Method to repair compromised inlet outlet piping

Abstract

Pipe fractures in cooling staves of blast furnaces are a common failure mechanism Herein is a repair method for a cooling stave utilized in a blast furnace, the cooling stave having a compromised stave inlet outlet pipe attached to the cooling pipe in the cooling stave, the method comprises of the steps of inserting a rigid pipe into the compromised stave inlet outlet pipe to form a first annulus; inflating a bladder disposed inside the inner pipe and cooling stave; injecting a first uncured epoxy material into the first annulus; permitting the first uncured epoxy to cure; and removing the bladder.

What is claimed is: 
     
         1 . A method for repairing a cooling stave in situ wherein, the cooling stave having a stave inlet outlet pipe attached to a cooling pipe in the cooling stave, the method comprising:
 inserting a pipe into the stave inlet outlet pipe to form a first annulus;   inflating a bladder disposed inside the pipe and cooling stave;   injecting a first uncured epoxy material into the first annulus;   permitting the first uncured epoxy to cure; and   removing the bladder.   
     
     
         2 . The repair method of  claim 1  wherein a first end of the pipe distal to the cooling stave further comprises a means for introduction of the first uncured epoxy to the first annulus, and a second end of the pipe proximal to the stave further comprises means for venting air displaced during injecting of a first uncured epoxy into the first annulus. 
     
     
         3 . The repair method of  claim 1  further comprising the steps of:
 applying an outer pipe external to the stave inlet outlet pipe to form a second annulus; 
 injecting a second uncured epoxy material into the second annulus; and 
 permitting the second uncured epoxy material to cure. 
 
     
     
         4 . The repair method of  claim 3  wherein the first and second uncured epoxies are cured concurrently. 
     
     
         5 . The repair method of  claim 3  wherein the first uncured epoxy is cured before the second uncured epoxy is cured. 
     
     
         6 . The repair method of  claim 3  wherein a first end of the outer pipe distal to the cooling stave further comprises a means for introduction of the second uncured epoxy to the second annulus, and a second end of the outer pipe proximal to the cooling stave further comprises a boot adapted to form seals with the outer pipe and the cooling stave, and the second end having an aperture in open communication with the second annulus. 
     
     
         7 . A method for repairing a cooling stave in site, comprising:
 rethreading an aperture in the cooling stave formed after removal of a compromised stave inlet outlet pipe;   installing a new inlet outlet pipe;   inserting an inner pipe into the new stave inlet outlet pipe to form an annulus;   inflating a bladder inside the inner pipe and the cooling stave;   injecting an uncured epoxy material into the annulus;   permitting the uncured epoxy to cure; and   removing the bladder.   
     
     
         8 . A repair system kit for a cooling stave utilized in a blast furnace, the cooling stave having a stave inlet outlet pipe comprised of:
 an inflatable bladder;   an inner rigid pipe;   a grout inlet; and   a vent tube.   
     
     
         9 . The repair system kit of  claim 8  further comprising a concentric outer pipe; and a flexible rubber seal.