Aerogel thermal insulation sea pipe and construction process thereof

Abstract

This invention provides an aerogel-insulated subsea pipeline, comprising an inner tube, an outer tube, and an insulation structure. The insulation structure includes an aerogel insulation layer and a support device. A sheath is provided between the aerogel insulation layer and the outer tube, covering the outer surface of the aerogel insulation layer. Several sliding strips are provided on the outer side of the support device to support the outer tube. The mating part is embedded in a groove at the end of the insulation layer, so that after the two basic components are assembled, the ends of the insulation layer at the joint on the same side are pressed against each other and remain sealed. A perforated groove is provided on the main body corresponding to the mating part, and a connecting component receiving groove is provided on the joint insulation layer on the inner side of the main body corresponding to the perforated groove. This invention uses silica aerogel felt as the insulation material for the insulation layer, resulting in excellent insulation performance, a smaller outer tube size, high laying efficiency, low production and usage costs, and long-term stable application in extreme high-temperature and high-pressure oil and gas transportation environments, ensuring a guaranteed service life.

Description

Technical Field

[0001] This invention belongs to the field of subsea oil pipeline technology, and in particular relates to an aerogel thermal insulation subsea pipeline and its construction process. Background Technology

[0002] Subsea pipelines are crucial facilities for offshore oil and gas development. To prevent heat loss during pipeline transportation, the traditional approach is to wrap the pipeline with an insulation layer made of thermal insulation material. Commonly used subsea pipelines are steel-jacketed insulated pipes, with the insulation layer positioned within the space between the two steel pipes. However, oil pipelines are typically very long, making it difficult to wrap them with a single, integral insulation structure. Segmented insulation materials are prone to gaps at the joints during installation, directly affecting the insulation effect. The insulated pipe shell structure inevitably encounters cooling issues, further impacting insulation performance. Furthermore, during the production of steel-jacketed insulated pipelines, jamming frequently occurs when the inner pipe is inserted into the outer pipe, affecting production efficiency and potentially damaging the insulation layer or the pipeline itself, also impacting insulation effectiveness. Therefore, it is necessary to improve the structure and construction process of insulated pipelines. Summary of the Invention

[0003] In view of this, the present invention aims to overcome the defects in the prior art and proposes an aerogel thermal insulation subsea pipeline and its construction process.

[0004] To achieve the above objectives, the technical solution created by this invention is implemented as follows:

[0005] An aerogel thermal insulation subsea pipeline includes an inner tube, an outer tube, and an insulation structure between them. The insulation structure includes a segmented aerogel insulation layer. Adjacent aerogel insulation layers are connected by a support device. A sheath is provided between the aerogel insulation layer and the outer tube, and the sheath wraps around the outer surface of the aerogel insulation layer.

[0006] The support device includes a body composed of two semi-circular base components. A joint insulation layer is provided inside the body. Several sliding strips are arranged along the circumference on the outside of the body. Each base component includes a semi-circular body. Both ends of the body are provided with inwardly folded docking parts. The docking parts on the same side of the two split structures are fixed by a connecting component, so that the joint insulation layer wraps around the outer wall of the inner tube, and the sliding strips provide support for the outer tube.

[0007] The docking part is embedded in the groove at the end of the insulation layer, so that after the two basic components are assembled, the ends of the joint insulation layers on the same side of the two components are pressed against each other and kept closed; the main body is provided with a hollow groove at the position corresponding to the docking part, and a connecting component receiving groove is provided on the joint insulation layer on the inner side of the main body at the position corresponding to the hollow groove.

[0008] Furthermore, the slider is made of nylon.

[0009] Furthermore, the slide bar is fixed to the base component by screws, and a recess is provided on the outer surface of the slide bar, with the nut portion of the screw submerged in the recess.

[0010] Furthermore, all edges and corners of the slider are rounded.

[0011] Furthermore, an open groove for embedding the mating part is provided on the outer end face of the end of the joint insulation layer. One side surface of the mating part is in contact with the bottom surface of the groove on the end of the joint insulation layer, and the other side surface is exposed on the outside of the joint insulation layer.

[0012] Furthermore, on the outer surface of the joint insulation layer, near its end there is a groove with an outer opening for the insertion of the mating part, and the two sides of the mating part are respectively attached to the two side walls of the groove.

[0013] Furthermore, the sheath is made of stainless steel plate that has been rolled into a round shape.

[0014] A construction process for the aforementioned subsea pipeline includes the following steps:

[0015] S1. Clean the outer surface of the inner tube;

[0016] S2. Cut the aerogel felt and the stainless steel sheath according to the designed insulation layer width, and roll the stainless steel sheath into a round shape.

[0017] S3. An aerogel insulation layer is formed by covering the outer wall of the inner tube with aerogel felt. At least one set of support devices is arranged near both ends of the inner tube so that the joint insulation layer of the support device is connected to the aerogel insulation layer. The aerogel felt covering the outer wall of the inner tube is tied with galvanized iron wire.

[0018] S4. Install a stainless steel sheath on the outside of the aerogel insulation layer and mark the direction and end position of the pipe. When the stainless steel sheath on each section of the aerogel insulation layer is assembled from multiple sections, the overlap width between each section of the stainless steel sheath shall not be less than 30mm and shall overlap sequentially in the same direction to facilitate pipe insertion. A set of temporary support rings or several sets of pulleys can be temporarily installed at both ends of the inner pipe to facilitate smooth and easy pipe insertion.

[0019] S5. Insert the inner tube into the outer tube according to the tube insertion direction and termination position marked on the sheath, and then remove the temporary support ring or the installed pulley.

[0020] Compared with existing technologies, the present invention has the following advantages:

[0021] This invention utilizes silica aerogel felt as the insulation material for the insulation layer, offering excellent insulation performance. Compared to traditional steel-jacketed insulated pipes, it reduces the outer pipe size, improves offshore laying efficiency, and lowers production, manufacturing, and usage costs. Furthermore, the designed support device not only slides with the outer pipe during the installation process but also provides effective support, enhancing the pressure resistance of the subsea pipeline. Therefore, this subsea pipeline can be safely and stably used in extreme oil and gas transportation environments with high temperature and pressure for extended periods, ensuring a guaranteed service life. Attached Figure Description

[0022] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments and descriptions of the invention are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0023] Figure 1 A schematic diagram of the structure created by this invention;

[0024] Figure 2 This is a schematic diagram of the invention after removing the outer tube;

[0025] Figure 3 This is a schematic diagram of the support device portion in this invention.

[0026] Figure 4 A schematic diagram of the base component for creating the support device of this invention;

[0027] Figure 5 A three-dimensional structural diagram of the support device for this invention;

[0028] Figure 6 A schematic diagram of the support device for this invention having an open groove insulation layer;

[0029] Figure 7 A schematic diagram of the support device of the present invention having an outer open groove insulation layer;

[0030] Figure 8 for Figure 6 A schematic diagram showing the installation of basic components.

[0031] Figure 9 for Figure 7 A schematic diagram showing the installation of basic components.

[0032] Figure 10 This is a schematic diagram of the sliding bar of the support device in this invention having an overlapping portion;

[0033] Figure 11 A schematic diagram showing a cavity provided for the joint insulation layer of the support device. Detailed Implementation

[0034] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0035] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on this invention. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0036] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0037] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0038] A type of aerogel-insulated subsea pipeline, such as Figures 1 to 11 As shown, the structure includes an inner tube 1, an outer tube 2, and an insulation structure 3 between them. The insulation structure includes segmented aerogel insulation layers 4, with adjacent aerogel insulation layers connected by a support device 5. A protective sleeve is provided between the aerogel insulation layer and the outer tube, covering the outer surface of the aerogel insulation layer. Typically, the protective sleeve is made of stainless steel plate rolled into a circle, with the seams welded for fixation. As an example, the aerogel insulation layer is made of silica aerogel felt.

[0039] The support device includes a body 6 composed of two semi-circular base components. A joint insulation layer 7 is provided inside the body, and several sliding strips 8 are arranged circumferentially on the outside of the body. Each base component includes a semi-circular main body 9, with inwardly folded connecting portions 10 at both ends. Connecting components 11 fix the connecting portions on the same side of the two separate structures, ensuring that the joint insulation layer wraps around the outer wall of the inner tube, and the sliding strips provide support to the outer tube. For example, the joint insulation layer is made of calcium silicate material.

[0040] Typically, the aforementioned slide bar is made of nylon. The slide bar is fixed to the base component by screws 17, and a countersunk edge is provided on the outer surface of the slide bar, with the screw nut portion submerged within the countersunk edge. All edges of the slide bar are rounded. The connecting assembly includes bolts (which pass through connecting holes on the same side of the mating portion) and is locked with nuts to secure the two mating portions on the same side.

[0041] The docking part is embedded in the groove at the end of the insulation layer, so that after the two basic components are assembled, the ends of the joint insulation layers on the same side of the two components are pressed against each other and kept closed; the main body is provided with a hollow groove 12 corresponding to the docking part, and on the joint insulation layer on the inner side of the main body, a connecting component receiving groove 13 is provided at the hollow groove.

[0042] In an optional embodiment, such as Figure 6 and Figure 8 As shown, an open groove 14 for embedding the mating part is provided at the outer end face of the aforementioned joint insulation layer. One side surface of the mating part is in contact with the bottom surface of the groove on the end of the joint insulation layer, while the other side surface is exposed outside the joint insulation layer (the groove depth is 1 / 2-2 / 3 of the insulation layer thickness). In another optional embodiment, such as... Figure 7 and Figure 9 As shown, on the outer surface of the joint insulation layer, near its end, a groove 15 with an open outer opening is provided for the insertion of the mating part. The two sides of the mating part are respectively attached to the two side walls of the groove (the groove depth is 1 / 2-2 / 3 of the insulation layer thickness). This structural design ensures that after the support device is installed, the two base components are tightly joined, resulting in better insulation performance.

[0043] In further improved solutions, such as Figure 10As shown, each sliding strip has an overlapping portion 16 extending outward from its main body at both ends. In the assembled subsea pipeline, the overlapping portions on both sides of the sliding strip overlap the outer side of the aerogel insulation layer on both sides of the support device, so that the support device and the aerogel insulation layer are connected by the sliding strip. This not only improves the safety during the pipe insertion process and prevents the aerogel insulation layer from being scratched, but also improves the stability of the connection between the aerogel insulation layer and the support device when applied to the seabed. The support device forms effective support for the outer pipe. The longer sliding strip has a better support effect. The pressure is transmitted to the support device and the aerogel insulation layer through the sliding strip. The pipeline has a stronger ability to resist seawater compression and better structural stability.

[0044] A construction process for the aforementioned subsea pipeline includes the following steps:

[0045] S1. Clean the outer surface of the inner tube (grease contaminants can be removed by solvent cleaning or alkaline cleaner, and rust can be removed by sandblasting);

[0046] S2. Cut the aerogel felt and the stainless steel sheath according to the designed insulation layer width, and roll the stainless steel sheath into a round shape.

[0047] S3. An aerogel insulation layer is formed by covering the outer wall of the inner tube with aerogel felt. At least one set of support devices is arranged near each end of the inner tube, and the joint insulation layer of the support device is connected to the aerogel insulation layer (the joint between the joint insulation layer and the aerogel insulation layer is less than 5mm). The aerogel felt covering the outer wall of the inner tube is tied with galvanized iron wire (the tying interval is not greater than 300mm, and the joints of each layer of aerogel felt are staggered, with a staggered distance of not less than 100mm).

[0048] S4. Install a stainless steel sheath on the outside of the aerogel insulation layer and mark the direction and end position of the pipe. When the stainless steel sheath on each section of the aerogel insulation layer is assembled from multiple sections, the overlap width between each section of the stainless steel sheath shall not be less than 30mm and shall be overlapped sequentially in the same direction to facilitate pipe insertion. A set of temporary support rings or several sets of pulleys can also be temporarily installed at both ends of the inner pipe to facilitate smooth and easy pipe insertion.

[0049] S5. Insert the inner tube into the outer tube according to the tube insertion direction and termination position marked on the sheath, and then remove the temporary support ring or the installed pulley.

[0050] Typically, all the edges and corners of the slide bar are rounded, i.e., rounded corners are applied. Each slide bar (in the axial direction of the body) has an arc-shaped guide structure at both the front and rear ends. This makes it easier for the outer tube and the support device to slide smoothly with the help of the slide bar during the tube insertion process, improving work efficiency and avoiding damage to structural components.

[0051] In an optional embodiment, such as Figure 11As shown, a closed cavity 18 is provided inside the joint insulation layer. For example, the width of this cavity along the radial direction of the support device is generally 1-3 mm, and the width of the cavity (along the radial direction of the support device) gradually decreases from the middle of the main body to both ends of the main body. When the support device is installed, the main body compresses the inner insulation layer, and the cavity adapts to the deformation, which is more conducive to the installation of the support device. When inserting the pipe, the adaptive deformation of the cavity can minimize the jamming between the support device and the inner wall of the outer pipe, making the pipe insertion process smoother and more free.

[0052] In a further improved design, filler material can be added to the cavity. The filler material can be at least one of asbestos, glass fiber, rubber, hollow glass microspheres, light calcium carbonate, and alumina hollow spheres. The total amount of filler material accounts for 1 / 4 to 1 / 2 of the cavity volume, which improves the cavity's partial support capacity without affecting its ability to adapt to deformation.

[0053] This invention utilizes silica aerogel felt as the insulation material for the insulation layer, offering excellent insulation performance. Compared to traditional steel-jacketed insulated pipes, it reduces the outer pipe size, improves offshore laying efficiency, and lowers production, manufacturing, and usage costs. Furthermore, the designed support device not only slides with the outer pipe during the installation process but also provides effective support, enhancing the pressure resistance of the subsea pipeline. Therefore, this subsea pipeline can be safely and stably used in extreme oil and gas transportation environments with high temperature and pressure for extended periods, ensuring a guaranteed service life.

[0054] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An aerogel-insulated subsea pipeline, characterized in that: It includes an inner tube, an outer tube, and an insulation structure between them. The insulation structure includes a segmented aerogel insulation layer. Adjacent aerogel insulation layers are connected by a support device. A protective sleeve is provided between the aerogel insulation layer and the outer tube, and the protective sleeve is wrapped around the outer surface of the aerogel insulation layer. The support device includes a body composed of two semi-circular base components. A joint insulation layer is provided inside the body. Several sliding strips are arranged along the circumference on the outside of the body. Each base component includes a semi-circular body. Both ends of the body are provided with inwardly folded docking parts. The docking parts on the same side of the two split structures are fixed by a connecting component, so that the joint insulation layer wraps around the outer wall of the inner tube, and the sliding strips provide support for the outer tube. The docking part is embedded in the groove at the end of the joint insulation layer, so that after the two basic components are assembled, the ends of the joint insulation layers on the same side of the two components are pressed against each other and kept closed; the main body is provided with a hollow groove at the position corresponding to the docking part, and a connecting component receiving groove is provided on the joint insulation layer on the inner side of the main body at the position corresponding to the hollow groove. A closed cavity is set inside the joint insulation layer. The width of the cavity gradually decreases from the middle of the main body to both ends along the radial direction of the support device. When the support device is installed, the main body compresses the inner joint insulation layer, and the cavity adapts to the deformation to facilitate the installation of the support device. When the pipe is inserted, the adaptive deformation of the cavity avoids jamming between the support device and the inner wall of the outer pipe. Filler is added to the cavity, and the total amount of filler accounts for 1 / 4 to 1 / 2 of the cavity volume.

2. The aerogel thermal insulation subsea pipeline according to claim 1, characterized in that: The slider is made of nylon.

3. The aerogel thermal insulation subsea pipeline according to claim 1, characterized in that: The slide bar is fixed to the base component by screws, and the outer surface of the slide bar is provided with a recess, with the nut part of the screw submerged in the recess.

4. The aerogel thermal insulation subsea pipeline according to claim 1, characterized in that: All edges and corners of the slider are rounded.

5. The aerogel thermal insulation subsea pipeline according to claim 1, characterized in that: An open groove for embedding the mating part is provided at the outer end face of the end of the joint insulation layer. One side surface of the mating part is in contact with the bottom surface of the groove on the end of the joint insulation layer, and the other side surface is exposed on the outside of the joint insulation layer.

6. The aerogel thermal insulation subsea pipeline according to claim 1, characterized in that: On the outer surface of the joint insulation layer, near its end, there is a groove with an outer opening for the mating part to be inserted, and the two sides of the mating part are respectively attached to the two side walls of the groove.

7. The aerogel thermal insulation subsea pipeline according to claim 1, characterized in that: The sheath is made of stainless steel plate that has been rolled into a round shape.

8. A construction process for the subsea pipeline according to any one of claims 1 to 7, characterized in that, Includes the following steps: S1. Clean the outer surface of the inner tube; S2. Cut the aerogel felt and the stainless steel sheath according to the designed insulation layer width, and roll the stainless steel sheath into a round shape. S3. An aerogel insulation layer is formed by covering the outer wall of the inner tube with aerogel felt. At least one set of support devices is arranged near both ends of the inner tube so that the joint insulation layer of the support device is connected to the aerogel insulation layer. The aerogel felt covering the outer wall of the inner tube is tied with galvanized iron wire. S4. Install a stainless steel sheath on the outside of the aerogel insulation layer and mark the direction of pipe insertion and the termination position. S5. Insert the inner tube into the outer tube according to the tube insertion direction and termination position marked on the sheath.

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