Flexible pipe body and method for manufacturing same

Abstract

A flexible pipe body for delivering production fluid, a flexible riser, and a method of manufacturing a flexible pipe body are disclosed. The flexible pipe body includes: an internal pressure sheath; a helically wound armor layer, the helically wound armor layer being radially outward of the inner pressure sheath; and a continuous metal permeation barrier layer disposed radially inward of the helically wound armor layer; wherein the continuous metal permeable barrier layer includes a helically wound tape and a connecting portion configured to couple laterally adjacent tape wrap turns of the helically wound tape.

Description

Technical Field

[0001] The present invention relates to a flexible pipe body comprising a permeation barrier and a method of manufacturing the same. In particular, but not exclusively, the present invention relates to a flexible pipe body comprising a continuous metallic permeation barrier formed from a helically wound tape. Background Art

[0002] Flexible pipes can be used in particular to connect a seafloor location (which may be deep sea) to a sea level location. The pipe may have an inner diameter typically up to about 0.6 meters (e.g., the diameter may be in the range of 0.05 m to up to 0.6 m). Flexible pipes are typically formed as an assembly of a flexible pipe body and one or more end fittings. The flexible pipe body is typically formed as a combination of layered materials that form a pressure-bearing conduit. The pipe structure allows large flexures without causing bending stresses that would impair the function of the pipe during its life. The flexible pipe body is typically constructed as a combined structure comprising polymer layers and / or metal layers and / or composite material layers. For example, the flexible pipe body may include a polymer layer and a metal layer, or a polymer layer and a composite material layer, or a polymer layer, a metal layer and a composite material layer.

[0003] API Recommended Practice 17B provides guidance for the design, analysis, manufacture, testing, installation, and operation of flexible pipes and flexible pipe systems for onshore, subsea, and offshore applications. API Specification 17J, titled "Specification for Unbonded Flexible Pipe," defines the technical requirements for safe, dimensionally and functionally interchangeable flexible pipes that are designed and manufactured to uniform standards and criteria.

[0004] The flexible pipe body typically includes a fluid retaining layer (called a barrier layer or liner), which is typically formed as a polymer jacket or pressure jacket. Such a layer operates as a primary fluid retaining layer. In order to prevent the rupture of such a layer caused by the pressure of the conveying fluid, an interlocking wire layer (called a pressure armor layer) is typically located radially outside the fluid retaining layer. A typical flexible pipe body includes one or more armor layers, optionally including a pressure armor layer. The main load on such a layer is formed by radial forces. The pressure armor layer typically has a specific cross-sectional profile to interlock so that it can hold and absorb the radial forces generated by the external or internal pressure on the pipe. Therefore, the cross-sectional profile of the winding wire that prevents the pipe from collapsing or rupturing due to pressure is sometimes called a pressure-resistant profile. When the armor layer is formed by a spirally wound wire forming a hoop component, the radial force from the internal or external pressure on the pipe causes the hoop component to expand or contract, thereby applying a tensile or compressive load to the wire, respectively.

[0005] One or more tensile armour layers may be positioned radially outwardly of the pressure armour layers. The tensile armour is used to withstand tensile loads and internal pressure. The tensile armour layers are typically formed from a plurality of wires (to give the layer strength) which are positioned above the inner layer and wound helically along the length of the tube. The tensile armour layers are typically metal layers, such as formed from carbon steel. The tensile armour layers may alternatively be composite tendons of a matrix material reinforced with suitable fibres, such as glass, carbon, aramid, basalt or metal.

[0006] As used herein, armor refers to either a tensile armor or a pressure armor.

[0007] Flexible pipes are used to transport produced fluids such as oil and / or gas and / or water from one location to another. As used herein, "fluid" includes both liquid and gaseous substances. When produced fluids are transported through flexible pipes, fluids such as carbon dioxide and hydrogen sulfide gas, for example, can penetrate the innermost layer (e.g., internal pressure sheath) of the body of the flexible pipe. As used herein, penetration, particularly penetration of a fluid through a layer of a flexible pipe, can include both transmission of the fluid through the body of the layer and leakage of the fluid through discontinuities or gaps in the layer, as can be readily seen from the context of the accompanying description.

[0008] These fluids then accumulate in the pipe annulus. This can result in a corrosive environment, especially when associated with the presence of water in the annulus, such as during an annulus flooding event. Corrosive environments are known to cause pipe failures due to stress corrosion cracking of the metal layers used within the armor layer. Additionally, the accumulation of annulus fluids can result in over-pressurization and mechanical failure of the flexible pipe.

[0009] Some known examples of flexible pipe bodies provide a tape layer radially outward of an inner jacket layer. As used herein, tape refers to an elongated material provided in a wrappable or spoolable form so as to form a layer by wrapping around a radially inward layer of a flexible pipe body. The tape layer is typically formed by wrapping the tape around the inner jacket layer such that the longitudinal edge of a first tape wrap turn overlaps the opposite longitudinal edge of the tape of a laterally adjacent tape wrap turn.

[0010] A problem with some flexible pipe bodies is that fluids can penetrate into the pipe annulus through the flexible pipe body. Fluids can penetrate into the pipe annulus by transport through the body of the layers. Additionally or alternatively, fluids can penetrate into the pipe annulus by seepage through discontinuities or gaps in the layers. Specifically, when the wrapping provides overlapping edges along the longitudinal edges of the tape, the reliability of the seal against seepage depends on surface-to-surface engagement. Repeated buckling causes the overlapping surfaces to disengage from each other. Thus, fluid seepage occurs due to the pressure of the produced fluid conveyed in the fluid pipe forcing the fluid in between adjacent tape wrap turns.

[0011] Another problem is that some barrier layers impose limitations on the bending and load limits of the flexible pipe body, making it impossible for the flexible pipe to buckle without damaging the barrier layer. Specifically, the flexible pipe has a minimum bend radius limit that limits the degree to which the flexible pipe is allowed to buckle in use. That is, the flexible pipe has a lower radius of curvature around which the flexible pipe can bend or buckle. Bending the flexible pipe tighter than the minimum bend limit can cause the overlapping surfaces to separate from each other. Again, fluid leakage occurs due to the pressure of the produced fluid transported in the fluid pipe forcing the fluid into between adjacent tape wrap turns.

[0012] Certain examples of the present invention are intended to at least partially solve, mitigate or eliminate at least one of the problems and / or disadvantages associated with the prior art. Certain embodiments are intended to provide at least one of the advantages described below. Summary of the invention

[0013] The invention is set out in the appended claims.

[0014] According to one aspect of the present invention, there is provided a flexible pipe body for conveying produced fluids, the flexible pipe body comprising:

[0015] Internal pressure sheath;

[0016] a helically wound armor layer radially outwardly of the inner pressure sheath; and

[0017] a continuous metal permeation barrier layer disposed radially inwardly of the helically wound armor layer;

[0018] Wherein the continuous metal permeation barrier layer comprises a helically wound tape and a connecting portion configured to connect laterally adjacent tape wrap turns of the helically wound tape. Suitably, the continuous metal permeation barrier layer is provided between the internal pressure sheath and the helically wound armour layer.

[0019] Suitably, the continuous metal permeation barrier layer is provided radially inwardly of the internal pressure sheath.More suitably, the flexible pipe body comprises a carcass layer and the continuous metal permeation barrier layer is provided radially between the carcass layer and the internal pressure sheath.

[0020] Suitably, the continuous metallic permeation barrier layer is disposed radially between a pressure armour layer and a tensile armour layer, wherein the pressure armour layer is formed as a composite tape layer.

[0021] Suitably, the connecting portion is configured to couple a first tape wrap turn of the helically wound tape to a laterally adjacent second tape wrap turn of the helically wound tape.The helically wound tape may be a helically wound metal tape.

[0022] By providing a flexible pipe body having a permeation barrier of continuous metal construction, the internal pressure sheath is thereby surrounded by the sleeve without gaps or discontinuities, even when the flexible pipe body is bent. Undesirable penetration of fluids into the pipe annulus through leaks is reduced or even prevented. Furthermore, the internal pressure sheath is thereby surrounded by a sleeve of substantially fluid-impermeable material, so that the transmission of fluids is greatly reduced. Thus, the resulting annulus environment can be milder, e.g., less corrosive, than conventional flexible pipes, thereby increasing pipe life.

[0023] Suitably, the continuous metallic permeation barrier layer is positioned radially inwardly of and directly adjacent to the helically wound pressure armour layer.

[0024] Suitably, the connecting portion extends around the circumference of the flexible pipe body.

[0025] Suitably, the flexible pipe body further comprises at least one sacrificial layer, the at least one sacrificial layer being radially adjacent to the continuous metal permeation barrier layer. The flexible pipe body may comprise a sacrificial layer positioned radially inwardly of the continuous metal permeation barrier layer. Additionally or alternatively, the flexible pipe body comprises a sacrificial layer positioned radially outwardly of the continuous metal permeation barrier layer. Thus, the flexible pipe body may comprise two sacrificial layers, each sacrificial layer being radially adjacent to the continuous metal permeation barrier layer, such that the continuous metal permeation barrier layer is arranged between the two sacrificial layers. Thus, the continuous metal permeation barrier layer may be sandwiched between two sacrificial layers. As will be appreciated, one or more sacrificial layers may be arranged radially adjacent to the continuous metal permeation barrier layer, regardless of the position of the continuous metal permeation barrier layer relative to the other layers of the flexible pipe body.

[0026] The sacrificial layer advantageously reduces or prevents direct contact between the continuous metal permeation barrier layer and other structural layers of the pipe, thereby helping to reduce wear of the continuous metal permeation barrier layer. In addition, the contact pressure between the sacrificial layer and the pressure armor layer can further improve the shielding of the helically wound armor layer from corrosion attack.

[0027] Suitably, the sacrificial layer is a polymer layer. In this way, the sacrificial layer may provide an additional shielding effect between the contacting surface of the sacrificial layer and the helically wound pressure armour layer. Fluids in particular cannot penetrate the tape of the helically wound pressure armour layer by transport. Thus, fluid movement towards the gaps between laterally adjacent wrapped turns of the pressure armour tape is restricted by contact between the sacrificial layer and the surface of the pressure armour layer.

[0028] Suitably, the sacrificial layer may be provided via extrusion or alternatively via tape winding.The sacrificial layer may comprise any suitable polymer, for example polyethylene, polypropylene, polyamide, polyester, polyurea, PEEK, PEKK or PVDF, or a combination of any suitable polymers.

[0029] Suitably, the continuous metal permeation barrier layer and the sacrificial layer are at least partially bonded to each other using an adhesive. Alternatively, the continuous metal permeation barrier layer and the sacrificial layer may be at least partially bonded to each other using a melt consolidation portion or a melt bonding portion, or by a spray application process. Each of these at least partially bonded portions is a bond without an adhesive.

[0030] Suitably, the connection portion comprises a bond between laterally adjacent tape wrap turns. That is, the connection portion comprises a bond between the first tape wrap turn of the helically wound tape and the laterally adjacent second tape wrap turn of the helically wound tape. More suitably, the bond between adjacent tape wrap turns of the helically wound tape comprises a weld bond, a braze bond, a solder bond or an adhesive bond.

[0031] Suitably, the continuous metal permeation barrier layer comprises an overlap region between laterally adjacent tape wrap turns such that each tape wrap turn at least partially covers a laterally adjacent tape wrap turn. In this way, in the overlap region, a first tape wrap turn at least partially covers a laterally adjacent second tape wrap turn.

[0032] Suitably, the bonding portion follows the pitch of the helically wound tape. The helically wound tape comprises two surfaces and a first longitudinal edge and a second longitudinal edge. The first longitudinal edge and the second longitudinal edge are mutually opposite edges extending along the helically wound tape. Thus, by following the pitch of the helically wound tape, the bonding portion follows the longitudinal edge of the helically wound tape. The bonding portion may be spaced apart from the longitudinal edge, for example where there is an overlap region between laterally adjacent tape wrap turns.

[0033] Suitably, the helically wound tape comprises a cross-sectional profile having at least one curved or arcuate region. That is, the cross-sectional profile extends across the tape wrap turns of the helically wound tape. For example, the cross-sectional profile extends between opposite longitudinal edges of the tape, typically extending orthogonally.

[0034] More suitably, the cross-sectional profile comprises undulating regions.

[0035] Suitably, the helically wound tape has a lay angle relative to the axis of the flexible pipe body, wherein the lay angle is in the range of 20 degrees to 80 degrees.

[0036] Suitably, the helically wound armour layer is a pressure armour layer or a tensile armour layer.

[0037] Suitably the helically wound armour layer is metal, typically carbon steel.

[0038] Suitably, the continuous metal permeation barrier layer comprises stainless steel or an alloy comprising at least one of nickel, titanium, aluminium, zinc, copper, tin or silver.

[0039] Suitably, the continuous metal permeation barrier layer comprises one or more sub-layers. More suitably, each sub-layer may be formed of the same metal. Alternatively, each sub-layer may be formed of a different metal (such as any of the examples disclosed herein).

[0040] According to another aspect of the present invention, there is provided a flexible riser comprising a flexible pipe body as described herein.

[0041] According to yet another aspect of the present invention, there is provided a method of manufacturing a flexible pipe body, the method comprising:

[0042] Provide internal pressure sheath;

[0043] providing a metallic permeation barrier layer radially outwardly of the inner pressure sheath, wherein the metallic permeation barrier layer comprises a helically wound tape;

[0044] coupling laterally adjacent tape wrap turns of the helically wound tape via connecting portions using a bonding process; and

[0045] A helically wound armor layer is provided radially outwardly of the metallic permeation barrier layer such that the metallic permeation barrier layer is positioned between the internal pressure sheath and the helically wound armor layer.

[0046] According to yet another aspect of the present invention, there is provided a method of manufacturing a flexible pipe body, the method comprising:

[0047] Providing carcass layers;

[0048] providing a metal permeation barrier layer radially outward of the carcass layer, wherein the metal permeation barrier layer comprises a spirally wound tape;

[0049] coupling laterally adjacent tape wrap turns of the helically wound tape via a connecting portion using a bonding process;

[0050] Providing an internal pressure sheath; and

[0051] A helically wound armour layer is provided radially outwardly of the internal pressure sheath such that the continuous metallic permeation barrier is positioned radially inwardly of the helically wound armour layer.

[0052] Suitably, a method further comprises the step of providing at least one sacrificial layer, the at least one sacrificial layer being radially adjacent to the metal permeation barrier layer. More suitably, the method further comprises the step of providing at least two sacrificial layers, each sacrificial layer being radially adjacent to the metal permeation barrier layer, such that the metal permeation barrier layer is arranged between the at least two sacrificial layers.

[0053] Suitably, a method further comprises the step of providing at least one sacrificial layer radially adjacent the metal permeation barrier layer, wherein the sacrificial layer of the at least one sacrificial layer is extruded over the carcass layer.

[0054] Suitably, the step of providing a metal permeation barrier layer comprises embedding the metal permeation barrier layer in a sacrificial layer. More suitably, the sacrificial layer is a radially inward layer.

[0055] Suitably, the helically wound armour layer is provided as one or both of a pressure armour layer and a tensile armour layer.

[0056] Suitably, the bonding process comprises a welding process, a brazing process, a soldering process or an adhesive bonding process. More suitably, the welding process is performed by one or more of the following: tungsten inert gas welding; metal inert gas welding; laser welding; induction heating; resistance welding; friction welding; or roller bonding.

[0057] Suitably, the welding process or the brazing process of a method follows the pitch of the spirally wound tape. That is, the welding process or the brazing process follows the longitudinal edge of the spirally wound tape. The welding process or the brazing process may provide a junction of laterally adjacent tape wrap turns spaced from the longitudinal edge. For example, the junction may be provided in an overlap region between laterally adjacent tape wrap turns.

[0058] Unless explicitly stated otherwise, all features of the invention are considered to be combinable with each other.

[0059] Certain embodiments of the present invention provide the following advantages: A flexible pipe body with reduced penetration of unwanted fluids into the pipe annulus can be provided. Penetration through transmission can be reduced. Penetration due to leaks can be reduced. Thus, the resulting annulus environment can be milder than conventional flexible pipes, which can achieve increased pipe life.

[0060] Certain embodiments of the present invention allow for a more flexible pipe body. The minimum bending radius of a flexible pipe is reduced without compromising its barrier properties. The minimum bending radius of a flexible pipe is reduced without risking damage to its barrier layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0061] Embodiments of the present invention are further described below with reference to the accompanying drawings, in which:

[0062] Figure 1 A flexible pipe body is illustrated;

[0063] Figure 2 illustrates a riser system;

[0064] Figure 3 An example pressure armor layer comprising wires wound at a lay angle is illustrated;

[0065] Figure 4 illustrates a cross-sectional view of an example layer arrangement of a flexible pipe body;

[0066] Figure 5 illustrates a cross-sectional view of a portion of another example layer arrangement of a flexible pipe body;

[0067] Figure 6 illustrates a cross-sectional view of a portion of a further example layer arrangement of a flexible pipe body;

[0068] Figure 7 illustrates a cross-sectional view of another example layer arrangement of a flexible pipe body;

[0069] Figure 8 A schematic diagram illustrating an example apparatus for manufacturing a flexible pipe body;

[0070] Fig. 9 A flow chart illustrating a method of manufacturing a flexible pipe body;

[0071] Fig.10 a flow chart illustrating another method of manufacturing a flexible pipe body; and

[0072] Fig.11 A flow chart illustrating a further method of manufacturing a flexible pipe body.

[0073] In the drawings, like reference numerals refer to like parts. DETAILED DESCRIPTION

[0074] Certain terms are used in the following description for convenience only and are not limiting. The words "lower" and "upper" refer to directions in the drawings to which reference is made and are relative to the components described when assembled and installed. The words "inward", "inwardly" and "outwardly", "outwardly" refer to directions toward and away from a designated centerline or geometric center (e.g., central axis) of the described element, respectively, and the specific meaning is readily apparent from the context of the description.

[0075] Furthermore, unless otherwise stated, the use of ordinal adjectives such as "first," "second," "third," etc. merely indicates different instances of similar objects being referred to and is not intended to imply that the objects so described must be in a given order temporally, spatially, in sequence, or in any other manner.

[0076] Throughout the specification reference will be made to flexible pipe.It will be understood that a flexible pipe is an assembly of a portion of a flexible pipe body and one or more end fittings in each of which a respective end of the flexible pipe body terminates. Figure 1 1 illustrates how a flexible pipe body 100 may be formed from a combination of layered materials that form a pressure containing conduit according to one embodiment. Figure 1 Although a number of specific layers are illustrated in the drawings, it should be understood that the flexible pipe body is broadly applicable to coaxial structures including two or more layers made of a variety of possible materials. For example, the flexible pipe body can be formed of polymer layers, metal layers, composite layers, or a combination of different materials. It should also be noted that the layer thicknesses are shown only for illustrative purposes.

[0077] Although some layers of the flexible pipe body may be described as bonded or consolidated, the flexible pipe may generally be considered to be an unbonded flexible pipe. That is, unless otherwise stated, the layers of the flexible pipe body are unbonded and are thus able to move longitudinally relative to adjacent layers during bending or flexing of the flexible pipe body.

[0078] As used herein, a layer may optionally include sublayers. Multiple sublayers cooperate to form a layer with a specific purpose. For example, a sacrificial layer may be formed from one or more sublayers.

[0079] As used herein, composite materials refer to materials formed from two or more different materials, such as materials formed from a matrix material and reinforcing fibers. In some examples, the composite material may be a composite tape layer. In other examples, the composite material may include an extruded layer. The fibers within the composite material may include carbon fibers, or glass fibers, or basalt fibers, or stretched polymer fibers, or metal wires, or any combination thereof. It should be understood that throughout this specification, tapes are mentioned, and it should be understood that the term should be broadly interpreted to encompass any elongated structure having a preformed cross-section that can be wound around an underlying structure in a spiral manner.

[0080] Tape refers to an elongated material provided in a wrappable or spoolable form so as to form a helically wound tape by being wound around a radially inward layer of a flexible pipe body. In an example, the tape is a wrappable or spoolable metal tape, such as a metal material used to form a helically wound metal tape. The tape generally includes a pair of mutually opposed longitudinal edges with the tape body located between the pair of longitudinal edges.

[0081] As used herein, the term "lay angle" refers to the angle at which a tape or layer is applied to (i.e. wrapped around) a flexible pipe body relative to the longitudinal axis of the flexible pipe body. A tape with a lay angle of 90° would be a tape wrapped around a radius of the cross-section of the flexible pipe body (i.e. perpendicular to the longitudinal axis of the pipe body).

[0082] It will be appreciated that the term "radially" is used to refer to a position relative to a radius of the flexible pipe body. For example, the term "radially inward" means a position relatively closer to the center or central longitudinal axis of the flexible pipe body, and "radially outward" means a position relatively further away from the center or central longitudinal axis of the flexible pipe body.

[0083] Reference now Figure 1 , illustrates a conventional layer arrangement of a flexible pipe body 100. In this example, the flexible pipe body 100 includes an optional innermost carcass layer 101. The carcass layer 101 provides an interlocking structure that can be used as an innermost layer to completely or partially prevent the internal pressure sheath 102 from collapsing due to pipe decompression, external pressure, and tensile armor pressure and mechanical breaking loads. The carcass layer 101 is typically a metal layer formed, for example, of stainless steel. The carcass layer 101 can also be formed of a composite material, a polymer, or other material, or a combination of materials. It should be understood that certain embodiments are suitable for "smooth hole" operations (i.e., without a carcass layer) as well as such "rough hole" applications (with a carcass layer).

[0084] The internal pressure sheath 102 acts as a fluid retaining layer and comprises a polymer layer that ensures the integrity of the internal fluid. It should be understood that this layer itself may comprise multiple sub-layers. It should be understood that when the optional carcass layer 101 is used, the internal pressure sheath 102 is generally referred to as a barrier layer by those skilled in the art. In operations without such a carcass (so-called smooth-hole operations), the internal pressure sheath 102 may be referred to as a liner.

[0085] The flexible pipe body 100 includes an armor layer having a pressure armor layer 103 and first and second tensile armor layers 105, 106. As will be appreciated, the pressure armor layer 103 is optional, such that the first and second tensile armor layers 105, 106 can substantially withstand the pressure and tension forces in the flexible pipe body 100 without the pressure armor layer 103.

[0086] An optional pressure armour layer 103 is disposed radially outwardly of the internal pressure sheath 102. The pressure armour layer 103 is a structural layer that increases the resistance of the flexible pipe to internal and external pressures and mechanical breaking loads. That is, the pressure armour layer 103 bears radial loads. The pressure armour layer 103 provides hoop strength to the flexible pipe body 100. The pressure armour layer 103 also structurally supports the internal pressure sheath 102.

[0087] Additional references Figure 3, the pressure armour layer is formed by a helically wound wire arrangement. The wires form an interlocking configuration of wires wound at a lay angle α relative to the flexible pipe body axis AA. The lay angle α is typically close to 90°. In this way, the laterally adjacent interlocking wires provide a rigid pressure armour layer 103 that provides maximum hoop strength for the entire flexible pipe body 100.

[0088] The flexible pipe body 100 also includes a first tensile armor layer 105 and a second tensile armor layer 106. Each tensile armor layer is used to withstand tensile loads and internal pressure. Additional tensile armor layers may also be optionally added. The tensile armor layer is formed of a plurality of wires (to give strength to the layer) that are located above the inner layer and are helically wound along the length of the pipe at a lay angle typically between about 10° and 55°. The tensile armor layers are typically wound in pairs and counter-wound to balance the torque in the pipe body. The tensile armor layer is typically a metal layer formed, for example, of carbon steel or alloy steel (but may be a higher alloy or stainless steel, or may be a composite tendon).

[0089] The flexible pipe body 100 shown also includes optional tape layers 104 provided radially outwardly of the tensile armour layers 105, 106 which help to contain underlying layers and to provide a degree of protection against abrasion between adjacent layers.

[0090] The flexible pipe body 100 also typically includes an optional insulation layer 107 and an outer jacket 108 comprising a polymer layer for protecting the pipe from penetration by seawater and other external environments, corrosion, abrasion and mechanical damage.

[0091] Each flexible pipe includes at least one portion (sometimes referred to as a section or segment of the flexible pipe body 100) and an end fitting located at at least one end of the flexible pipe. The end fitting provides a mechanical device that forms a transition between the flexible pipe body and the connector. For example, Figure 1 The different pipe layers shown terminate in end fittings so that loads are transferred between the flexible pipe and the connector.

[0092] Reference now Figure 2 , shows a known riser assembly 200 suitable for transporting produced fluids such as oil and / or gas and / or water from a seafloor location 201 to a floating facility. Figure 2 In the embodiment, the seafloor location 201 includes a seafloor flow line. The flexible flow line 205 includes a flexible pipe 203 that is fully or partially resting on or buried below the seafloor 204 and is used for static applications. The floating facility can be composed of a platform and / or a buoy or a floating structure such as a mobile station. Figure 2The vessel 200 is shown provided. The riser assembly 200 is provided in the form of a flexible riser, ie a flexible pipe 203 connecting the vessel to a seabed facility. The flexible pipe may be located in a section of a flexible pipe body having connecting end fittings.

[0093] It should be understood that there are different types of risers, as is well known to those skilled in the art. Embodiments may be used with any type of riser, such as a freely suspended riser (free catenary riser), a riser constrained to some extent (buoy, chain), a fully constrained riser or enclosed in a tube (I-tube or J-tube). Figure 2 It is also illustrated how sections of flexible pipe may be used as flow lines 205 or jumpers.

[0094] Reference now Figure 4 , shows an example layer arrangement of a flexible pipe body 300 in cross section. In this example, the flexible pipe body 300 includes an internal pressure sheath 302. The internal pressure sheath 302 defines a flexible pipe bore. In some examples, a carcass layer (not shown) may be disposed radially inwardly of the internal pressure sheath 302 to define the pipe bore.

[0095] The tape layers (not numbered) and the outer jacket 308 are provided in a radially outer portion of the flexible pipe body 300. Figure 1 These layers are described and therefore will not be described again for the sake of brevity.Although not illustrated, one or more insulation layers may also be included in the flexible pipe body 300 as is known in the art.

[0096] The flexible pipe body 300 comprises an armour layer 320. In the example shown, the armour layer 320 comprises a pressure armour layer formed as a helically wound armour layer 323.

[0097] The armor layer 320 also includes tensile armor layers 325, 326. Figure 1 The tensile armor layers 325, 326 are described and therefore will not be described again for the sake of brevity.

[0098] The helically wound armor layer 323 comprises pressure armor wires. The pressure armor wires are wrapped or wound around the continuous metal permeation barrier layer 310. The pressure armor wires are wound around the continuous metal permeation barrier layer 310 at a lay angle greater than 80° relative to the axis of the flexible pipe body.

[0099] The helically wound armor layer 323 is disposed radially outwardly of the inner pressure sheath 302. In the example shown, the helically wound armor layer 323 is disposed radially outwardly of the continuous metal permeation barrier layer 310.

[0100] The helically wound armor layer 323 has an interlocking configuration. Each pressure armor wire includes opposing longitudinal edges 323a, 323b having interengaging features as known in the art. When the helically wound armor layer is wound onto the flexible pipe body 300, laterally adjacent wire wrap turns of the helically wound armor layer 323 interlock in the region of the overlapping longitudinal edges 323a, 323b. In this manner, the helically wound armor layer 323 primarily provides hoop strength to the flexible pipe body 300.

[0101] The flexible pipe body 300 includes a continuous metal permeation barrier layer 310 positioned radially inwardly of the helically wound armour layer 323. In the example shown, the continuous metal permeation barrier layer 310 is disposed between the inner pressure sheath 302 and the pressure armour layer 323. The inner pressure sheath 302 is positioned radially inwardly of the continuous metal permeation barrier layer 310. In the example shown, the inner pressure sheath 302 is positioned directly radially adjacent to the continuous metal permeation barrier layer 310.

[0102] The continuous metal permeation barrier layer 310 includes spirally wound tapes 312, 313. The spirally wound tapes 312, 313 are helically wound metal tapes. The spirally wound tapes 312, 313 are wrapped or wound around the internal pressure jacket 302 to form the metal permeation barrier layer. Continuous tape wrap turns of the spirally wound tapes 312, 313 are wrapped around the internal pressure jacket 302 to provide a series of laterally adjacent tape wrap turns.

[0103] The helically wound tape 312, 313 includes two surfaces and a first longitudinal edge and a second longitudinal edge. The first longitudinal edge and the second longitudinal edge are mutually opposing edges extending along the helically wound tape 312. Thus, when the helically wound tape 312 is wrapped around the internal pressure sheath 302, the first longitudinal edge 312a of a first tape wrap turn 312 abuts the second longitudinal edge 313a of a second laterally adjacent tape wrap turn 313.

[0104] The continuous metal permeation barrier layer 310 includes a connecting portion 318 that is configured to connect laterally adjacent tape wrap turns of the spirally wound tape 312. The connecting portion 318 forms a bond between laterally adjacent tape wrap turns. In the example shown, the connecting portion 318 is a welded bond. Advantageously, the bond ensures that the metal permeation barrier layer is a continuous metal permeation barrier layer 310, thereby providing a continuous permeation barrier along the flexible pipe body 300 (i.e., there are no gaps even when the pipe is bent). Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through leakage. Specifically, the barrier is a continuous barrier of metal. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through transmission.

[0105] The connecting portion 318 forms a weld bond between the adjacent first longitudinal edge 312a of the first tape wrap turn 312 and the second longitudinal edge 313a of the second tape wrap turn 313. The connecting portion 318 extends around the circumference of the flexible pipe body. The connecting portion 318 coexists between the opposing first and second longitudinal edges of adjacent tape wrap turns of the helically wound tape 312, 313 on the flexible pipe body. In this way, the connecting portion 318 forms a bond following the pitch of the helically wound tape 312, 313.

[0106] Reference now Figure 5 , shows a portion of another example layer arrangement of a flexible pipe body. In addition to including two sacrificial layers, the flexible pipe body is similar to the reference Figure 4 The described examples are substantially the same. Each sacrificial layer is radially adjacent to the continuous metal permeation barrier layer 410 such that the continuous metal permeation barrier layer 410 is disposed therebetween. The use of a sacrificial layer, such as the first sacrificial layer or the second sacrificial layer, prevents local strain and wear.

[0107] The continuous metal permeation barrier layer 410 includes spirally wound tapes 412, 413. The spirally wound tapes 412, 413 are spirally wound metal tapes. The spirally wound tapes 412, 413 are wrapped or wound around the internal pressure jacket 402 to form the metal permeation barrier layer. Continuous tape wrap turns of the spirally wound tapes 412, 413 are wrapped around the internal pressure jacket 402 to provide a series of laterally adjacent tape wrap turns.

[0108] The continuous metal permeation barrier layer 410 includes a connecting portion 418 configured to couple laterally adjacent tape wrap turns of the helically wound tape 412. The connecting portion 418 forms a bond between laterally adjacent tape wrap turns.

[0109] A tape layer, a tensile armor layer, and an outer jacket are also provided. These layers are substantially as described herein with reference to Figure 4 described, and therefore will not be described again for the sake of brevity.

[0110] In the example shown, the first sacrificial layer 431 is radially inward of the continuous metal permeation barrier layer 410, and the second sacrificial layer 432 is radially outward of the continuous metal permeation barrier layer 410. The first sacrificial layer 431 is thus located between the spirally wound armor layer (not shown) and the continuous metal permeation barrier layer 410. Therefore, this prevents the continuous metal permeation barrier layer 410 from direct contact with the spirally wound armor layer. The first sacrificial layer 431 will protect the continuous metal permeation barrier layer 410 and the connecting portion 418 from damage caused by contact with the spirally wound armor layer. The use of the first sacrificial layer 431 also prevents the continuous metal permeation barrier layer 410 and the connecting portion 418 from being affected by the gaps between the wires of the spirally wound armor layer.

[0111] The second sacrificial layer 432 is located between the continuous metal permeation barrier layer 410 and the internal pressure jacket (not shown). Therefore, this prevents the continuous metal permeation barrier layer 410 and the connecting portion 418 from direct contact with the internal pressure jacket. The second sacrificial layer 432 will protect the internal pressure jacket from damage that may be caused by contact with the continuous metal permeation barrier layer 410 and the connecting portion 418 during use. The second sacrificial layer 432 also partially protects the internal pressure jacket from the heat required to provide the connecting portion 418 in the continuous metal permeation barrier layer 410.

[0112] Optionally, one or both of these sacrificial layers can be bonded to the continuous metal permeation barrier layer 410. In the example shown, the continuous metal permeation barrier layer 410 and the first sacrificial layer and the continuous metal permeation barrier layer 410 and the second sacrificial layer are at least partially bonded to each other using an adhesive. Alternatively, the continuous metal permeation barrier layer and each corresponding sacrificial layer can be at least partially bonded to each other using a fusion consolidation portion or a fusion bonding portion without an adhesive. Alternatively, the sacrificial layer can be applied by a spray coating process.

[0113] Reference now Figure 6 , showing a portion of another example layer arrangement for a flexible pipe body. The flexible pipe body is similar to the reference pipe body except that the continuous metal permeation barrier layer 510 includes an overlap region between laterally adjacent tape wrap turns. Figure 5 The described examples are substantially the same. The continuous metal permeation barrier layer 510 includes overlapping regions between laterally adjacent metal tape wrap turns. In this manner, a first tape wrap turn 512, in particular a longitudinal edge 512a of the first tape wrap turn 512, overlaps a laterally adjacent second tape wrap turn 513. The second tape wrap turn 513, in particular a longitudinal edge (not shown) of the second tape wrap turn 513, then overlaps a laterally adjacent third tape wrap turn (not shown). In this manner, each tape wrap turn at least partially covers a laterally adjacent tape wrap turn.

[0114] The continuous metal permeation barrier layer 510 includes a connecting portion 518 configured to couple laterally adjacent tape wrap turns of the spirally wound tape. The connecting portion 518 forms a bond between laterally adjacent tape wrap turns. In the example shown, the bond is a weld bond.

[0115] The connecting portion 518 forms a weld bond between the longitudinal edge 512a of the first tape wrapping turn 512 and the surface portion 514 of the second tape wrapping turn 513. In the example shown, the surface portion 514 of the second tape wrapping turn 513 is an outer surface portion of the second tape wrapping turn 513.

[0116] Alternatively, the continuous metal permeation barrier layer can be configured to invert the overlap region between laterally adjacent tape wrap turns. In this manner, the connecting portion can form a bond between the longitudinal edge of a first tape wrap turn and the inner surface portion of a second tape wrap turn. Further alternatively (not shown), the connecting portion can be disposed between corresponding surface portions of two tape wrap turns, rather than at the longitudinal edges.

[0117] Advantageously, the bonding ensures that the metal permeation barrier layer is a continuous metal permeation barrier layer 510, thereby providing a continuous permeation barrier along the flexible pipe body. The internal pressure sheath is thereby surrounded by the sleeve without gaps or discontinuities. Undesirable fluids from the produced fluids are thereby prevented from penetrating into the pipe annulus through leakage. Specifically, the barrier is a continuous barrier of metal. Thus, the sheath is surrounded by a sleeve of substantially fluid-impermeable material. Undesirable fluids from the produced fluids are thereby prevented from penetrating into the pipe annulus through transmission.

[0118] The connecting portion 518 extends around the circumference of the flexible pipe body. The connecting portion 518 is coextensive with the longitudinal edge 512a of the helically wound band 512 on the flexible pipe body. In this way, the connecting portion 518 follows the pitch of the helically wound bands 512, 513 to form a bond.

[0119] The connecting portion 518 is coextensive with the overlapping region between adjacent tape wrap turns of the helically wound tapes 512, 513. In this manner, the connecting portion 518 follows the pitch of the helically wound tapes 512, 513 to form a bond.

[0120] Advantageously, the weld bonds between the overlapped regions provide an increased bond area between laterally adjacent tape wrap turns, thereby providing a more reliable continuous metal permeation barrier layer 510.

[0121] Reference now Figure 7 , shows another example layer arrangement of a flexible pipe body 600. The flexible pipe body 600 is similar to the reference 600 except that the spirally wound bands 612, 613 include a cross-sectional profile with an undulating region 615. Figure 5 The examples described are essentially the same.

[0122] The cross-sectional profile extends in the longitudinal direction along the band of the helically wound bands 612, 613. Thus, an undulating region 615 of the cross-sectional profile extends around each band wrapping turn. In this way, the continuous metal permeation barrier layer 610 of the flexible body is generally undulating. Thus, the helically wound bands 612, 613 and thus the continuous metal permeation barrier layer 610 are able to withstand additional axial strains. The minimum bending radius of the flexible pipe is reduced without risking damage to its barrier layer.

[0123] As will be appreciated, the cross-sectional profile may be provided in any suitable shape so that the continuous metal permeation barrier layer 610 can withstand additional axial strain. The cross-sectional profile may include one or more curved or arcuate regions. For example, the cross-sectional profile may include one or more of a protrusion, groove, depression, or concave or convex curve relative to the internal pressure sheath. Thus, the cross-sectional profile may provide one or more ribs, grooves, or channels extending in the longitudinal direction of the spirally wound tape. Thus, the cross-sectional profile may provide one or more ribs, grooves, or channels around each tape wrap turn.

[0124] Reference now Fig. 9 , shows a flow chart of a method 900 of manufacturing a flexible pipe body, such as those described herein. The method may be performed using any suitable operating options, such as mechanically or manually winding the layers.

[0125] The first step 910 comprises providing an internal pressure jacket for the flexible pipe body. Suitably, the internal pressure jacket is formed by an extrusion process known in the art.

[0126] The second step 930 includes providing a metal permeation barrier. The method provides a metal permeation barrier formed of a spirally wound tape disposed radially outwardly of the inner pressure jacket. The spirally wound tape is wrapped or wound around the inner pressure jacket to form the metal permeation barrier. Successive tape wrap turns of the spirally wound tape are wrapped around the inner pressure jacket to provide a series of laterally adjacent tape wrap turns.

[0127] The third step 940 includes coupling laterally adjacent tape wrap turns of the spirally wound tape via a connecting portion. The laterally adjacent tape wrap turns are coupled using a bonding process such that the connecting portion forms a portion of a continuous metal permeation barrier layer. The connecting portion forms a bond between the laterally adjacent tape wrap turns. In an example method, the connecting portion is a weld bond.

[0128] Advantageously, the bonding process ensures that the metal permeation barrier layer is a continuous metal permeation barrier layer, thereby providing a continuous permeation barrier along the flexible pipe body. Specifically, the barrier is a continuous barrier of metal. Undesirable fluids from the production fluid are thereby prevented from penetrating into the pipe annulus.

[0129] In an example, the method uses a bonding process to couple a first longitudinal edge of a first tape wrap turn with a second longitudinal edge of a second tape wrap turn. The bonding process thereby provides a connection portion extending around the circumference of the flexible pipe body. The bonding process thereby provides a connection portion extending coextensively between opposing first and second longitudinal edges of adjacent tape wrap turns of the helically wound tape on the flexible pipe body. In this manner, the bonding process (e.g., welding process) follows the pitch of the helically wound tape.

[0130] A fourth step 960 includes providing a helically wound armor layer. The helically wound armor layer is disposed radially outwardly of the continuous metallic permeation barrier layer such that the continuous metallic permeation barrier layer is positioned between the internal pressure sheath and the helically wound armor layer.

[0131] Reference now Figure 8 , shows a schematic diagram of an example apparatus 700 for manufacturing a flexible pipe body as described herein. Thus, an internal pressure sheath, in particular a preformed internal pressure sheath 702, is advanced by a first actuation system 751 to a tape laying area of ​​the apparatus.

[0132] A tape 712 suitable for forming a permeation barrier layer is provided from a tape dispenser 753. The tape 712 is wrapped around the internal pressure jacket 702 at a lay angle relative to the axis of the internal pressure jacket 702. The tape dispenser 753 is oriented so that the tape 712 is typically wrapped at a lay angle of 20° to 80°. As will be appreciated, when the flexible pipe body is fully formed, the axis of the internal pressure jacket 702 will extend coaxially with the axis of the flexible pipe body. In this way, any reference herein to the axis of the internal pressure jacket 702 corresponds equivalently to the axis of the flexible pipe body.

[0133] The internal pressure sheath 702 comprising a helically wound tape is advanced to a welding machine. In the illustrated example, the welding machine is an orbital welding machine 755. As the tape-wrapped internal pressure sheath is advanced in an axial direction, the orbital welding machine 755 couples laterally adjacent tape-wrapped turns of the helically wound tape by rotating.

[0134] The orbital welder 755 joins the first longitudinal edge of the leading tape wrap turn with the second longitudinal edge of the trailing tape wrap turn. The orbital welder 755 provides a continuous joint between the leading tape wrap turn and the trailing tape wrap turn of the helically wound tape. The continuous joint thus provided follows the pitch of the helically wound tape.

[0135] Advantageously, the bonding process ensures that the metal permeation barrier layer is a continuous metal permeation barrier layer, thereby providing a continuous permeation barrier along the flexible pipe body. The internal pressure sheath is thereby surrounded by the sleeve without gaps or discontinuities. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through leakage. Specifically, the barrier is a continuous barrier of metal. Thus, the sheath is surrounded by a sleeve of substantially fluid-impermeable material. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through transmission.

[0136] The continuous metal permeable barrier layer is advanced away from the tape laydown area of ​​the apparatus by the tensioner 757. The advancement speed provided by the tensioner 757 and the rotation and welding speed of the orbital welder 755 are controlled by a suitable controller system 759. In this manner, the apparatus 700 ensures that an optimal joint is provided between the tape wrap turns of the helically wound tape.

[0137] As will be appreciated, the example apparatus 700 may be optionally modified to enable the apparatus to operate with an internal pressure sheath including a sacrificial layer disposed thereon. Alternatively, it will also be appreciated that the example apparatus may be optionally modified to enable the apparatus to operate with an internal carcass and a sacrificial layer disposed thereon. Thus, a tape adapted to form a permeability barrier is wrapped around the sacrificial layer at a suitable lay angle and then welded in a corresponding manner.

[0138] The continuous metallic permeation barrier layer may then be further processed to provide additional layers of the flexible pipe body, including a helically wound armor layer, as is known in the art.

[0139] Reference now Fig.10 , a flow chart illustrating another method 1000 of manufacturing a flexible pipe body, such as those described herein, is shown. The method 1000 is similar to the method of reference 1000 except that it includes the additional step of providing a sacrificial layer. Fig. 9 The method 900 described is substantially the same. The method may be performed using any suitable operating options, such as mechanically or manually winding the layers.

[0140] A first step 1010 comprises providing an internal pressure sheath for the flexible pipe body. Suitably, the internal pressure sheath is formed by an extrusion process known in the art.

[0141] The second step 1020 includes providing a sacrificial layer radially adjacent to the continuous metal permeation barrier layer. The sacrificial layer prevents direct contact between the continuous metal permeation barrier layer and the internal pressure jacket. Damage caused by such contact is prevented. The sacrificial layer also has some shielding properties, which further reduces permeation through the flexible pipe body.

[0142] The third step 1030 includes providing a metal permeation barrier. The method provides a metal permeation barrier formed of a spirally wound tape disposed radially outwardly of the inner pressure jacket. The spirally wound tape is wrapped or wound around the inner pressure jacket to form the metal permeation barrier. Successive tape wrap turns of the spirally wound tape are wrapped around the inner pressure jacket to provide a series of laterally adjacent tape wrap turns.

[0143] A fourth step 1040 includes coupling laterally adjacent tape wrap turns of the spirally wound tape via a connecting portion. The laterally adjacent tape wrap turns are coupled using a bonding process such that the connecting portion forms a portion of a continuous metal permeation barrier layer. The connecting portion forms a bond between the laterally adjacent tape wrap turns. In an example method, the connecting portion is a weld bond.

[0144] Advantageously, the bonding process ensures that the metal permeation barrier layer is a continuous metal permeation barrier layer, thereby providing a continuous permeation barrier along the flexible pipe body. The internal pressure sheath is thereby surrounded by the sleeve without gaps or discontinuities. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through leakage. Specifically, the barrier is a continuous barrier of metal. Thus, the sheath is surrounded by a sleeve of substantially fluid-impermeable material. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through transmission.

[0145] In an example, the method uses a bonding process to couple a first longitudinal edge of a first tape wrap turn with a second longitudinal edge of a second tape wrap turn. The bonding process thereby provides a connection portion that extends around the circumference of the flexible pipe body. The bonding process thereby provides a connection portion that extends coextensively between opposite edges of the spirally wound tape of the continuous metal permeation barrier layer. In this way, the bonding process (in this case, a welding process) follows the pitch of the spirally wound tape.

[0146] A fifth step 1060 includes providing a helically wound armor layer. The helically wound armor layer is disposed radially outwardly of the continuous metallic permeation barrier layer such that the continuous metallic permeation barrier layer is positioned between the internal pressure sheath and the helically wound armor layer.

[0147] It should be understood that reference Fig.10 The order of the above steps described can be changed to provide alternative radial arrangements of the flexible pipe layers. For example, a first step provides a sacrificial layer, and then a second step provides a metal permeation barrier layer. A third step then joins adjacent tape wrap turns. A fourth step then provides an internal pressure sheath, and then a fifth step provides a helically wound armor layer. With this order, a continuous metal permeation barrier layer is disposed radially inwardly of both the internal pressure sheath and the helically wound armor layer.

[0148] Reference now Fig.11 , a flow chart illustrating another method 1100 of manufacturing a flexible pipe body, such as those described herein, is shown. The method 1100 is similar to the method of reference 1100 except that it includes the step of providing a second sacrificial layer. Fig.10 The methods described are essentially the same.The method may be performed using any suitable operating options, such as winding the layers mechanically or manually.

[0149] A first step 1110 comprises providing an internal pressure sheath for the flexible pipe body. Suitably, the internal pressure sheath is formed by an extrusion process known in the art.

[0150] The second step 1120 includes providing a first sacrificial layer radially adjacent to the continuous metal permeation barrier layer. The first sacrificial layer prevents direct contact between the continuous metal permeation barrier layer and the internal pressure jacket. Damage caused by such contact is prevented. The first sacrificial layer also has some shielding properties, which further reduces permeation through the flexible pipe body.

[0151] The third step 1130 includes providing a metal permeation barrier. The method provides a metal permeation barrier formed of a spirally wound tape disposed radially outwardly of the inner pressure jacket. The spirally wound tape is wrapped or wound around the inner pressure jacket to form the metal permeation barrier. Successive tape wrap turns of the spirally wound tape are wrapped around the inner pressure jacket to provide a series of laterally adjacent tape wrap turns.

[0152] A fourth step 1140 includes coupling laterally adjacent tape wrap turns of the spirally wound tape via a connecting portion via a bond of laterally adjacent tape wraps. The laterally adjacent tape wrap turns are coupled using a bonding process such that the connecting portion forms a portion of a continuous metal permeation barrier layer. The connecting portion forms a bond between laterally adjacent tape wrap turns. In an example method, the coupling is a weld bond or a braze bond.

[0153] Advantageously, the bonding process ensures that the metal permeation barrier layer is a continuous metal permeation barrier layer, thereby providing a continuous permeation barrier along the flexible pipe body. The internal pressure sheath is thereby surrounded by the sleeve without gaps or discontinuities. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through leakage. Specifically, the barrier is a continuous barrier of metal. Thus, the sheath is surrounded by a sleeve of substantially fluid-impermeable material. Undesirable fluids from the produced fluid are thereby prevented from penetrating into the pipe annulus through transmission.

[0154] In an example, the method uses a bonding process to couple a first longitudinal edge of a first tape wrap turn with a second longitudinal edge of a second tape wrap turn. The bonding process thereby provides a connection portion that extends around the circumference of the flexible pipe body. The bonding process thereby provides a connection portion that extends coextensively between opposite edges of the spirally wound tape of the continuous metal permeation barrier layer. In this way, the bonding process (in this case, a welding process) follows the pitch of the spirally wound tape.

[0155] A fifth step 1150 includes providing a second sacrificial layer radially adjacent to the continuous metal permeation barrier layer. The second sacrificial layer prevents direct contact between the continuous metal permeation barrier layer and the helically wound armor layer. Damage caused by such contact is prevented. The second sacrificial layer also has some shielding properties, which further reduces permeation through the flexible pipe body.

[0156] A sixth step 1160 includes providing a helically wound armor layer. The helically wound armor layer is disposed radially outwardly of the continuous metallic permeation barrier layer such that the continuous metallic permeation barrier layer is positioned between the internal pressure sheath and the helically wound armor layer.

[0157] It should be understood that Fig.10 The order is the same, Fig.11 The sequential steps of can be varied to provide alternative radial arrangements of the flexible pipe layers. For example, a first step provides a sacrificial layer, and then a second step provides a metal permeation barrier layer. A third step then couples adjacent tape wrapped turns. A fourth step then provides a second sacrificial layer in step 1150. A fifth step then provides an internal pressure sheath, and then a sixth step provides a helically wound armor layer. With this sequence, a continuous metal permeation barrier layer is disposed radially inwardly of both the internal pressure sheath and the helically wound armor layer. Various modifications to the detailed arrangements and methods described above are possible.

[0158] For example, any of these methods can be used to manufacture a flexible pipe body having the layer arrangements described herein. Thus, a method can be configured to use a continuous metal permeation barrier layer comprising an arcuate, curved, or undulating cross-sectional profile disposed on each tape wrap turn to manufacture a flexible pipe body capable of withstanding additional axial strain.

[0159] It will be apparent to those skilled in the art that the features described with respect to any of the above embodiments may be applied interchangeably between the different embodiments.The above embodiments are examples for illustrating the various features of the present invention.

[0160] Throughout the detailed description and claims of this specification, the words "comprise" and "contain" and their variations mean "including but not limited to", and they are not intended to (and do not) exclude other parts, additives, components, wholes or steps. Throughout the detailed description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. Specifically, where the indefinite article is used, the specification should be understood to contemplate both the plural and the singular unless the context otherwise requires. It should also be understood that throughout this specification, language expressed in the general form of "X for Y" (where Y is some action, activity or step, and X is some means for performing the action, activity or step) covers means X that are specifically (but not exclusively) adjusted or arranged to perform Y.

[0161] Unless otherwise expressly stated, each feature disclosed in this specification may be replaced by an alternative feature used for the same, equivalent or similar purpose. Therefore, unless otherwise expressly stated, each feature disclosed is only an example of a general series of equivalent or similar features.

[0162] The features, structures, entities, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention should be understood to be applicable to any other aspect, embodiment or example described herein, unless incompatible therewith. All features disclosed in this specification (including any attached claims, abstract and drawings) and / or all steps of any method or process so disclosed may be combined in any combination, except that at least some of such features and / or steps are mutually exclusive combinations. The present invention is not limited to the details of any foregoing embodiments. The present invention extends to any novel feature structure or any novel combination of the features disclosed in this specification (including any attached claims, abstract and drawings), or to any novel step or any novel combination of the steps of any method or process so disclosed.

[0163] The reader's attention is directed to all papers and documents filed in connection with this patent application concurrently with or before this specification and which disclose public inspection of the present specification, and the contents of all these papers and documents are incorporated herein by reference.

Claims

1. A flexible pipe body for conveying produced fluid, the flexible pipe body comprising: Internal pressure sheath; a helically wound armor layer, the helically wound armor layer being radially outward of the internal pressure sheath; and a continuous metal permeation barrier layer, the continuous metal permeation barrier layer being disposed radially inward of the spirally wound armor layer; Wherein the continuous metal permeation barrier layer comprises a helically wound tape and a connecting portion configured to couple laterally adjacent tape wrap turns of the helically wound tape.

2. The flexible pipe body according to claim 1, wherein the connecting portion extends around the circumference of the flexible pipe body.

3. The flexible pipe body according to claim 1 or 2, further comprising at least one sacrificial layer radially adjacent the continuous metal permeation barrier layer.

4. The flexible pipe body of claim 3, wherein the flexible pipe body comprises at least two sacrificial layers, each sacrificial layer being radially adjacent to the continuous metal permeation barrier layer such that the continuous metal permeation barrier layer is arranged between the at least two sacrificial layers.

5. Flexible pipe body according to any preceding claim, wherein the connection portion comprises a bond between laterally adjacent tape wrap turns.

6. A flexible pipe body as claimed in claim 5, wherein the bonds between adjacent tape wrap turns of the helically wound tape comprise weld bonds, braze bonds, solder bonds or adhesive bonds.

7. A flexible pipe body as claimed in claim 6, wherein the bond follows the pitch of the helically wound tape.

8. A flexible pipe body as claimed in any preceding claim, wherein the continuous metal permeation barrier layer comprises an overlap region between laterally adjacent tape wrap turns such that each tape wrap turn at least partially covers a laterally adjacent tape wrap turn.

9. The flexible pipe body of claim 8, wherein the helically wound band of the continuous metal permeation barrier layer comprises a cross-sectional profile including at least one curved or arcuate region.

10. The flexible pipe body of claim 9, wherein the cross-sectional profile comprises an undulating region.

11. Flexible pipe body according to any preceding claim, wherein the helically wound tape has a lay angle relative to the axis of the flexible pipe body, wherein the lay angle is in the range of 20 to 80 degrees.

12. A flexible riser comprising a flexible pipe body according to any preceding claim.

13. A method of manufacturing a flexible pipe body, the method comprising: Provide internal pressure sheath; providing a metal permeation barrier layer, wherein the metal permeation barrier layer comprises a spirally wound tape; coupling laterally adjacent tape wrap turns of the spirally wound tape via connecting portions using a bonding process to provide the continuous metal permeation barrier layer; and A helically wound armor layer is provided, the helically wound armor layer being radially outward of the continuous metallic permeation barrier layer such that the continuous metallic permeation barrier is positioned radially inward of the helically wound armor layer.

14. The method of claim 13, further comprising providing at least one sacrificial layer radially adjacent to the continuous metal permeation barrier layer.

15. The method of claim 14, further comprising providing at least two sacrificial layers, each sacrificial layer being radially adjacent to the continuous metal permeation barrier layer, such that the metal permeation barrier layer is disposed between the at least two sacrificial layers.

16. The method according to any one of claims 13 to 15, wherein the bonding process comprises a welding process, a brazing process, a soldering process or an adhesive bonding process.

17. The method of claim 16, wherein the welding process is performed by one or more of: tungsten inert gas welding; metal inert gas welding; laser welding; induction heating; resistance welding; friction welding; or roll bonding.

18. The method according to claim 16 or 17, wherein the welding process or the brazing process follows the pitch of the helically wound tape.

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