises a stent <NUM> for repairing the leak <NUM> at the leak region <NUM> (shown in <FIG>). Aspects of the stent <NUM> are expandable and compressible, such that the stent <NUM> can be oriented in an expanded configuration, as shown, and a compressed configuration (not shown). The stent <NUM> comprises a spring <NUM> and a sealing layer <NUM> defining a substantially cylindrical structure. A void <NUM> can extend through a center of the cylindrical structure. The spring <NUM> biases the stent <NUM> to the expanded configuration, as shown. In the present aspect, the spring <NUM> can comprise a metal wire <NUM> defining a wave pattern in the axial direction. However, other aspects of the spring <NUM> can comprise any other suitable material and define any other suitable spring <NUM> pattern or design. The sealing layer <NUM> wraps around a circumference of the spring <NUM>, engaging an outer surface of the spring <NUM>. Aspects of the sealing layer <NUM> comprise a flexible and compressible material, such as, for example, neoprene. In other aspects, the sealing layer <NUM> can be formed from foam, another rubber material, epoxy, silicone, or any other suitable flexible material for providing a watertight seat between the stent <NUM> and the inner surface <NUM> of the pipe <NUM> at the leak region <NUM>. Optionally, the spring <NUM> and sealing layer <NUM> can be formed from NSF/ANSI <NUM> certified materials that are approved as safe for use in drinking-water applications.

The stent <NUM> can be oriented in the compressed configuration for transport of the stent <NUM> by the pipe repair device <NUM> to the leak region <NUM>. The stent <NUM> can be compressed by a compression mechanism, such as a compression sleeve (not shown). In other aspect, a tensioning mechanism can be used to orient the stent <NUM> in the compressed configuration, such as, for example, a cable (not shown) configured to contract the stent <NUM> radially inward. As the stent <NUM> is driven through the pipeline <NUM> by the pipe repair device <NUM>, fluid in the pipeline <NUM> can continue to flow around and/or through the compressed stent <NUM>. As such, the flow of fluid in the pipeline <NUM> can continue uninterrupted as the stent <NUM> is navigated through the pipeline <NUM>. According to example aspects, the stent <NUM> can be positioned proximate the leak <NUM> and can be expanded within the pipe <NUM> by removing a compression force applied by the compression mechanism. In the expanded configuration, the sealing layer <NUM> can engage the inner surface <NUM> of the pipe <NUM> at the leak region <NUM>. The sealing layer <NUM> can press against the leak region <NUM> to create a watertight seal between the stent <NUM> and the inner surface <NUM> of the pipe <NUM> at the leak region <NUM> to repair the leak <NUM>. As such, the sealing layer <NUM> of the stent <NUM> can serve as the repair material. In example aspects, fluid pressure from the fluid flow in the pipeline <NUM> can also assist in pressing the stent <NUM> against the inner surface <NUM> of the pipe <NUM>.

With the stent <NUM> positioned in the pipe <NUM> in the expanded configuration, fluid in the pipeline <NUM> can flow through the void <NUM> in the stent <NUM>. Example aspects of the stent <NUM> can be sized and shaped to fit tightly within the pipeline <NUM> in the expanded configuration. For example, in one aspect, a diameter of the stent <NUM> in the expanded configuration can be slightly greater than a diameter of the inner surface <NUM> of the pipe <NUM>. The tight fit of the stent <NUM> within the pipe <NUM>, along with fluid pressure against the stent <NUM>, can aid in retaining the stent <NUM> in position at the leak region <NUM>. Some aspects of the stent <NUM> can also comprise an attachment mechanism (not shown), such as an adhesive, for attaching the stent <NUM> to the inner surface <NUM> of the pipe <NUM> at the leak region <NUM>. Whether an attachment mechanism is desired, and the type of attachment mechanism, can be determined based on the surface friction of inner surface <NUM> of the pipe <NUM> at the leak region <NUM> and the surface friction of the sealing layer <NUM>.

Example aspects of the pipe repair subsystem <NUM>, or portions thereof, can be attached to the body <NUM> of the pipe repair device <NUM> at any location. In one aspect, wherein the pipe repair subsystem <NUM> comprises the stent <NUM>, the stent <NUM> can be attached to the pipe repair device <NUM> at the second end <NUM> of the body <NUM>, such that the stent <NUM> trails behind the pipe repair device <NUM> as it moves forward through the pipeline <NUM>. Once the stent <NUM> has been positioned as desired and expanded to repair the leak <NUM>, the pipe repair device <NUM> can reverse out of the pipeline <NUM>, passing through the void <NUM> of the stent <NUM>. In other aspects, the stent <NUM> can be located elsewhere.

In a third aspect, the repair material can comprise metal compounds introduced into the leak region <NUM> to repair the leak <NUM>. For example, repairing the leak <NUM> can comprise spot-welding the leak <NUM>, and the repair material can comprise pipe material proximal the leak region <NUM> and/or additional metallic filler material that is melted into the leak region <NUM> (e.g., using a submersible welding head) and cooled (e.g., actively cooled, passively cooled) in situ to repair the leak <NUM>.

While the repair technologies of a stent <NUM>, an underwater liquid-phase epoxy injection, and spot-welding are discussed in detail in this application, other example aspects of the pipe repair device <NUM> can comprise additional or alternative technologies for repairing the leak <NUM> within the pipeline <NUM>. For example, other technologies and/or repair materials can include, but are not limited to, an inflatable sleeve, natural rubber, synthetic rubber such as EPDM rubber, cyanoacrylates, tape, epoxy putty, concrete, cement, resin, an epoxy or resin-soaked cloth, and magnets. Example aspects of the epoxy putty can be an acrylic-based epoxy putty, a polyester-based epoxy putty, a resin-based epoxy putty, or any other suitable epoxy putty. Furthermore, example aspects of the epoxy-soaked cloth can comprise an acrylic-based epoxy, a polyester-based epoxy, a resin-based epoxy, or any other suitable epoxy. Moreover, the repair material can comprise a compound of various materials (e.g., precursors, binders, catalysts, filler material, resins, etc.), be a single material (e.g., a unitary compound), or any other suitable material. Additionally, the repair material can be a liquid-phase repair material that is solidified in situ (e.g., an epoxy compound), a solid material (e.g., neoprene), a paste, a gas, a matrix, or can have any other suitable composition.

According to example aspects, the pipe repair device <NUM> can also comprise an evaluation subsystem <NUM>. The evaluation sub-system can function to determine whether the repair successfully met a predetermined repair criteria (e.g., whether the leak <NUM> was stopped, whether the leak rate was reduced below a threshold leak rate, etc.). In example aspects, as shown in <FIG>, the evaluation subsystem <NUM> can comprise a leak evaluation mechanism <NUM>. An example aspect of the leak evaluation mechanism <NUM> can comprise the hydrophone <NUM> and a processor <NUM>. In some example aspects, the processor <NUM> can be located on or within the pipe repair device <NUM>, while in other aspects, the processor <NUM> can be located remote from the pipe repair device <NUM>. The hydrophone <NUM> can extract a frequency power spectrum of noise in the pipe <NUM> proximal the leak region <NUM>, and the processor <NUM> can identify an audio signature corresponding to the leak <NUM> and determine a change in the signature (e.g., disappearance of the audio signature, reduction of the audio signature signal power below a threshold signal power) indicative of leak repair and/or satisfaction of the predetermined repair criteria. However, the evaluation subsystem <NUM> can comprise any suitable components for evaluating the leak repair.

Various methods for repairing a pipeline <NUM> with the pipe repair device <NUM> are disclosed. In an example aspect, a method for repairing the pipeline <NUM> can comprise the steps of inserting the pipe repair device <NUM> into a pipeline <NUM>, detecting a leak <NUM> at a leak region <NUM> in the pipeline <NUM>, transporting the pipe repair device <NUM> through the pipeline <NUM> to the leak region <NUM>, and repairing the leak <NUM>. In some aspects, the steps of detecting the leak <NUM> and transporting the pipe repair device <NUM> through the pipeline <NUM> can be performed concurrently. Further, in some aspects, the method can further comprise the step of detecting a second leak at a second leak region in the pipeline <NUM> before, during, or after the step of repairing the leak <NUM>. Some methods can also comprise the steps of preparing the leak region <NUM> and/or evaluating the repaired leak <NUM>.

In example aspects, the pipe repair device <NUM> can be inserted into the pipeline <NUM> at an existing access point, such as, for example, a fire hydrant, a service entrance, or any other suitable point of entry that allows for easy insertion of the pipe repair device <NUM> into the pipeline <NUM>. Inserting the pipe repair device <NUM> into the pipeline <NUM> at an existing access point and remotely navigating the pipe repair device <NUM> through the pipeline <NUM> can eliminate the need to dig up the surrounding terrain to locate and repair the leak <NUM>, which can save time and costs when performing repairs.

Once inserted into the pipeline <NUM>, the leak detection subsystem <NUM> can detect a leak <NUM> in the pipeline <NUM> and can pinpoint the location of the leak <NUM> (e.g. leak region <NUM>) in the pipeline <NUM>. In a first aspect, the step of detecting a leak <NUM> can comprise visually identifying the leak region <NUM>. Visually identifying the leak region <NUM> can comprise streaming video data collected via an image sensor <NUM> of the pipe repair device <NUM> to a remote operator in order to manually identify the leak region <NUM> based on the visibility of air bubbles entering the pipe <NUM> proximal the leak region <NUM> or by the visibility of damage to the pipeline <NUM>. In a second aspect, detecting the leak <NUM> can comprise aurally identifying the leak region <NUM>. Aurally identifying the leak region <NUM> can comprise tracking on or more hydrophones <NUM> proximal the inner surface <NUM> of the pipe <NUM> while transporting the pipe repair device <NUM> (e.g., using a locomotion subsystem <NUM>), and identifying the axial and azimuthal position of the leak region <NUM> based on triangulation of hydrophone-derived audio signatures corresponding to leakage out of the pipeline <NUM>.

Upon detection of a leak <NUM>, the locomotion subsystem <NUM> can transport the pipe repair device <NUM> to the leak region <NUM>. In one aspect, transporting the pipe repair device <NUM> through the pipeline <NUM> can comprise rolling the pipe repair device <NUM> along the inner surface <NUM> of the pipeline <NUM>. Rolling along the inner surface <NUM> of the pipeline <NUM> can comprise biasing the one or more tracks <NUM> of the pipe repair device <NUM> against the inner surface <NUM> of the pipeline <NUM>, supplying power to one or more motors of the pipe repair device <NUM>, and driving the tracks <NUM> with the motors. In another aspect, transporting the pipe repair device <NUM> through the pipeline <NUM> can comprise propelling the pipe repair device <NUM> through the pipeline <NUM>. Propelling through the pipeline <NUM> can comprising supplying power to one or more motors of the pipe repair device <NUM>, and driving a propulsion mechanism with the motors. In example aspects, the propulsion mechanism can be an impeller, propeller, and/or any other suitable submersible propulsion mechanism.

In some aspects, a current of the fluid flowing in the pipeline <NUM> can assist in moving the pipe repair device <NUM> through the pipeline <NUM>. In other aspects, a water hammer can be introduced into the pipeline <NUM> to generate a pressure force to assist in moving the pipe repair device <NUM> through the pipeline <NUM>. As the pipe repair device <NUM> moves through the pipeline <NUM>, fluid in the pipeline <NUM> can continue to flow around and/or through the pipe repair device <NUM>. As such, the flow of fluid in the pipeline <NUM> can continue uninterrupted as the pipe repair device <NUM> is navigated through the pipeline <NUM>. Such a configuration prevents the need to shut off the fluid flow during repairs, which can save costs for the service provider and prevent interruption of service to customers.

The method can optionally comprise the step of preparing the leak region <NUM> before repairing the leak <NUM>. In one aspect, the step of preparing the leak region <NUM> can comprise preparing the inner surface <NUM> of the pipe <NUM> by removing material proximal the leak region <NUM>. For example, a resurfacing mechanism <NUM> can reduce the surface roughness to produce a suitable (e.g., substantially smooth) surface at which to repair the leak <NUM>. Preparing the inner surface <NUM> can comprise grinding, abrading, or otherwise mechanically preparing the inner surface <NUM>, compressing the inner surface <NUM>, chemically reacting the inner surface <NUM>, or otherwise preparing the inner surface <NUM>.

The step of preparing the leak region <NUM> can optionally comprise controlling a volume of the pipe <NUM> proximal the leak region <NUM> with a volume control mechanism. Preparing the leak region <NUM> can further comprise providing a suction force to the volume proximal the leak region <NUM> (e.g., to prevent removed pipe material and/or resurfacing material from contaminating the water flowing through the pipe <NUM>) and/or providing a barrier to temporarily block and/or limit water flow passed the barrier (e.g., an inflatable bladder and/or balloon that can be expanded downstream of the leak region <NUM>). However, in other aspects, a fire hydrant (not shown) can be opened downstream of the leak region <NUM>, and any contaminated water can be flushed out.

Upon preparing the leak region <NUM>, the leak <NUM> can be repaired. The step of repairing the leak <NUM> can comprise applying a repair material to the leak region <NUM> using a repair mechanism of the repair subsystem <NUM>. In one aspect, the repair material can be a liquid-phase repair material, and applying the repair material can comprise, for example, suffusing the leak region <NUM> with an epoxy compound. In another aspect, the repair material can be a solid material, applying the repair material can comprise, for example, affixing a patch to the leak region <NUM>.

Optionally, the repair material can comprise curable compounds. Thus, repairing the leak <NUM> can optionally comprise curing the curable compounds included in the repair material, such as by exposing the curable compounds to heat (e.g., heating the curable compounds using a heater of the repair subsystem <NUM>), exposing the curable compounds to water (e.g., by introducing water into the controlled volume <NUM> proximal the leak region <NUM> and into which repair material has been applied), exposing the curable compounds to electromagnetic radiation (e.g., by shining ultraviolet light onto the leak region <NUM> at which repair material has been applied, using a light emitter of the repair subsystem <NUM>), and/or by any other suitable mechanism or technique.

Repairing the leak <NUM> comprises providing a stent <NUM> in a compressed configuration, the stent <NUM> comprising a spring <NUM> and a sealing layer <NUM>, reconfiguring the stent <NUM> from the compressed configuration to an expanded configuration, and pressing the sealing layer <NUM> of the stent <NUM> against the inner surface <NUM> of the pipe <NUM> at the leak region <NUM> to create a water-tight seal between the sealing layer <NUM> and the leak region <NUM>. Another example aspect of repairing the leak <NUM> can comprise spot-welding the leak <NUM>. Spot-welding the leak <NUM> can comprise melting pipe material proximal the leak region <NUM> and/or additional metallic filler material into the leak region <NUM> (e.g., using a submersible welding head) and cooling the material (e.g., actively cooled, passively cooled) in situ to repair the leak <NUM>.

Repairing the leak <NUM> can comprise creating a controlled volume <NUM> surrounding the leak region <NUM>, which can function to isolate the controlled volume <NUM> proximal the leak region <NUM> from the remainder of the internal volume of the pipe <NUM>. The controlled volume <NUM> (e.g., repair lumen) can exhibit a flow rate through the controlled volume <NUM> that is less than a threshold flow rate (e.g., the background flow rate through the pipe <NUM>, a predetermined threshold flow rate, etc.), but can alternatively exhibit any suitable flow rate. The controlled volume <NUM> can comprise a liquid water level (e.g., volume of liquid water) less than a threshold water level (e.g., less than <NUM>% liquid water, less than <NUM>% water, less than <NUM>% water, etc.), but can alternatively comprise any suitable water level. The pressure within the controlled volume <NUM> can be less than a threshold pressure (e.g., the background pressure within the pipe <NUM>, a predetermined fraction of the background pressure within the pipe <NUM>, etc.), but can alternatively be any suitable pressure.

In a first aspect, not covered by the claims, creating the controlled volume <NUM> can comprise pushing a concave structure defining an open lumen against the inner surface <NUM> of the pipe <NUM> proximal the leak region <NUM>. The concave structure can be a hemispherical structure, a conical structure, and/or any other suitable structure exhibiting any suitable degree of concavity. The open lumen can be transformed into a closed lumen upon arranging the concave structure adjacent to the inner surface <NUM>, wherein the inner surface <NUM> and the concave structure cooperatively define the controlled volume <NUM> about the leak region <NUM>. However, the controlled volume <NUM> can be otherwise suitable defined. The concave structure can comprise at least one orifice through which the repair material can be introduced (e.g., injected, pumped).

In a second aspect, not covered by the claims, creating the controlled volume <NUM> can comprise pushing an expandable bladder against the inner surface <NUM> of the pipe <NUM> proximal the leak region <NUM>. Repairing the leak <NUM> can comprise injecting repair material (e.g., binder) into the expandable bladder, and bursting the bladder adjacent to the leak region <NUM> to form a mound of repair material covering the leak region <NUM>. Bursting the bladder can be performed by utilizing the inner surface <NUM> (e.g., rough features of the inner surface <NUM>, sharp features of the inner surface <NUM>) to puncture the surface of the bladder, utilizing an internal puncture mechanism to burst the bladder, or can be otherwise performed in any other suitable manner.

In a third aspect, not covered by the claims, creating the controlled volume <NUM> can comprise expanding a first balloon upstream of the leak region <NUM> to block upstream pipe flow (e.g., reduce the upstream flow below a threshold flow rate), and expanding a second balloon downstream of the leak region <NUM> to block flow downstream of the pipe repair device <NUM> and/or backflow (e.g., reduce the downstream flow and/or backflow below a threshold flow rate). This variation can optionally comprise pumping the water within the controlled volume <NUM> defined between the first and second balloon. In example implementations, the pipe repair device <NUM> can define a water flow path between the first and second balloon and can actively augment the flow rate (e.g., using an impeller, a reciprocating pump, etc.) between the first and second balloon along the flow path in order to reduce the upstream pressure rise caused by the first (upstream) balloon (e.g., matching the flow rate to the background flow rate through the pipe <NUM>. ) The step of repairing the leak <NUM> can then be performed.

A specific aspect of repairing the leak <NUM>, not covered by the claims, can comprise isolating the leak region <NUM> from the surrounding pipe <NUM> by pressing a flexible cap <NUM> against the inner surface <NUM> of the pipe <NUM>, creating a fluid-impermeable seal around the leak region <NUM>, and pumping epoxy reagents <NUM> into the repair lumen defined within the flexible cap <NUM> (e.g., proximal the isolated leak region <NUM>). This example aspect can further comprise mixing the epoxy reagents <NUM> within the repair lumen (e.g., using an agitator, by modulating the in-flow of the reagents <NUM> to layer the reagents <NUM> within the lumen such that passive diffusion processes result in mixing, etc.). However, other aspects can comprise pre-mixing the reagents and subsequently pumping the epoxy reagents <NUM> into the repair lumen, and/or otherwise suitably mixing the epoxy reagents <NUM> (e.g., impregnating an inner surface <NUM> of the flexible cap <NUM> with an epoxy reagent <NUM> such that contact between an injected epoxy component and the inner surface <NUM> of the flexible cap <NUM> results in reagent mixing).

Another specific example aspect of repairing the leak <NUM>, not covered by the claims, can comprise providing an epoxy applicator that can comprise a flexible tube (not shown) attached to a linear actuator, actuating the epoxy applicator proximal to the leak region <NUM>, wherein an outlet of the flexible tube is arranged adjacent to the leak region <NUM>, forcing a quantity of epoxy through the tube to create an epoxy bead that covers the leak region <NUM>, pausing for a predetermined time period (e.g., <NUM> seconds, <NUM> minutes, <NUM> hour, etc.) for the epoxy to transition to a solid state (e.g., a cured state), and mechanically separating the solidified epoxy bead from the tube (e.g., using a guillotine of the repair subsystem <NUM> such as a single bladed guillotine, a double bladed guillotine, etc.). In some aspects, as described above, the tube can be a mixing nozzle.

Example aspects of the method can also comprise the step of evaluating the repair. Evaluating the repair can be performed by the evaluation subsystem <NUM>. A first aspect of evaluating the repair can comprise visually evaluating the repair. Visually evaluating the repair can comprise collecting imagery data at an image sensor <NUM> of the pipe repair device <NUM> and transmitting the imagery data to a remote operator (e.g., wherein the remote operator views the imagery data rendered on a display outside the pipe) that can manually evaluate that the leak rate has been reduced below a threshold level. A second aspect of evaluating the repair can comprise sonically evaluating the repair. Sonically evaluating the repair can comprise collecting auditory data at a hydrophone <NUM> of the pipe repair device <NUM>, extracting auditory signatures from the auditory data, and determining that the auditory signatures are indicative of a reduced fluid leakage rate (e.g., reduced below a threshold leakage rate, reduced by a predetermined ratio relative to an initial leakage rate, etc.).

Claim 1:
A pipe repair device (<NUM>) for repairing a leak (<NUM>) in a pipe (<NUM>) of a pipeline (<NUM>), the pipe repair device (<NUM>) comprising:
a body (<NUM>);
a sensor attached to the body (<NUM>) for detecting the leak in (<NUM>) the pipe (<NUM>);
a transport mechanism attached to the body (<NUM>) for transporting the pipe repair device (<NUM>) along the pipe (<NUM>), the transport mechanism comprising a continuous track (<NUM>), wherein the continuous track (<NUM>) is biased outward from the body (<NUM>) for being biased against an inner surface of the pipeline (<NUM>); and
a repair mechanism comprising a repair material for repairing the leak (<NUM>),
wherein the repair mechanism comprises a stent (<NUM>), the stent (<NUM>) reconfigurable between an expanded orientation and a compressed orientation, wherein the stent (<NUM>) comprises a spring (<NUM>) and a sealing layer (<NUM>) defining a substantially cylindrical structure, the spring (<NUM>) biasing the stent (<NUM>) to the expanded orientation, wherein the sealing layer (<NUM>) is wrapped around a circumference of the spring (<NUM>), engaging an outer surface of the spring, wherein the sealing layer (<NUM>) comprises a flexible and compressible repair material.