US20040106366A1

US20040106366A1 - Portable pipe restoration system

Info

Publication number: US20040106366A1
Application number: US10/641,201
Authority: US
Inventors: Robert Robinson; Stephen McGrady
Original assignee: Media Blast and Abrasives Inc
Current assignee: Media Blast and Abrasives Inc
Priority date: 2002-08-26
Filing date: 2003-08-14
Publication date: 2004-06-03

Abstract

There is provided a pipe restoration system which uses abrasives to remove encrustation from a piping system. The pipe restoration system first comprises a main header having a plurality of header outlets. A pressure generator with abrasives is also provided with the system and is connected to one of the header outlets to receive air pressure therefrom. The pressure generator is further connected to one of piping system's inlets so as to discharge the abrasives therethrough via the air pressure. A separator is connected to the piping system's outlet to receive and separate the abrasives from the encrustation removed thereby. The separator retains the abrasives therewithin. Lastly, a particle collector is connected to the separator to receive and retain the encrustation separated in the separator.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 60/406,017 entitled “PORTABLE PIPE RESTORATION SYSTEM” filed Aug. 26, 2002, the entirety of the disclosure of which is expressly incorporated herein by reference.[0001]

STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

The present invention relates generally to pipe restoration systems, and more particularly to an improved, portable pipe restoration system featuring a unique combination of portable devices which collectively operate to effectively remove and contain low water pressure causing encrusted layers disposed within various piping of the plumbing system.

It is inevitable that most residential and commercial buildings suffer from encrusted plumbing systems as they age. Plumbing systems within these buildings are typically laid out in a manner as to provide water to certain designated areas such as kitchens, bathrooms, garages, yards, and the like. Water is usually drawn into the residential/commercial buildings by a single piping and exits the same by a different single piping after use.

However, due to the fundamental material characteristics of the piping forming the conventional plumbing system, encrustation of the piping appears to be unavoidable over time. More specifically, these piping are typically constructed from either copper or galvanized steel, and form relatively small diameter conduits for channeling water through different areas of the building. Repeated exposures to water over long durations of time within these copper or galvanized steel piping can lead to undesired consequences such as calcium buildups resulting from gradual accumulation of encrustation layers therein.

Encrusted piping typically lower the quality of water and its use which can become very frustrating to building and home owners, property managers, tenants and the like. For instance, the layers of encrustation within the piping may become so thick that the water supply is barely flowing. In addition to the lower water pressure, encrusted piping may cause the water to smell. They may even lead to freeze-outs or scalds when a toilet is flushed or faucet is turned on. These problems associated with encrustation of the piping system progressively get worse if they remain neglected.

One effective long-term remedy for encrusted piping is to repipe the whole piping system. However, such procedure is very expensive to perform as it requires new piping materials and extensive labor time. Further to the expense, repiping procedure usually leads to nuisance of dirt, noise and several weeks of being deprived of water. As such, although repiping may generally resolve encrustation problems, the expense and inconvenience associated with such procedure greatly detract from its overall utility.

As an alternative to the often frustrating repiping procedure, some companies in the piping industry have developed and used a procedure where the existing in-placed pipes are essentially restored to their original working conditions. Generally, the existing piping system is inspected for integrity and repairs are made where there are excessively worn joints and fittings. The piping system is then drained of any sitting water and dried with heated compressed air to remove all moisture. Thereafter, the air medium is once again used to shoot abrasives through the piping system to remove layers of encrustation accumulated therein.

Perhaps the greatest deficiency of such in-place pipe restoration procedures is their inability to remove the layers of encrustation in a time efficient manner. A conventional restoration system is typically connected to an open end of a sizably elongated piping in order to shoot out abrasives through that end via continuous discharges of air pressure. However, due to the sizable elongation of such piping, the discharged air pressures may weaken toward the opposite end of the piping.

As such, the existing in-place pipe restoration procedures may not be so effective in removing the encrustation layers that are accumulated toward the opposite end of the piping. The known remedy for this inadequacy is to prolong the operation time in hopes that the continuous flow of abrasives would remove substantial portions of the encrustation toward the opposite end of the piping. However, even with the unusually long operational time which would obviously prolong the overall pipe restoration process, the successful removal of the encrustation layers does not appear to be guaranteed as the air pressure tends to weaken toward the piping's opposite end.

In view of the above-described shortcomings of conventional pipe restoration systems and procedures, there exists a need in the art for an in-place pipe restoration system that can effectively remove layers of encrustation from an entirety of the piping system so as to restore it into its original working conditions. More specifically, there exists a need for an in-place pipe restoration system which can accomplish the overall pipe restoration process in a time-efficient manner so that any nuisance or inconvenience to the living tenants is greatly mitigated.

BRIEF SUMMARY OF THE INVENTION

The present invention specifically addresses and alleviates the above-referenced deficiencies associated with the use of conventional pipe restoration systems and procedures. More particularly, the present invention is an improved, portable pipe restoration system that is applied upon a plumbing pipe system which is first divided into a plurality of manageable segments. The present pipe restoration system features a unique collection of portable devices which are designed to operate together for the purpose of effectively removing and containing low water causing encrusted layers accumulated within various piping. It is expressly contemplated herein that the use of the present pipe restoration system is not merely limited to plumbing systems. Its application may extend to other similar pipe utilizing settings such as air conditioning drain pipes for example.

In accordance with a preferred embodiment of the present invention, there is provided an in-place pipe restoration system which is configured to quickly, efficiently and effectively eliminate substantial portions of low water pressure causing encrustation deposits from a plumbing pipe system. For the purposes of this patent, the term encrustation will be understood hereon out as any substance that slows down water flow within the piping. In this regard, encrustation will be associated with various substances that negatively affect the water flow within the piping.

The pipe restoration system of the present invention first features a main header which is connected with an outside pressure source and the present system's pressure generator. The main header primarily serves as a conduit between the outside pressure source and the pressure generator such that the requisite air pressure generated from the outside pressure source is supplied to the pressure generator. To achieve this objective, the main header includes a header tank which has at least one header inlet, of which one of the header inlets is placed in communication with the outside pressure source. The remaining header inlet or inlets (if provided) may be used to connect with additional pressure sources should a need to increase the air pressure exist. The header tank is preferably formed of metal.

Extending from the sides of the tank body are a plurality of header outlets. One of these header outlets is connected to a pressure generator which is hooked up to one of several open pipe inlets of the segmented piping. By doing so, the main header is able to provide the air pressure necessary to discharge the abrasives from the pressure generator into the connected pipe inlet. Simultaneously, the other header outlets are selectively utilized to connect and discharge only the air pressure through the remaining open pipe inlets of the segmented piping so that none of the abrasives shot out from the pressure generator becomes lodged or stuck in any sections of the segmented piping.

A header tank enclosure may be provided to enclose the header tank therewithin. Such enclosure can be fabricated from any sturdy material but metal is preferred. The header tank enclosure defines multiple openings which allow all of the header inlets and outlets to be extended therethrough. Moreover, main header wheels may be attached adjacent to the tank enclosure's bottom surface to provide mobility to the main header, thus making it portable. Additionally, a main header support can be formed at the bottom surface of the tank enclosure laterally across from the main header wheels so that it may be used to support the main header when standing in an upright position.

As briefly mentioned above, the pipe restoration system of the present invention also includes a pressure generator which is used for discharging the stored abrasives through the connected open pipe inlet of the segmented piping. The pressure generator comprises a generator body which is preferably made out of metal and forms an internal generator compartment therewithin. A pressure discharger assembly is disposed within the internal generator compartment. The pressure discharger assembly has an abrasive loading hopper which can be selectively accessed by an openable/closeable upper lid member formed at the top of the generator body. In this regard, by opening the upper lid member, a system operator may manually load the abrasives into the abrasive loading hopper. The abrasives are then fed and stored into an abrasive storage container which is located immediately underneath the lower end of the abrasive loading hopper.

An abrasive mixing valve is disposed immediately underneath the lower end of the abrasive storage container. Such mixing valve is used to receive and then discharge the abrasives through its discharge end. The abrasive mixing valve is connected to one of the header outlets of the main header at an end substantially opposite from its discharge end which results in the acquisition of air pressure needed to shoot out the abrasives therefrom. Due to such configuration, and further due to the additional air pressure supplied through the other pipe inlets by the remaining header outlets, abrasives may be effectively passed through the segmented piping without becoming stuck or lodged so as to effectively abrade and remove any accumulated layers of encrustation disposed therein.

The pressure generator may become mobile, and hence portable, via attachment of pressure generator wheels thereto. Preferably, the pressure generator wheels are attached adjacent to the lower surface of the generator body. In this regard, the movement of the pressure generator between various locations can be greatly facilitated by its use of the pressure generator wheels.

In accordance with the preferred embodiment of the present invention, there is further provided a separator which is adapted to connect with a pipe outlet formed by merging of the various separated sections of the piping. The separator becomes connected to the pipe outlet through at least one separator inlet formed on its separator body. Such connection ensures the reception of the used abrasives and the encrusted particles which are removed thereby.

Subsequent to receiving the used abrasives and removed encrusted particles, the separator is utilized for separating the abrasives from the removed particles. Due to the negatively pressurized atmosphere generated within the separator body which in turn creates a very low velocity, the heavier abrasives drop to the bottom of the separator body while the lighter encrusted particles travel to the system's particle collector. The separator discharges the removed encrusted particles to the particle collector through its outlet.

An abrasive removal assembly is formed close to the separator body's lower surface. Such assembly is primarily used for retaining the abrasives after they are separated from the encrusted particles and fall to the bottom of the separator body. A removable abrasive drawer is included in such assembly so that the used abrasives can be easily and conveniently thrown away after operation. Separator wheels may be attached at the separator body's lower surface laterally across from the removable abrasive drawer to provide mobility, and thus portability, to the separator.

In the preferred embodiment of the present invention, a particle collector is provided for receiving and retaining the removed encrusted particles from the separator. The particle collector has a collector body which is preferably fabricated from metal and forms an inside collector compartment. A collector inlet which is used for receiving the encrusted particles from the separator outlet is defined on the collector body. Disposed within the inside collector compartment is a particle filter. This particle filter is preferably made out of polyester and is essentially utilized for filtering the removed encrusted particles.

A particle removal assembly is formed adjacent to the collector body's lower surface. This assembly is used for retaining the encrusted particles after being subjected to filtration. The particle removal assembly includes a removable particle drawer which allows convenient disposal of the collected particles. Particle collector wheels may be attached adjacent to the collector body's lower surface for facilitating movement of the particle collector.

In operation, several preparatory procedures need to be conducted before undergoing the encrustation removal process. First, the piping system, whether it's plumbing or other types of system (e.g., air conditioning drain pipes), is mapped. The piping system is then divided into manageable segments, of which each segment results in the formation of multiple pipe inlets which typically lead to a single pipe outlet. Thereafter, each segment is drained of any sitting water and dried thoroughly using hot air pressure.

After performing the above preparatory procedures, the in-place pipe restoration system of the present invention can now be applied upon the piping system. The system's pressure generator is first connected to a particular segmented piping to be worked on. Such connection may be established through flexible hosing. Next, the separator can be connected to the pipe outlet also through the use of flexible hosing. By connecting one of the header outlets to the pressure generator while some or all of the remaining ones connect to the other exposed pipe inlets of the piping, the abrasives can be discharged from the discharge end of the pressure generator through its connected pipe inlet. The discharged abrasives would then work to remove the layers of encrustation that are accumulated within the segmented piping.

The abrasives and the removed encrusted particles are then received by the separator which is already connected to the pipe outlet. The separator can now function to separate the used abrasives from the removed encrusted particles within its body due to the establishment of negatively pressurized and low velocity atmosphere therein. The encrusted particles are thereafter discharged to the particle collector which operates to filter the particles through the use of its particle filter. The encrusted particles are retained within the particle collector until they are manually removed and disposed of by the system operator.

After undergoing the encrustation removal process, each of the segmented piping are visually inspected at every connection point to assure proper cleaning. The segments are then flushed to ensure that the layers of encrustation are properly removed from the piping. The piping system is further pressure checked for leaks. Thereafter, epoxy coating material is injected into the piping to repair any existing pinhole leaks. The water system and water supply is reconnected back to the piping system. Moreover, complete systems check, testing and evaluation should be carried out to assure a leak-free system. The piping system is then flushed with hot water for about two hours or so and evaluation of water flow and quality is conducted thereafter.

BRIEF DESCRIPTION OF THE DRAWINGS

These as well as other features of the present invention will become more apparent upon reference to the drawings wherein: [0029]
FIG. 1 is a perspective view of a main header constructed in accordance with a preferred embodiment of the present invention and illustrating its multiple header inlets which are designed for connection to an outside pressure source (not shown); [0030]
FIG. 2 is a side view of the main header of FIG. 1 and illustrating its header tank which is connected to the header inlets of FIG. 1 through solid piping; [0031]
FIG. 3 is a cross-sectional view of the main header of FIG. 1 and illustrating its multiple header outlets sized and configured to connect with the present invention's pressure generator (shown in FIG. 4) and the pipe inlets of a segmented piping (not shown); [0032]
FIG. 4 is a perspective view of a pressure generator constructed in accordance with a preferred embodiment of the present invention and illustrating its control panel which is used for operation thereof; [0033]
FIG. 5 is a cross-sectional view of the pressure generator of FIG. 4 and illustrating its pressure discharger assembly used for discharging abrasives stored therein via the air pressure supplied from the main header of FIG. 1; [0034]
FIG. 6 is a front view of the pressure generator of FIG. 4 and illustrating its air and discharge holes which are adapted to accommodate their respective flexible hosing therethrough; [0035]
FIG. 7 is a perspective view of a separator and a particle collector constructed in accordance with a preferred embodiment of the present invention and illustrating an elongated, flexible connection hosing placed therebetween; [0036]
FIG. 8 is a perspective view of the separator of FIG. 7 and illustrating its separator outlet used for discharging the removed encrusted particles to the particle collector of FIG. 7; and [0037]
FIG. 9 is a cutaway view of the particle collector of FIG. 7 and illustrating its particle filter used for filtering the removed encrusted particles received from the separator of FIG. 7.[0038]

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein the showings are for purposes of illustrating preferred embodiments of the present invention only, and not for purposes of limiting the same, FIG. 1 perspectively illustrates a [0039] main header 10 of a portable pipe restoration system 12 constructed in accordance with a preferred embodiment of the present invention. As indicated above, various portable devices featured in the present pipe restoration system 12 are collectively and simultaneously applied upon an already existing, in-place plumbing pipe system (not shown) which is first divided into a plurality of manageable piping segments. In brief summary, such application is established through shooting abrasives into one of several exposed pipe inlets defined by a segmented piping, while further discharging air pressure into the remaining pipe inlets thereof. Thereafter, the used abrasives and removed encrusted particles are processed and contained within the system 14 itself until they are manually disposed of by a system operator. It is recognized herein that the present pipe restoration system 12 may be utilized upon other types of piping systems such as air conditioning drain pipes.
Before describing the specific features of the present pipe restoration system [0040] 12, it should be noted that the term encrustation is referred to as any substance that is accumulated within a piping and slows down water flow therewithin. As such, the term encrustation should be construed broadly to apply to various substances which negatively affect the flow of water within the piping.
Referring more particularly to FIGS. 1 and 4, the pipe restoration system [0041] 12 of the present invention first includes a main header 10 which is connected with an outside pressure source (not shown) and a pressure generator 14 (via flexible hosing). The main header 10 essentially functions as a conduit-like device as it operates to supply the pressure generator 14 with the air pressure generated from the outside pressure source. To accomplish this objective, the main header 10 defines a header tank 16 forming a number of header inlets 18, of which one of those header inlets 18 is connected (via flexible hosing) with the outside pressure source. The remaining header inlets 18 may be optionally used to connect with additional pressure sources depending upon the particular needs of the operator (i.e., further need to increase pressure intensity within the header tank 16). However, under normal operating conditions, the use of only one header inlet 18 should suffice for creating the desired regulated pressure within the header tank 16. Preferably, the connection to the selected header inlet or inlets 18 is achieved through cam lock.
The [0042] header tank 16 of the main header 10 defines a tank body 20. Although the tank body 20 may be constructed from any sturdy material, it is preferably formed of metal. An exemplary tank body 20 would be fabricated from a 12 inch diameter pressure vessel and has a capacity of 16 gallons. However, it is in no way limited to those specifications. Furthermore, the header inlets 18 extend out from the tank body 20 but maintain fluid communication with the inside of the tank body 20. Such extensions may be formed through solid piping 22 laid therebetween (shown in FIG. 2) or through utilizing flexible header hoses 24 which connect to the solid piping 26 extending from the tank body 20 (shown in FIG. 3). It is irrespective which configuration is used as long the header inlets 18 and the tank body 20 remain fluidly connected to each other. Moreover, it is preferable that the tank body 20 comprises a one way check valve installed at the connection points of the header inlets 18 to prevent any back flow of pressure.
Referring now to FIGS. 1 and 3, the [0043] tank body 74 defines two opposing tank sides 28. A plurality of header outlets 30 can extend outwardly either from only one tank side 28 or from both of the tank sides. The decision is an engineering choice which can be made in view of the present system's application. From these multiple header outlets 30, one header outlet 30 is selected to connect with the pressure generator 14 to provide the necessary air pressure thereto for discharging the abrasives into one of the connected open pipe inlet. Preferably, such connection is made via flexible hosing which is cam locked to the selected header outlet 30. Moreover, further connections are formed (also preferably by flexible hosing) between the unused header outlets 30 and the corresponding number of pipe inlets of the segmented piping remaining open. The purpose of such connections is to shoot air pressure directly into the pipe inlets such that the risks of abrasives becoming lodged or stuck in differing sections of the segmented piping are greatly reduced. A pressure gauge is preferably provided to allow discharge pressure reading during the operation of the main header 10.
Preferably, the [0044] header outlets 30 are extended from only one tank side 28 of the tank body 20. Placement of the header outlets 30 on one tank side 28 permits ease of operation. However, additional header outlets 12 may be provided on the opposite tank side 28 of the tank body 20 to increase the level of operation. Further, the number of header outlets 30 may vary depending upon the particular setting the pipe restoration system 12 is applied. In smaller scale applications such as residential houses, condensed one-story buildings and the like, only few header outlets 30 such as three on one tank side 28 may be necessary to sufficiently carry out their operation (best shown in FIG. 1). However, when being applied in larger settings such as hotels, resorts, multiple leveled buildings and the like, increase of header outlets 30 such as to seven may be optimal (best shown in FIG. 7). Of course, it should be appreciated that such descriptions of header outlets 30 should in no way be limiting as variations thereof are foreseeable.
As shown in FIGS. 1 and 2, a [0045] header tank enclosure 32 is provided to enclose the header tank 16 therewithin. This enclosure 32 prevents the view of the header tank 16 and its manifold assembly, as well as protecting the same from being inadvertently damaged by outside environmental factors (e.g., thrown rocks, sudden impacts, etc.). In this respect, the header tank enclosure 32 should be fabricated from a sturdy material. It is preferably constructed from a metallic material such as gallium. The tank enclosure 32 forms a plurality of header openings 34 thereabout to respectively accommodate each of the header inlets and outlets 18, 30 therethrough. The control handles of the header inlets and outlets 18, 30 should be located outside the header tank enclosure 32 for ease of their operation.
Referring more particularly to FIG. 2 now, [0046] main header wheels 36 may be attached adjacent to the tank enclosure's bottom header surface 38. A header dolly handle 40 may also be provided so as to facilitate movement of the main header 10 between various locations. Additionally, a main header support 42 may be provided at the bottom header surface 38 laterally across from the main header wheels 36 so that it may support the main header 10 when the bottom header surface 38 is disposed towards the ground to stand in an upright position.
Referring now to FIGS. 4 and 6, the pipe restoration system [0047] 12 of the present invention further includes a pressure generator 14. The pressure generator 14 essentially functions to discharge abrasives that are stored therein. It defines a generator body 44 preferably constructed out of a metallic material such as gallium. However, the generator body 44 may be fabricated from other types of metals such as aluminum, for example, in order to reduce the overall weight of the pressure generator 14.
Referring now to FIG. 5 only, the [0048] generator body 44 forms an internal generator compartment 46 therewithin. Disposed within the internal generator compartment 46 is a pressure discharger assembly 48. The pressure discharger assembly 48 comprises an abrasive loading hopper 50 which can be selectively accessed by an openable/closeable upper lid member 52 hinged to the generator body 44. In particular, the upper lid member 52 can be opened relative to the abrasive loading hopper's upper hopper end 54 so that the abrasives can be manually loaded thereinto and closed thereafter to prevent their escape during pot pressure sealing. The abrasive loading hopper 50 includes spring loaded plunger for pot seal during pressurized operation and abrasive loading plunger for pressure pot loading. It is preferably made out of metal such as gallium.
The [0049] pressure discharger assembly 48 also features an abrasive storage container 56 which is disposed underneath the abrasive loading hopper 50. More specifically, an upper container end 58 of the abrasive storage container 56 is fluidly connected, preferably by welding means, to a lower hopper end 60 of the abrasive loading hopper 50. By forming such configuration, the abrasives may then be fed and stored into the abrasive storage container 56. Although the capacity of such container 56 may vary depending on the amount of abrasives to be stored, it is believed that one-third cubic foot of the pressure generator 14 is sufficient to adequately conduct the overall operation.
An [0050] abrasive mixing valve 62 is placed beneath the abrasive storage container 56. To be more descriptive, an upper valve end 64 of the abrasive mixing valve 62 is fluidly engaged, preferably by welding, to the abrasive storage container's lower container end 66. Such manner of engagement allows the abrasive mixing valve 62 to receive the abrasives from the abrasive storage container 56. Similar to the rest of the pressure discharger assembly 48, the abrasive mixing valve 62 is also preferably fabricated from metal such as gallium.
Referring now to FIGS. 5 and 6, the [0051] abrasive mixing valve 62 is used to discharge the abrasives through the connected pipe inlet of the segmented piping. To accomplish this objective, the abrasive mixing valve 62 has a first side valve end 68 which is connected to one of the header outlets 30 via an elongated flexible air hose 70, for example. The flexible hose 70 is advanced through an air hole 72 formed on the generator body 44 to connect the first side valve end 68 with one of the header outlets 30.
Utilizing the acquired air pressure from one of the [0052] header outlets 30, the abrasive mixing valve 62 operates to discharge the abrasives received from the abrasive storage container 56 through its second side valve end 74. The second side valve end 74 is generally located opposite from the first side valve end 68 (best shown in FIG. 5). Likewise, the second side valve end 74 is connected by an elongated flexible discharge hose 76 which extends out of the generator body 44 through its discharge hole 78. The discharge hose 76 is thereafter connected to one of the exposed pipe inlets defined by the segmentation of the piping. This aspect will be discussed shortly below.
FIG. 6 shows the pressure generator's [0053] control panel 80 defining various operational components such as a pressure gauge 82, pressure timer 84 and pressure adjuster 86. The discharge pressure should be preset using the pressure gauge 82 and pressure adjuster 86. The discharge pressure time relay may also be set to a desired time via the pressure timer 84. Of course, the pressure generator 14 will be connected to an electrical power source to draw the necessary electrical power therefrom.
The [0054] pressure generator 14 may become a portable device by attachment of pressure generator wheels 88 (e.g., heavy duty wheels) thereto. The pressure generator wheels 88 should preferably be attached adjacent to the generator body's lower surface 90. Further, a generator dolly handle 92 may be attached adjacent to the generator body's upper surface 94 to ease the movement of the pressure generator wheels 88. As such, the movement of the pressure generator 14 can be greatly facilitated by the collective use of the pressure generator wheels 88 and the generator dolly handle 92.
FIG. 7 shows a [0055] separator 96 of the present pipe restoration system 12. The separator 96 is designed to connect with a pipe outlet which is typically formed by merging of the various separated sections of the piping. More particularly, the separator 96 defines a separator body 98 having a separator inlet 100 formed thereon. The separator inlet 100 is placed in communication with the pipe outlet via a flexible hosing, for example. By establishing such connection, the used abrasives and the encrusted particles that are abraded and removed thereby flow into the separator inlet 100 due to the force of the air pressure being applied from the pipe inlets. An additional separator inlet 100 may be provided should a need to accommodate another pipe outlet arise. The separator body 98 is preferably constructed from metal such as gallium so that it can withstand the impact of the abrasives injected and collected therein.
Referring now to FIG. 8, the [0056] separator 96 receives the used abrasives and removed encrusted particles. The separator 96 is then utilized to separate the abrasives from the removed particles. As will be described below, through the utilization of an exhaust blower (not shown), a negatively pressurized atmosphere is maintained within the separator body 98 which in turn creates a very low velocity therein. Due to such negative pressure and slow velocity, the heavier abrasives are allowed to fall to the bottom of the separator body 98 while the encrusted particles, which are lighter in weight than the abrasive, travel to the present system's particle collector 102. Put simply, the separator 96 operates to substantially segregate the encrusted particles from the used abrasives and discharges such particles to the particle collector 102 through its separator outlet 104.
An [0057] abrasive removal assembly 106 is disposed about the separator body's lower separator surface 108. The abrasive removal assembly 106 is provided in order to collect the used abrasives after they fall and accumulate at the bottom of the separator body 98. The removal assembly 106 has a slidably removable abrasive drawer 110 which can be used to provide convenient disposal of the accumulated abrasives. Preferably, separator wheels 112 are attached about the lower separator surface 108 laterally across from the removable abrasive drawer 110 so as to provide the separator 96 with easy mobility. Additionally, a separator dolly handle 114 may be formed adjacent the upper separator surface 116 to better facilitate the separator's mobility.
As briefly noted above, an exhaust blower (not shown) may be provided which essentially operates to maintain the inside of the [0058] separator body 98 at negative pressure and slow velocity. Although other types of exhaust blowers may be used, the exhaust blower which is preferably incorporated along with the present invention should consist of a 12 inch diameter blower impeller and a 1½ H.P. 120 volt blower motor. The 1½ H.P. motor has been chosen to enable operation on 120 volt, 20 amp. in-house circuit.
An exhaust silencer (not shown) may be laid in communication with the exhaust blower. The exhaust silencer is primarily used to reduce the exhaust blower's noise level. The exhaust silencer contains sound deadening materials for blower noise level reduction. Of course, a control box (not shown) may be provided to perform various functions such as establishing connection to an electrical power source, operating the exhaust blower, or the like. [0059]
Referring now to FIG. 9, a [0060] particle collector 102 is provided for receiving and retaining the removed encrusted particles from the separator 96. The particle collector 102 has a collector body 118 which is preferably fabricated from metal and forms an inside collector compartment 124. A collector inlet 120 which is used for receiving the encrusted particles from the separator outlet 104 is formed on the side collector surface 122 of the collector body 118. Such connection is established through the use of an elongated, flexible hose 126 which places the separator outlet 104 and the collector inlet 120 in communication with each other (best shown in FIG. 7).
Disposed within the [0061] inside collector compartment 124 is a particle filter 128. This particle filter 128 is preferably made out of polyester and is essentially utilized for filtering the removed encrusted particles. Constant cleaning of this filter 128 is unnecessary due to the large filter surface area. However, the particle filter 128 may be cleaned from time to time through the use of an outside air pressure source. Furthermore, the particle filter 128 may be removably installed within the inside collector compartment 124 so that it may be conveniently taken out for replacement or cleaning. The filter 128 is selectively accessible via an openable/closeable separator door defined on the separator body 98 (not shown).
A [0062] particle removal assembly 132 is disposed about the collector body's lower collector surface 134. Similar to the abrasive removal assembly 106, this assembly 132 is provided in order to collect the removed encrusted particles before and/or after undergoing the filtration process. The particle removal assembly 132 has a slidably removable particle drawer 136 which can be used to provide convenient disposal of the removed encrusted particles. Collector wheels 138 may be attached adjacent to the lower collector surface 134 so as to provide the particle collector 102 with easy mobility.
The following paragraphs will generally describe the overall pipe cleaning process which incorporates the use of the present pipe restoration system [0063] 12. More particularly, several preparatory procedures need to be conducted before undergoing the encrustation removal process. First, the piping system, whether it's plumbing or other types of system (e.g., air conditioning drain pipes), is mapped. The piping system is then divided into manageable segments, of which each segmented piping typically results in the formation of multiple pipe inlets which generally lead to a pipe outlet. Thereafter, each segment is drained of any sitting water and dried thoroughly using hot air pressure.
After the preparatory procedures are completed, the present pipe restoration system [0064] 12 is then applied to the piping system. The pipe restoration system 12 is set up with respect to the piping system by first connecting the pressure generator 14 to one of the pipe inlets of the segmented piping to be worked on (via a flexible hosing, for example). Shortly thereafter, the separator 96 is connected to the pipe outlet also through the use of flexible hosing. Then, the main header 10 is placed in communication with the pressure generator 14 by connecting one of its header outlets 30 thereto, while simultaneously connecting some or all of the remaining header outlets 30 directly to the exposed open pipe inlets of the subject segmented piping. By operating in the manner described above, the abrasives are discharged by the pressure generator 14 to its connected pipe inlet 12 as the main header 10 further works to discharge air pressure into the remaining ones of the pipe inlets so that the abrasives do not become dislodged or stuck within the subject segmented piping.
The abrasives and the abraded encrusted particles are then received by the [0065] separator 96 which is already connected to the pipe outlet. Utilizing the negatively pressurized and low velocity atmosphere, the separator 96 operates to segregate the used abrasives from the removed encrusted particles. The particles are then discharged to the particle collector 102 whereat such collector 102 filters the encrusted particles from the flow of air that they are disposed in. The encrusted particles are retained within the particle collector 102 while the air flow exits thereoutof.
After undergoing the encrustation removal process, the piping system is visually inspected at every connection point to assure proper cleaning. The segments are then flushed to ensure that the encrustation are properly removed from the piping system. The piping system is further pressure checked for leaks. Thereafter, epoxy coating material is injected into the piping system to repair any existing pinhole leaks. The water system and water supply is reconnected back to the piping system. Moreover, complete systems check, testing and evaluation should be carried out to assure a leak-free system. The piping system is then flushed with hot water for about two hours or so and evaluation of water flow and quality is conducted thereafter. [0066]
Additional modifications and improvements of the present invention may also be apparent to those of ordinary skill in the art. Thus, the particular combination of parts described and illustrated herein is intended to represent only certain embodiments of the present invention, and is not intended to serve as limitations of alternative devices within the spirit and scope of the invention. [0067]

Claims

What is claimed is:

1. A pipe restoration system for removing encrustation from a piping system, the piping system defining a plurality of pipe inlets which lead to a pipe outlet, the pipe restoration system comprising:

a main header having a plurality of header outlets;

a pressure generator with abrasives connected to one of the header outlets for receiving air pressure therefrom, the pressure generator further being connected to one of the plurality of pipe inlets for discharging the abrasives therethrough via the air pressure;

a separator connected to the pipe outlet for receiving and separating the abrasives and the encrustation removed thereby, the separator being sized and configured to retain the abrasives therewithin; and

a particle collector connected to the separator for receiving and retaining the encrustation separated in the separator.

2. The pipe restoration system of claim 1 wherein the pressure generator has a generator body forming an internal generator compartment, the internal generator compartment having a pressure discharger assembly disposed therewithin.

3. The pipe restoration system of claim 2 wherein the pressure discharger assembly comprises an abrasive storage container for storing the abrasives therein, the abrasive storage container having upper and lower container ends.

4. The pipe restoration system of claim 3 wherein the pressure discharger assembly comprises an abrasive loading hopper having a lower hopper end, the lower hopper end being engaged to the upper container end so as to provide the abrasives from the abrasive loading hopper to the abrasive storage container.

5. The pipe restoration system of claim 4 wherein the abrasive loading hopper has an upper hopper end and the generator body comprises an upper lid member, the upper lid member being sized and configured to open and close with respect to the upper hopper end so as to selectively access the abrasive loading hopper when providing the abrasives thereto.

6. The pipe restoration system of claim 3 wherein the pressure discharger assembly comprises an abrasive mixing valve having an upper valve end, the upper valve end being engaged to the lower container end so that the abrasive mixing valve receives the abrasives from the abrasive storage container.

7. The pipe restoration system of claim 6 wherein the abrasive mixing valve has a first side valve end, the first side valve end being in communication with one of the header outlets for receiving the air pressure therefrom.

8. The pipe restoration system of claim 6 wherein the abrasive mixing valve has a second side valve end, the second side valve end being in communication with one of the pipe inlets for discharging the abrasives therethrough.

9. The pipe restoration system of claim 2 wherein the generator body defines a lower generator surface, the lower generator surface having pressure generator wheels attached adjacent thereto for facilitating movement of the pressure generator.

10. The pipe restoration system of claim 1 wherein the main header comprises a header tank having a tank body whereat the plurality of header outlets are extended therefrom.

11. The pipe restoration system of claim 10 wherein the tank body defines two opposing tank sides and the plurality of header outlets are extended from respective ones of the opposing tank sides.

12. The pipe restoration system of claim 10 wherein the tank body comprises at least one header inlet in communication with an outside pressure source for receiving the air pressure generated therefrom.

13. The pipe restoration system of claim 10 wherein the main header comprises a header tank enclosure disposing the header tank therewithin and having a plurality of side openings for allowing the header outlets to be extended therethrough.

14. The pipe restoration system of claim 13 wherein the header tank enclosure defines a bottom header surface, the bottom header surface having main header wheels attached adjacent thereto for facilitating movement of the main header.

15. The pipe restoration system of claim 14 wherein the header tank enclosure comprises a main header support formed adjacent to the bottom header surface for supporting the main header when erected in an upright position.

16. The pipe restoration system of claim 1 wherein the particle collector has a collector body forming an inside collector compartment, the inside collector compartment having a particle filter disposed therewithin for filtering the encrustation received from the separator.

17. The pipe restoration system of claim 16 wherein the collector body comprises a collector inlet in communication with the separator for receiving the abrasives therefrom.

18. The pipe restoration system of claim 16 wherein the collector body comprises at least one collector outlet for discharging the air pressure therethrough.

19. The pipe restoration system of claim 16 wherein the particle filter is a polyester filter.

20. The pipe restoration system of claim 16 wherein the collector body defines a lower collector surface, the lower collector surface having a particle removal assembly formed thereabout, the particle removal assembly having a removable particle drawer used for disposing the abrasives.

21. The pipe restoration system of claim 16 wherein the collector body has a lower collector surface, the lower collector surface having collector wheels attached adjacent thereto for facilitating movement of the particle collector.

22. The pipe restoration system of claim 1 wherein the separator has a separator body, the separator body including a separator outlet in communication with the particle collector for discharging the separated encrustation thereto.

23. The pipe restoration system of claim 22 wherein the separator body defines a lower separator surface, the lower separator surface having an abrasive removal assembly formed adjacent thereto, the abrasive removal assembly having a removable abrasive drawer used for disposing the abrasives.

24. The pipe restoration system of claim 22 wherein the separator body has a lower separator surface, the lower separator surface having separator wheels attached adjacent thereto for facilitating movement of the separator.