Supporting shaft

Abstract

Described herein is an apparatus for supporting an elongate strip element during manufacture of a flexible pipe body and a method of manufacturing a flexible pipe body using an elongate shaft member comprising an outer surface comprising a profiled surface area, and a profiled surface region extending along at least a portion of the shaft member and having a profiled cross-section comprising a repeating flat constant radius cross-sectional region, the repeating flat constant radius cross-sectional area is provided by a helically extending smooth surface area of the outer surface located on an imaginary cylindrical surface coaxial with the central longitudinal axis of the shaft member, disposed between spaced apart strip alignment cross-sectional areas, the strip alignment cross-sectional area is provided by a continuous repeating helical extension variant of the outer surface located on the imaginary cylindrical surface.

Description

[0001] The present invention relates to a method and apparatus for manufacturing a flexible pipe body. In particular, but not exclusively, the present invention relates to a shaft member for supporting an elongate strip of material during the manufacture of a flexible pipe body.

[0002] Traditionally, flexible pipes are used to transport produced fluids such as oil and / or gas and / or water from one location to another. Flexible pipes are particularly useful when connecting a seafloor location (which may be a deep sea, such as 1000 meters or deeper) to a sea level location. The pipe may have an inner diameter generally up to about 0.6 meters (e.g., a diameter may be in the range of 0.05 m to up to 0.6 m). Flexible pipes are generally formed as a component of a flexible pipe body and one or more end fittings. The pipe body is generally formed as a combination of layered materials, which form a pressure-bearing conduit. The pipe structure allows large flexures without causing bending stresses that would damage the function of the pipe during its life. There are different types of flexible pipes, such as non-bonded flexible pipes or composite flexible pipes manufactured according to API 17J, etc. The pipe body is generally constructed as a combined structure including a polymer layer and / or a composite layer and / or a metal layer. For example, the pipe body may include a polymer layer and a metal layer, or a polymer layer and a composite layer, or a polymer layer, a metal layer and a composite layer. The layers may be formed from a single piece, such as an extruded tube, or by spirally winding one or more wires at a desired pitch, or by connecting together a plurality of discrete rings arranged concentrically side by side. Depending on the layers of flexible pipe used and the type of flexible pipe, some of the pipe layers may be bonded together or remain unbonded.

[0003] Some flexible pipes have been used in deepwater (less than 3,300 feet (1,005.84 meters) and ultra-deepwater (greater than 3,300 feet) developments. There is a growing demand for oil to be explored at greater and greater depths (e.g., greater than 8202 feet (2500 meters)), where environmental factors are becoming more extreme. For example, in such deepwater and ultra-deepwater environments, ocean floor temperatures increase the risk of produced fluids cooling to a temperature that can cause pipe plugging. In practice, flexible pipes have traditionally been designed to operate at operating temperatures of -30°C to +130°C, and are being developed for even more extreme temperatures. Increased depths also increase the risk of the production fluids cooling to a temperature that can cause pipe plugging. Pressures associated with the environment in which the flexible pipe must operate. For example, a flexible pipe may be required to operate with an external pressure in the range of 0.1 MPa to 30 MPa acting on the pipe. Likewise, the transport of oil, gas or water may well result in high pressures acting on the flexible pipe from the inside, such as internal pressures in the range of zero to 140 MPa acting on the pipe from wellbore fluids. Therefore, the need for high levels of performance of certain layers of the flexible pipe body, such as the pipe carcass layers or the pressure armour layers or the tensile armour layers, is increased. Note, for completeness, that the flexible pipe may also be used in shallow water applications (e.g., depths less than about 500 meters) or even in coastal (onshore) applications.

[0004] Conventionally, flexible pipe bodies may be constructed with a carcass layer as the radially innermost layer in a so-called "rough hole" operation. Gaps between carcass tape coils can result in reduced production fluid flow rates because the velocity of the fluid at the outer boundary of the hole is slowed by the fluid entering and leaving these gaps. Folded tape inserts may be used to help mitigate this. However, due to the size and shape of such folded tapes, it is still possible for fluid to break through these inserts into the gaps between carcass coils and affect fluid flow.

[0005] Further problems arise because increasing the width of the folded tape has the effect that the wider folded tape cannot be wrapped with the desired overlap during conventional flexible pipe body manufacturing processes.

[0006] It is an object of the present invention to at least partially alleviate one or more of the above problems.

[0007] Certain embodiments of the present invention are directed to at least partially smoothing the bore of a flexible pipe.

[0008] It is an object of certain embodiments of the present invention to completely or at least partially prevent production fluid flowing in a flexible pipe from entering the gap created by repeated instances of helical gaps between adjacent coils of carcass strip material.

[0009] It is an object of certain embodiments of the present invention to provide a flexible pipe body comprising an insert for facilitating smoothing of a bore of the flexible pipe.

[0010] It is an aim of certain embodiments of the present invention to provide a method of manufacturing a flexible pipe body having an insert for facilitating smoothing of a bore of the flexible pipe.

[0011] It is an object of certain embodiments of the present invention to provide apparatus for manufacturing a flexible pipe body having a folded tape having an increased width relative to conventional folded tape inserts.

[0012] It is an aim of certain embodiments of the present invention to provide a method of manufacturing a flexible pipe body having a folded tape having an increased width relative to conventional folded tape inserts.

[0013] It is an object of certain embodiments of the present invention to provide a windable insert which bridges the helical gap formed between adjacent coils or carcass strip and thus covers the helical gap, but which does not significantly intrude into the gap in the radial direction and therefore does little to limit possible axial play between adjacent carcass strip coils when the flexible tube is flexed.

[0014] It is an object of certain embodiments of the present invention to provide a windable insert and associated method of manufacture that facilitates positioning of the insert relative to the coils of carcass strip material so that the insert will not separate from the carcass coils in use.

[0015] It is an object of certain embodiments of the present invention to provide an insert having a spoolable profile in which adjacent coils of the insert itself interlock to some extent to help reduce any risk of separation in use, but which also enables adjacent instances of the insert coils to slide freely relative to each other in use, thereby not unduly affecting the flexing of the flexible pipe body.

[0016] It is an object of certain embodiments of the present invention to provide a wrappable insert that can help close the spiral gap and can be manufactured from a flat strip folded into a desired cross-sectional profile using a carcass winding machine used in any manner during the manufacture of a flexible pipe body.

[0017] It is an aim of certain embodiments of the present invention to provide a shaft member having one or more helical extension variations for positioning an elongate strip of material during manufacture of a flexible pipe body.

[0018] According to a first aspect of the invention there is provided an apparatus for supporting an elongate strip element during manufacture of a flexible pipe body, comprising an elongate shaft member including an outer surface including a profiled surface region extending along at least a portion of the shaft member and having a profiled cross section including repeating flat constant radius cross section regions provided by helically extending smooth surface regions of the outer surface located on an imaginary cylindrical surface coaxial with a central longitudinal axis of the shaft member, disposed between spaced apart strip alignment cross section regions provided by continuously repeating helically extending variations of the outer surface located on the imaginary cylindrical surface.

[0019] Suitably, each strip alignment cross-sectional area comprises a recessed area or a raised area or a combination of recessed and raised areas in or from said outer surface relative to the imaginary cylindrical surface.

[0020] Suitably, the strip alignment cross-sectional region comprises a recess in the outer surface and the variation comprises a helical recess having a common cross-section extending helically through at least 720 degrees and thereby repeatedly along said profiled region of the outer surface of the shaft member.

[0021] Suitably, the common cross-section of the recess comprises a first recess end and another recess end spaced apart from the first recess end, the first recess end comprising a step extending radially inwardly at an abrupt change extending into the outer surface of the shaft member adjacent to the first end at approximately 90 degrees, and the other recess end comprising a position where an inclined surface of the recess rising from the bottom of the recess meets the imaginary cylindrical surface.

[0022] Suitably, the common cross-section of the recess also includes a constant radius region having a constant depth radially inside the imaginary cylindrical surface and extending from the bottom of the mutation step to the starting part of the inclined surface as the inclined surface rises from the bottom of the recess toward the imaginary cylindrical surface.

[0023] Suitably, the shaft cross section comprises a cross section of the outer surface of a semi-cylindrical side of the shaft member at a plane passing through and containing the central longitudinal axis of the shaft member.

[0024] Suitably, the helical extension has a constant cross-section and a constant pitch.

[0025] Suitably, the elongate shaft member comprises a mandrel supported at least at one end thereof.

[0026] Suitably, the device also includes at least one fluid communication channel, which extends axially along and within the corresponding lubrication area of ​​the shaft member and includes a channel portion extending to the outer surface of the shaft member; and at least one lubrication hole, which is located at the outer surface of the shaft member and at the corresponding end of the corresponding channel portion, for selectively providing lubricant at a corresponding position at the interface area on the outer surface of the slender shaft member.

[0027] Suitably, the apparatus supports the elongate strip element during manufacture of a carcass layer of a flexible pipe body.

[0028] According to a second aspect of the present invention, there is provided a method for manufacturing a flexible pipe body, comprising the steps of: when winding an elongated tape element, helically winding the elongated tape element around a profiled area of ​​an outer surface of an elongated shaft member, orienting a first section of the tape cross-section of the elongated tape element to be adjacent to a helically extending smooth surface area of ​​the outer surface; and aligning another section of the tape cross-section oblique to the smooth surface area of ​​the outer surface via a helically extending deformation to the outer surface.

[0029] Suitably, the method further comprises winding a lead-in coil of the elongate tape element between the outer surface and another portion of an immediately preceding coil of the elongate tape element.

[0030] Suitably, the first section of the orientated elongate tape element further comprises a helically extending smooth surface region positioning the first section of the elongate tape element proximate the outer surface.

[0031] Suitably, the method further comprises helically winding another strip onto at least one already wound coil of the elongated strip element, thereby positioning a first portion of a coil of the other elongated strip element at least partially in a gap between another adjacent coil of the other strip, and positioning another portion of an adjacent coil of the elongated strip element adjacent to said coil of the elongated strip element at least partially in said gap.

[0032] Suitably, the method further comprises helically winding another strip onto at least one coil of the elongated strip element, whereby an area of ​​the coil of the other strip is nested within a mating area of ​​a preceding coil of the elongated strip element, the mating area being arranged obliquely to the smooth surface area prior to interlocking adjacent coils of the other strip.

[0033] Suitably, when helically winding the elongated strip element, the end of the cross-section of the introduced coil of the elongated strip element corresponding to the free edge of the elongated strip element is positioned against an abutment surface provided by the stepped edge of the spiral recess in the outer surface of the shaft member, thereby determining the spacing relationship and therefore the pitch of adjacent coils for the elongated strip element.

[0034] Suitably, when helically winding the elongate strip element, a region of the cross-section of the lead-in coil of the elongate strip element is supported via the inclined surface of the recess, thereby positioning the remaining portion of the cross-section of the elongate strip element not disposed in the recess in the desired configuration.

[0035] Suitably, the method further comprises helically winding the elongate tape element on the outer surface whereby at least a portion of a plurality of successively wound adjacent coils of the elongate tape element is provided below a touchdown footprint of an incoming coil of the further tape when winding the further tape.

[0036] Suitably, the method further comprises providing at least a portion of at least three successively wound adjacent coils of the elongate tape element beneath a footprint of an incoming coil of the further tape when winding the further tape.

[0037] Suitably, said further strip comprises a carcass strip and adjacent coils of the wound carcass strip self-interlock following application of compression pressure downstream of the footprint.

[0038] Suitably, the method further comprises supporting the elongate tape element during manufacture of the carcass layer of the flexible pipe body.

[0039] According to a third aspect of the invention there is provided a use of an elongate shaft member for manufacturing a flexible pipe body, the elongate shaft member comprising an outer surface comprising a profiled surface region extending along at least a portion of the shaft member and having a profiled cross section comprising repeated flat constant radius cross section regions provided by helically extending smooth surface regions of the outer surface located on an imaginary cylindrical surface coaxial with a central longitudinal axis of the shaft member, arranged between spaced apart tape alignment cross section regions provided by continuously repeated helically extending variations of the outer surface located on the imaginary cylindrical surface.

[0040] According to a fourth aspect of the present invention, there is provided a slender strip element having a cross-section comprising: a first portion extending from a first free edge of the slender strip element corresponding to a first end of the cross-section of the slender strip element, wherein the first portion is bent for positioning in a first gap region extending between two adjacent coils of a carcass strip of a flexible tube body; and a main body portion extending between the first portion and a remaining end of the cross-section corresponding to a remaining free edge of the slender strip element, having a length for bridging another gap region extending between one of the two adjacent coils and another adjacent coil of the carcass strip adjacent to the one of the two adjacent coils of the carcass strip, wherein the main body portion comprises an intermediate region bent for positioning at least partially in the other gap region.

[0041] Suitably, the first portion is configured to extend into the first gap region by a distance between 10% and 50% of the total thickness of the coils of carcass strip.

[0042] Suitably, the first portion has a curved shape which matches the curved shape of the carcass coil at a lift point where the carcass strip coil curves away from a radially innermost surface of the carcass strip coil.

[0043] Suitably, the remaining end of the cross-section of the elongated strip element is turned over for positioning at least partially between a further adjacent coil and another adjacent coil of the carcass strip towards a further gap region and at least partially into a recessed region of an adjacent elongated strip element coil.

[0044] Suitably, the intermediate region comprises a single curve having a bell-curve profile, the curve having an apex pointing away from the main plane associated with said cross-section in the same direction as the direction in which the first portion turns away from the main plane.

[0045] Suitably, the first portion extends between 5% and 20% of the width of the cross-section of the elongate strip element from the first free edge of the cross-section to the remaining free edge of the cross-section.

[0046] Suitably, the cross-section of the elongate strip element has a thickness of no more than 60% of the thickness of the carcass strip, and optionally the elongate strip element has a thickness of less than 35% of the thickness of the carcass strip.

[0047] Suitably, the apex of the curve in the intermediate region extends into the further gap by a distance between 5% and 15% of the total thickness of the coils of carcass strip.

[0048] Suitably, the cross-section consists only of the first portion and the main portion, and the main portion consists only of the vertical region between the first portion and the middle region, and optionally consists only of the vertical region between the middle and the remaining end, or of the vertical region extending from the middle region and the other curved end of the main portion close to the remaining end.

[0049] Suitably, the elongate strip element has a cross-section which is a cross-section extending between the first free edge and the remaining free edge and which is perpendicular to the major axis of the elongate strip element.

[0050] Suitably, the cross-section of the elongate strip element is a cross-section in a mid-axial plane.

[0051] Suitably, the cross-section of the elongate strip element has a uniform thickness throughout the cross-section.

[0052] Suitably, the elongate strip element is a folded strip of metal, optionally stainless steel.

[0053] Suitably, the elongate strip element body portion is curved proximate a remaining free edge of the elongate strip element, and the curvature of the body portion proximate the remaining free edge at least partially matches the curvature of the intermediate region.

[0054] According to a fifth aspect of the present invention, there is provided a flexible pipe body comprising a wound carcass strip element, the wound carcass strip element comprising a plurality of carcass coils, adjacent carcass coils being interlocked and providing a gap therebetween; and a helically wound elongated strip element, the helically wound elongated strip element being at least partially interposed between the coils of the carcass strip element, having a cross section comprising a first portion and a main portion, the first portion extending from a first free edge of the elongated strip element corresponding to a first end of the cross section, the first portion being curved and extending at least partially into a first gap region extending between two adjacent coils of the carcass strip, the main portion extending between the first portion and a remaining end of the cross section corresponding to a remaining free edge of the elongated strip element, the main portion bridging another gap region extending between one of the two adjacent coils and another adjacent coil adjacent to the one of the two adjacent coils of the carcass strip; wherein the main portion comprises an intermediate region, the intermediate region being curved and at least partially positioned into the other gap region.

[0055] Suitably, the first portion of the elongate strip element extends into the first gap region by a distance of between 10% and 50% of the total thickness of the coils of carcass strip.

[0056] Suitably, the remaining end of the elongate strip element cross-section is turned over for positioning at least partially between a further adjacent coil and another adjacent coil of carcass strip towards a further gap region and at least partially into a recessed region of an adjacent elongate strip element coil.

[0057] Suitably, when the carcass coil is lifted away from the radially innermost extent, the curvature of the remaining end of the elongate strip element cross-section at least partially matches the curvature of the intermediate region and the curvature of the carcass coil at the point of lifting.

[0058] Suitably, the flexible pipe body further comprises an inner polymeric barrier layer providing a fluid barrier and having a radially inner surface defining the fluid communication aperture; and at least one armour layer radially outwardly of the barrier layer.

[0059] Suitably, the carcass strip is a curved strip of uniform thickness in cross-section of the carcass coils, folded to provide adjacent coils which may interlock; and the elongate strip element is a curved strip of uniform thickness in cross-section of the elongate strip, folded to provide a cross-section comprising the first portion and the main body portion.

[0060] Suitably, the cross-section of the elongate strip element has a thickness of no more than 60% of the thickness of the carcass strip, and optionally the elongate strip element has a thickness of less than 35% of the thickness of the carcass strip.

[0061] Suitably, the apex of the curve in the middle region of the elongated strip element extends into the further gap by a distance of between 5% and 15% of the total thickness of the coils of carcass strip.

[0062] Suitably, the intermediate region comprises a single curve having a bell-curve profile, the curve having an apex pointing away from the main plane associated with said cross-section in the same direction as the direction in which the first portion turns away from the main plane.

[0063] Suitably, the remaining end of the cross-section of the elongated strip element has a curved shape which matches the shape of the turning area of ​​the middle area when the middle area turns away from the main plane associated with the cross-section, so as to enable the other curved end of the coil of the elongated strip element to be nested in the recess below the associated middle area of ​​the adjacent coil of the elongated strip element.

[0064] According to a sixth aspect of the present invention, there is provided a method for manufacturing a flexible pipe body, the method comprising the following steps: spirally winding an elongated tape element on the outer surface of a mandrel member, thereby causing the overlapping region of the elongated tape element of an introduced coil of the elongated tape element to at least partially overlap the overlapping region of a previous coil of the elongated tape element; spirally winding a carcass strip on the mandrel member, thereby positioning a portion of an introduced carcass coil on at least one region of an already wound coil of the elongated tape element, thereby positioning a curved first portion of the cross-section of the elongated tape element in a first gap region extending between two adjacent coils of the carcass strip, and positioning a main body portion of the elongated tape element to bridge another gap region extending between one of the two adjacent coils and another adjacent coil of the carcass strip adjacent to the one of the two adjacent coils of the carcass strip; and positioning an at least partially curved middle region of the main body portion into the other gap region.

[0065] Certain embodiments of the present invention help provide a smooth surface to the bore of a flexible pipe.

[0066] Certain embodiments of the present invention provide an apparatus that allows relative movement of adjacent carcass strip material coils while providing a substantially smooth radially inner surface to those wound carcass strip material coils of a flexible pipe body.

[0067] Certain embodiments of the present invention provide a method that allows for the manufacture of a flexible pipe body having a smooth insert overlapping a plurality of carcass layer coils.

[0068] Certain embodiments of the present invention provide apparatus and methods for manufacturing a flexible pipe body using a shaft member.

[0069] Certain embodiments of the present invention provide a windable elongated strip having a cross-section such that adjacent coils of the elongated strip at least partially overlap to help bridge and thereby cover the spiral gap created between adjacent coils of the carcass strip. The elongated strip effectively creates an insert that partially intrudes into the gap but does not extend radially into the gap more than 40% of the total thickness of the interlocked carcass coils. This helps to minimize any effect on axial play between the carcass coils when the flexible tube flexes in use.

[0070] Certain embodiments of the present invention may be used as risers and in flexible pipes exceeding 500 m in length and in the ocean at depths greater than 1000 m.

[0071] Certain embodiments of the present invention provide an insert cross-section that can be wound using a carcass winding machine that is in any case used for winding a carcass strip to form an anti-collapse layer of a flexible pipe body.

[0072] Certain embodiments of the present invention provide an elongated strip and a related method of producing a desired profile of the elongated strip and a related method of simultaneously winding the profiled elongated strip with a carcass strip, thereby producing an anti-collapse layer onto which a fluid barrier layer can be extruded. The elongated strip profile has a cross-section having an upturned end and an intermediate region spaced apart by a predetermined distance so that the coils of the carcass strip are nested between the upturned region and the intermediate region. The nesting helps to position the elongated strip relative to the carcass strip to help prevent separation in use. The upturned end of the elongated strip does not need to intrude too deeply into the spiral gap to keep the insert in place. This helps to maximize the axial play of the carcass coils, making manufacturing easier and can help control material costs.

[0073] Certain embodiments of the present invention will now be described hereinafter, by way of example only, with reference to the accompanying drawings, in which:

[0074] Figure 1 A flexible pipe body is shown;

[0075] Figure 2 Some uses of flexible pipe are shown;

[0076] Figure 3 shows a portion of a flexible pipe body viewed in cross-section;

[0077] Figure 4 shows an example elongated strip element cross section for smoothing the radially inner surface of a wrapped carcass strip;

[0078] Figure 5 shows an alternative portion of a flexible pipe body viewed in cross-section;

[0079] Figure 6 shows an alternative example elongated strip element cross section for smoothing the radially inner surface of a wrapped carcass strip;

[0080] Figure 7 Shown along with Figure 4 a cross-section of a plane extending through and through the longitudinal axis of a flexible pipe body of the elongate tape element shown, illustrating a portion of a method of manufacturing a flexible pipe body;

[0081] Figure 8 Shown along with Figure 6a cross-sectional view of a plane extending through and through the longitudinal axis of a flexible pipe body of the elongate tape element shown, illustrating a portion of a method of manufacturing a flexible pipe body;

[0082] Fig. 9 An example elongated shaft member for supporting an elongated strip of material during manufacture of a flexible pipe body is shown;

[0083] Fig.10 The use of a support having an outer surface area that is not purely cylindrical is shown to produce a Figure 4 A portion of the method of forming a flexible pipe body of an elongated strip element as shown;

[0084] Fig.11 Shows Fig.10 An enlarged cross-section of a flexible pipe body and associated recessed support is shown;

[0085] Fig.12 Shows the manufacturing Figure 4 A portion of an alternative method of a flexible pipe body of the elongated strip element shown; and

[0086] Fig.13 Alternative profiles of at least one region of an elongate shaft member that may be used to manufacture a flexible pipe body are shown.

[0087] In the drawings, like reference numerals refer to like parts.

[0088] Throughout the specification, reference will be made to flexible pipe. It should be understood that certain embodiments of the present invention are applicable to various flexible pipes. For example, certain embodiments of the present invention may be used for flexible pipe bodies and associated end fittings of the type manufactured in accordance with API 17J. Such flexible pipes are generally referred to as non-bonded flexible pipes. Other embodiments are associated with other types of flexible pipes.

[0089] It will be appreciated that the flexible pipe shown is an assembly of a portion of a pipe body and one or more end fittings (not shown) in each of which a respective end of the pipe body is terminated. Figure 1 1 shows how the pipe body 100 is formed from a combination of layered materials that form a pressure-containing conduit. Figure 1 Although a plurality of specific layers are shown in the drawings, it should be understood that certain embodiments of the present invention are broadly applicable to coaxial tube body structures including two or more layers made of a variety of possible materials. The tube body may include one or more layers comprising a composite material, thereby forming a tubular composite layer. It should also be noted that the layer thicknesses are shown for schematic illustration only. As used herein, the term "composite material" is used to broadly refer to a material formed of two or more different materials, such as a material formed of a matrix material and reinforcing fibers.

[0090] Thus, a tubular composite layer is a layer having a generally tubular shape formed of a composite material. Alternatively, a tubular composite layer is a layer having a generally tubular shape formed of a plurality of components, one or more of which are formed of a composite material. The layer or any element of the composite layer may be manufactured via an extrusion, pultrusion or deposition process, or via a winding process in which adjacent coils of a tape that itself has a composite structure are consolidated with adjacent coils. Regardless of the manufacturing technique used, the composite material may optionally include a matrix or body of a material having a first property in which additional elements having different physical properties are embedded. That is, elongated fibers aligned to a certain extent or smaller fibers randomly oriented may be placed into the body, or spheres or other regular or irregularly shaped particles may be embedded in the matrix material, or a combination of more than one of the above. Suitably, the matrix material is a thermoplastic material, suitably, the thermoplastic material is polyethylene or polypropylene or nylon or PVC or PVDF or PFA or PEEK or PTFE or an alloy of such materials with reinforcing fibers made of one or more of glass, ceramic, basalt, carbon, carbon nanotubes, polyester, nylon, aramid, steel, nickel alloy, titanium alloy, aluminum alloy, etc. or a filler made of glass, ceramic, carbon, metal, buckyball, metal silicate, carbide, carbonate, oxide, etc.

[0091] Figure 1 The pipe body 100 shown includes an internal pressure sheath 110, which acts as a fluid retaining layer and includes a polymer layer that ensures the integrity of the internal fluid. This layer provides a boundary for any transported fluid. It should be understood that this layer itself may include multiple sublayers. It should be understood that when a carcass layer 120 is utilized, the internal pressure sheath is generally referred to as a barrier layer by those skilled in the art. In operations without such a carcass (so-called smooth-bore operations), the internal pressure sheath may be referred to as a liner. Figure 1 The barrier layer 110 is shown in FIG.

[0092] It should be noted that the carcass layer 120 is a pressure resistant layer that provides an interlocking structure that can be used as the innermost layer to completely or partially prevent the internal pressure sheath 110 from collapsing due to pipe decompression, external pressure, and tensile armor pressure and mechanical breaking loads. The carcass is a pressure resistant layer. It should be understood that certain embodiments of the present invention are therefore suitable for "rough hole" applications (with carcasses). Suitably, the carcass layer is a metal layer. Suitably, the carcass layer is formed of stainless steel, corrosion resistant nickel alloys, etc. Suitably, the carcass layer is formed of a composite material, a polymer or other material or a combination of materials and components. The carcass layer is radially positioned within the barrier layer.

[0093] The carcass ply is a "ply" in the sense that the radially innermost and outermost surfaces are produced in a single pass at a single manufacturing node. A single manufacturing node may comprise a plurality of strip processing segments axially close together such that these segments are effectively a single node. The node suitably extends over an axial distance of less than 2.5 m. Suitably, the node has a length of 1 m or less.

[0094] The pipe body includes a pressure armour layer 130 which is a pressure resistant layer providing a structural layer which increases the resistance of the flexible pipe to internal and external pressures and mechanical breaking loads. This layer also structurally supports the internal pressure sheath. Suitably, as Figure 1 As shown, the pressure armour layer is formed as a tubular layer. Suitably, for an unbonded flexible pipe, the pressure armour layer consists of an interlocking construction of wires having a lay angle close to 90°. Suitably, in this case, the pressure armour layer is a metallic layer. Suitably, the pressure armour layer is formed of carbon steel, an aluminium alloy or the like. Suitably, the pressure armour layer is formed of a pultruded composite interlocking layer. Suitably, the pressure armour layer is formed of a composite material formed by extrusion or pultrusion or deposition. The pressure armour layer is positioned radially outside the underlying barrier layer.

[0095] The flexible pipe body also includes a first tensile armor layer 140 and a second tensile armor layer 150. Each tensile armor layer is used to maintain a tensile load and optionally also maintain an internal pressure. Suitably, for some flexible pipes, the tensile armor coil is a metal (e.g., steel, stainless steel, or titanium, etc.). For some composite flexible pipes, the tensile armor coil can be a polymer composite tape coil (e.g., provided with a thermoplastic, such as nylon, a matrix composite material, or a thermosetting material, such as an epoxy resin, a matrix composite material). For non-bonded flexible pipes, the tensile armor layer is formed by a plurality of wires (to give the layer strength), which are positioned above the inner layer and are spirally wound along the length of the pipe at a layout angle generally between about 10° and 55°. Suitably, the tensile armor layers are reversely wound in pairs. Suitably, the tensile armor layers are metal layers. Suitably, the tensile armor layers are formed by carbon steel, stainless steel, titanium alloy, aluminum alloy, etc. Suitably, the tensile armor layers are formed by composite materials, polymers or other materials or combinations of materials.

[0096] Suitably, the flexible pipe body includes an optional tape layer 160 that helps contain underlying layers and to some extent prevent abrasion between adjacent layers. The tape layer may optionally be a polymer or composite material or a combination of materials, and also optionally includes a tubular composite layer. The tape layer may be used to help prevent metal-to-metal contact to help prevent abrasion. The tape layer on the tensile armor may also help prevent "birdcaging".

[0097] The flexible pipe body also includes optional insulation layers 165 and an outer jacket 170 comprising a polymer layer for protecting the pipe from penetration, corrosion, abrasion and mechanical damage by seawater and other external environments. Any thermal insulation helps limit heat loss through the pipe wall to the surrounding environment.

[0098] Each flexible pipe includes at least one portion (referred to as a segment or section) of a pipe body 100, and an end fitting positioned 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 are terminated in end fittings so that loads are transferred between the flexible pipe and the connector.

[0099] Figure 2 A riser assembly 200 is shown that is suitable for transporting produced fluids such as oil and / or gas and / or water from a subsea location 221 to a floating facility 222. For example, in Figure 2 In the embodiment of the present invention, the seafloor location 221 includes a seafloor flow line 225. The flexible flow line 225 includes a flexible pipe that is fully or partially resting on or buried below the seafloor 230 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 2 The vessel shown provides a Riser assembly 200 is provided in the form of a flexible riser, ie a flexible pipe 240 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.

[0100] It should be understood that there are different types of risers, as is well known to those skilled in the art. Certain embodiments of the present invention may be used with any type of riser, such as a free-floating riser (free-hanging catenary riser), a riser constrained to some degree (buoy, chain), a fully constrained riser, or enclosed in a pipe (I-pipe or J-pipe). Some, though not all, examples of such configurations can be found in API 17J. Figure 2 It is also shown how a section of flexible tubing may be used as a jumper 250 .

[0101] Figure 3 An example portion of a flexible pipe body 300 is shown, comprising a cross section through a plane extending through the flexible pipe body in a direction parallel to the longitudinal axis of the flexible pipe body. This is referred to herein as a parallel cross section. The parallel cross section of the flexible pipe body shows an interlocking carcass tape coil 310. The carcass tape coil shown is self-interlocking in the sense that it does not require additional interlocking coils of interlocking tape. All embodiments described herein are not limited to self-interlocking carcass tape coils, but are applicable to any carcass coil that is wound to produce an anti-collapse layer that can be positioned within a barrier layer, whereby adjacent coils of carcass shaping tape create a spiral gap that would otherwise (in the absence of the insert) result in a risk of rollover. Figure 3 The parallel cross-section shown also shows a coil of elongated strip 320, which is a folded strip disposed radially inwardly of the carcass strip coil 310. The elongated strip is an example of an elongated strip element. The elongated strip 320 is made of metal, plastic, or a composite material. The elongated strip may be a strip of material. The elongated strip 320 shown is a folded or bent stainless steel metal to provide Figure 3 The alien shape shown. Figure 3 The elongated strip cross section 320 is shown having a first portion 330. The first portion corresponds to a first end of the cross section of the elongated strip and is configured to be positioned in a first gap region 340 between adjacent carcass strip coils. Positioning the first portion in the gap region between adjacent coils of the carcass strip helps prevent movement of the carcass strip coil 310 relative to the elongated strip coil 320. The coils of the carcass strip 310 may still be able to move relative to each other to allow for minor movement during bending of the flexible pipe body. This is referred to as axial play.

[0102] The coils of the elongated strip 320 also at least partially overlap to help support adjacent coils of the elongated strip. The overlapping coils of the elongated strip 320 help prevent production fluid flowing in the flexible pipe from entering the gaps between the carcass strip coils 310. The elongated strip 320 also helps smooth unidirectional fluid flow, which is Figure 3 The elongated strip 320 may also support bidirectional fluid flow. The coils of the elongated strip 320 may overlap at least 20% of the width of the elongated strip. Suitably, the overlap is 10% or more. Suitably, the overlap is 30% or less of the cross-sectional width of the elongated strip.

[0103] like Figure 3 As shown, the elongated strip cross section also includes a main body portion 350 extending from the first portion 330 of the elongated strip cross section to the remaining end. The main body portion 350 is shaped to bridge another gap region 360 between adjacent coils of the carcass strip 310. The first gap region corresponds to an example of a spiral gap, and the other gap region corresponds to an adjacent (in an axial sense) example of a spiral gap.

[0104] The first portion 330 of the elongated strip has a curved shape that matches the curved shape of the carcass coil at a lifting point 370 where the carcass strip coil bends away from the radially innermost surface 372 of the carcass strip coil 310. The radially outermost surface 374 provided by the carcass strip coil is also Figure 3 Shown in. Figure 3 It is also helpful to illustrate the total thickness l of the combined carcass coils and associated smooth insert 320 .

[0105] Figure 4 Shown perpendicular to Figure 3 The cross section of the plane extending along the longitudinal axis of the elongated strip 320 shown. This is referred to herein as an orthogonal cross section. The elongated strip cross section 320 has a first portion 410 that is bent to be positioned in the gap region between the coils of the carcass strip. The first portion 410 corresponding to the first end 420 of the elongated strip cross section extends from the first free edge 430 of the elongated strip to an area of ​​the elongated strip cross section that is substantially parallel to the imaginary flat surface 440. That is, the first portion 410 is curved and extends from the first free edge 420 of the elongated strip to an area of ​​the elongated strip cross section that is substantially flat. The imaginary flat surface 440 is perpendicular to both the axial direction of the elongated strip and the plane of the orthogonal cross section described above. The free edge 420 is an edge that extends along the length of the elongated strip to outside the plane of the cross section of the elongated strip. The degree of curvature of the first portion appropriately matches the corresponding curved portion of the radially inner surface of the carcass strip coil in the flexible pipe body. That is, the first portion 410 is shaped to match the profile of at least a portion of the carcass strip, wherein the shape of the carcass strip is intended to bend away from the radially inner surface of the wound carcass strip. This helps the elongated strip 320 to be at least partially positioned in the gap between adjacent coils of the carcass strip of the flexible pipe body adjacent to the coil instance of the elongated strip, and helps prevent the elongated strip 320 from sliding relative to the carcass strip when exposed to fluid flow in use. The degree of curvature of the first portion 410 is less than or equal to 90 degrees. The degree of curvature may substantially match the degree of curvature of the carcass strip coils at the edges of the gap region between adjacent carcass strip coils.

[0106] The first portion 410 is configured to bend "upwards" in a radially outward direction. That is, the first portion turns away from the central main axis of the flexible pipe body in use. The width of the tape that bends upward in the first portion is less than 50% of the total thickness 372 of the carcass tape coil. That is, the width of the first portion is less than 50% of the total thickness of the carcass tape coil. Suitably, the width e of the bent end is 40% or less, or 30% or less, or 20% or less, or 15% or less of the total thickness 372 of the carcass tape coil. The first portion does not need to extend very far into the gap between adjacent carcass tape coils to properly place and position the tape during use. Compared to the bottom, configuring the first portion 410 to extend farther into the gap between the carcass tape coils than the above amount may affect the position of the tape insert during use.

[0107] The elongated strip 320 also includes a remaining free edge 450 corresponding to the remaining end 455 of the elongated strip cross section. The elongated strip 320 also includes a main body portion 460 extending between the first portion 410 and the remaining edge 450. The main body portion 450 includes a middle region 470. The middle region 470 can be curved or include curved segments. The curved shape in the middle region can be a bell curve or an arc, etc. Figure 4 The curved segment of the intermediate region 470 shown in the figure is curved at a position along the cross section where, in use, the elongated strip 320 will help bridge the gap area between adjacent carcass strip coils. Therefore, the curved segment in the intermediate region 470 is configured to be positioned in the gap between adjacent coils of the carcass strip. At least a portion of the curved segment can also be profiled to substantially match the degree of curvature of the first portion 410 of the elongated strip cross section. Optionally, the curved segment 470 has a curved area that matches the curvature of the carcass coil when it is lifted away from the radially innermost extent toward the gap between adjacent coils of the carcass strip. Matching the curvature of the first portion can help locate and fix the coil of the elongated strip element in place because the first portion of the elongated strip element coil 320 can be pressed against the curved intermediate region 470 of the adjacent elongated strip element coil in use. Optionally, the intermediate region 470 is positioned toward the remaining free edge 450. Optionally, the intermediate region 470 is substantially centrally located across the width of the elongated strip cross-section.

[0108] Figure 5 Another example portion of a flexible pipe body 500 is shown. The cross section shows interlocking carcass strip coils 510. Coils of elongated strip 520 as an example of elongated strip elements 520 are also shown as being radially disposed inboard of the carcass strip coils 510. The elongated strip 520 is a strip made of metal, plastic or a composite material. The elongated strip 520 may be a strip of material. Figure 5 The elongated strip 520 shown in FIG. 1 starts with a stainless steel strip having a cross-section of generally uniform thickness and being long relative to the width of the strip. This is folded by progressive rollers during manufacture to produce Figure 5 The elongated strip 520 has a cross-section that is folded or bent to provide Figure 5 The elongated strip 520 has a first portion 530 extending into a first gap region 540 between adjacent coils of the carcass strip 510 .

[0109] Figure 5The elongated strip cross-section shown also includes a main body portion extending from the first portion 530 of the elongated strip cross-section to the remaining end portion 550. The main body portion includes a middle region 560 that bridges another gap region 570 between adjacent carcass strip coils.

[0110] The remaining end 550 of the elongated strip cross section is bent to be positioned into the curved middle region 560 of the adjacent coil of the elongated strip. The remaining end, the middle region and the main body all extend toward the common side of the cross section, away from the plane containing the flat cross-sectional area of ​​the inserted strip. The curved middle region is shaped to provide a recessed area 580 that can receive the remaining end 550 of the adjacent elongated strip coil. The first portion 530 of the elongated strip cross section and the remaining end 550 provide a positioning portion that helps prevent the carcass strip coil 510 from moving relative to the elongated strip coil 520. The ends of the cross section also help to fix each coil of the elongated strip 520 in place. The coils of the carcass strip 510 may still be able to move relative to each other to allow for minor movement during bending of the flexible pipe body. The carcass coil is nested between the upturned end of the insert cross section and the middle region of the elongated strip cross section. However, in extreme cases of bending of the flexible pipe, the carcass coil may slide laterally / axially relative to the inserted strip coil. Similarly, adjacent insert coils of the helically wound elongate ribbon 520 may slide along one another as desired during extreme flexing of the flexible pipe body.

[0111] The coils of the elongated tape element 520 also at least partially overlap to help support adjacent or neighboring elongated tape coils. Overlapping the elongated tape coils helps prevent or at least limit the production fluid flowing in the flexible pipe from entering the gaps between the carcass tape coils 510. The elongated tape 520 can also help smooth the unidirectional fluid flow, which is Figure 5 The elongated strip 520 may also support bidirectional fluid flow. The coils of the elongated strip 520 may overlap at least 40% of the width of the elongated strip. Suitably, adjacent coils of the insert / elongated strip overlap 30% or less, or 20% or less, or 10% or less of the total cross-sectional width of the insert.

[0112] like Figure 5 As shown, the elongated strip 520 is sized and positioned to include a portion of a first gap region between a first pair of carcass coils and to bridge another gap region 570 between another pair of adjacent coils of the carcass strip 510 (one of which is the first pair of coils).

[0113] The first portion 530 of the elongated strip has a curved shape that matches the curved shape of the carcass strip coil at a lift point 590 where the carcass strip coil curves away from the radially innermost surface of the carcass strip coil 510 .

[0114] Figure 6 Shows Figure 5 5. The cross section of the elongated strip 520 shown. The elongated strip 520 has a cross section 600 including a first portion 610 extending from a first free edge 620 of the elongated strip, the first portion being curved for positioning into the gap region between the coils of the carcass strip. The first portion 610 corresponds to a first end 630 of the cross section of the elongated strip. The first portion 610 of the elongated strip 520 extends from the first free edge of the elongated strip element to a substantially flat region of the elongated strip. That is, the first portion extends from the first free edge of the elongated strip along the width of the cross section of the elongated strip to a point where the cross section of the elongated strip is no longer curved. The degree of curvature of the first portion is shaped to match the degree of curvature of the curved portion of the radially inner surface of the carcass strip coil in the flexible pipe body. That is, the first portion 610 is shaped to match the profile of at least a portion of the carcass strip coil. This helps position the first free edge 620 of the elongated strip 520 into the gap between adjacent coils of the carcass strip of the flexible pipe body and helps prevent excessive sliding of the elongated strip 520 relative to the carcass strip. The degree of curvature of the first portion is less than or equal to 90 degrees. The degree of curvature may substantially match the degree of curvature of the carcass strip coils at the opening of the gap region between adjacent carcass strip coils.

[0115] Figure 6 The first portion 610 of the inserted strip shown is configured to bend upward relative to the figure. This corresponds to a direction away from the central hole of the flexible pipe body. The width f of the elongated strip that bends upward in the first portion 610 is less than 50% of the total thickness of the carcass strip coils in the flexible pipe body. Suitably, the width is less than 40% or optionally less than 30% or optionally less than 20% of the total thickness of the carcass coils (between the radially inner extent and the radially outer extent of each carcass coil). That is, the width of the elongated strip cross section corresponding to the first portion 610 does not exceed a distance equal to 50% of the total thickness of the carcass strip coils. The first portion does not need to extend far into the gap area between adjacent carcass strip coils to properly place and position the elongated strip. This is in contrast to the prior art inserts, which require deep penetration of the insert or clamping of the insert relative to the carcass. In contrast to the present invention, configuring the first portion to extend much more than the above amount into the gaps between the carcass strip coils may affect the position of the tape insert during use, which could potentially cause the coils of the tape insert to lose their overlap and allow fluid to flow into the gaps between the carcass strip coils.

[0116] Figure 6 The elongated strip 520 is shown to also include a remaining free edge 640. Figure 6 , the remaining free edge 640 corresponds to the remaining end 645 of the elongated strip cross section. The elongated strip cross section also includes a main body portion 650 extending between the first portion 610 of the elongated strip cross section and the remaining end 645. The remaining end 645 of the elongated strip cross section is bent close to the remaining free edge 640. Figure 6 The main body portion 650 of the elongated strip cross-section shown includes a middle region 655. The main body portion optionally also includes two generally flat axially extending regions 660,665.

[0117] The middle region 655 is curved or includes a curved segment. Optionally, the middle region is centrally located on the width of the elongated strip cross-section. Optionally, the curved middle region has the shape of a bell curve. Figure 6 The curved segment of the intermediate region 655 shown is curved at a position along the cross section where, in use, the elongated strip 520 will bridge the gap between adjacent carcass strip coils. Thus, the curved intermediate region is configured to be at least partially positionable in the gap region between adjacent coils of carcass strip. At least a portion of the curve of the intermediate region may also be shaped to substantially match the degree of curve of the first portion 610. This may help position and secure the coil of elongated strip in place, as the first portion of the elongated strip coil 520 may be pressed against the curved intermediate region 655 of an adjacent elongated strip coil. The intermediate region 655 provides a recessed region 670 for receiving the remaining free edge 640 of an adjacent elongated strip coil.

[0118] The bent remaining end of the elongated strip cross section helps locate the remaining free edge into the channel or recessed area created by the bent intermediate region 655 of the adjacent and / or neighboring elongated strip coil. Although the bent intermediate region shows a radially inward facing recess 672 extending helically along the tube body, this recess is smooth and not deep and is partially covered most of the time. Therefore, this small recess does not cause rollover. Figure 4 Compared to the elongated strip 320 shown, Figure 6 The arcuate shape of the remaining end of the elongated strip cross section shown provides additional positioning and / or fixing features. The remaining end 620 can be curved to match the curvature of the middle region 655. The width of the elongated strip 620 curved in the remaining end 620 (near the remaining free edge) does not exceed the width of the middle region 655 of the elongated strip cross section.

[0119] Two axially extending regions 660, 665 are shown disposed between the middle region 655 and each respective end 610, 645 of the elongated strip cross section. The axially extending regions 660, 665 are shaped to match the radially inner surface of the carcass strip of the flexible tube body. Although these regions are Figure 6 As shown as being substantially flat in FIG. 1 , these axially extending regions may be shaped to match the radially inner surface of the carcass strip for a variety of different carcass strip cross-sections.

[0120] Figure 4 and Figure 6 The elongated strip 320, 520 shown in FIG. 5 may be bent or folded into shape immediately before being wrapped around a mandrel for manufacturing a flexible pipe body or before any prior period of time.

[0121] Figure 7 Shows the use of Figure 4 Part of a method of manufacturing a flexible pipe body from an elongate strip of material is shown. Figure 7 A carcass strip 710 is shown wrapped around an elongated strip 720. In a first step, the elongated strip 720 is wrapped at least twice around an elongated shaft member 730 before the winding of the carcass strip 710 can begin. Thereafter, the winding of the elongated strip element and the winding of the carcass strip occur simultaneously. The elongated shaft member 730 is an example of a mandrel or mandrel member.

[0122] The elongated strip 720 is wound at an angle inclined relative to the longitudinal axis (A) of the shaft member 730, such that the elongated strip is disposed obliquely on the shaft member relative to a constant radius region of the outer surface 740 of the shaft member. Optionally, the angle of inclination of the elongated strip 720 relative to the longitudinal axis of the shaft member is less than 30 degrees. Suitably, the angle of inclination is continuous for all coils. Suitably, the angle of inclination is 25 degrees or less. Suitably, the angle is 20 degrees or less. Optionally, the elongated strip 720 is wound at a sufficient inclination to allow further winding of the elongated strip without affecting the previous winding of the strip. The elongated strip 720 is inclined such that when the elongated strip is wound, a first section 750 of the elongated strip contacts downwardly on the outer surface 740 of the shaft member. Optionally, the first section includes at least the remaining free edge of the elongated strip 720. The remaining section 760 of the strip is disposed at an inclination angle α to the longitudinal axis of the shaft member 730.

[0123] exist Figure 7The carcass strip 710 is wound in the middle, including winding a generally S-shaped carcass strip on the coils of the elongated strip 720. The carcass strip 710 is a folded strip. The pitch of the carcass strip 710 winding matches the pitch of the elongated strip element 720 winding. The carcass strip 710 is wound so that the leading portion of each coil of the elongated strip element 720 is positioned in a corresponding gap between adjacent coils of the carcass strip 710. Additionally or alternatively, in addition to Figure 7 In addition to or in place of the S-shaped carcass strip shown, another strip element may be wound around the elongated strip. A portion of the further section 760 provides a mating region 770 extending from the first free edge of the elongated strip to the middle region of the cross-section of the elongated strip for receiving the radially innermost surface of the mating portion of the carcass strip. A portion of the carcass coil is thereby nested in the mating portion of the insert coil.

[0124] Figure 8 An alternative cross section of a portion of a flexible pipe body during its manufacture is shown, showing the pipe being wrapped in a Figure 7 The carcass strip 810 on the elongated strip 820 is different from the elongated strip shown, this time having a cross-section similar to Figure 6 The cross-section of the elongated strip shown is similar. In a first step, the elongated strip 820 is wrapped at least twice around the outer surface 825 of the shaft member 830 before the winding of the carcass strip 810 can begin. Thereafter, the winding of the elongated strip and the winding of the carcass strip occur simultaneously.

[0125] The elongated strip 820 is wound at a bending angle relative to the longitudinal axis (A') of the shaft member 830. Optionally, the bending angle β of the elongated strip 820 relative to the longitudinal axis of the shaft member is less than 30 degrees. The elongated strip may be bent at a position near the middle region 840 along the elongated strip cross-section. Optionally, the elongated strip 820 is wound with sufficient curvature to allow further winding of the strip insert without affecting the previous winding of the strip insert. The elongated strip element 820 is bent so that when the elongated strip is wound, the first section 850 of the elongated strip is positioned substantially flat on the outer surface 825 of the shaft member 830. Optionally, the first section 850 of the elongated strip 820 extends from the remaining edge of the elongated strip to the middle region of the elongated strip cross-section. Optionally, the first section 850 partially includes the middle region 840.

[0126] The elongated strip 820 is wound at a predetermined first pitch. The pitch at which the elongated strip 820 is wound is predetermined by the desired overlap between adjacent coils of the elongated strip and / or the desired position of the portions of the elongated strip 820 relative to the gaps between the coils of the carcass strip 810. After the first elongated strip coil is placed around the shaft member 830, the incoming elongated strip coil 820 is wound around the shaft member between the outer surface of the shaft member and the previous elongated strip coil. Winding the strip in this manner is facilitated by the bending of the strip as it is wound. Alternatively, the elongated strip may be bent prior to winding. After the coils of the carcass strip are placed on the elongated strip coils 820, the elongated strip is pressed against the outer surface of the shaft member, thereby flattening or at least reducing the bending angle as adjacent carcass strip coils are pressed and interlocked. A portion of the further section 760 provides a mating region 770 extending the first free edge of the elongated strip to an intermediate region of the cross-section of the elongated strip for receiving the radially innermost surface of the carcass strip.

[0127] exist Figure 8 The mid-winding of the carcass strip 810 comprises winding a generally S-shaped strip on the coils of the elongated strip element 820. The pitch of the carcass strip 810 winding matches the pitch of the elongated strip element 820 winding. The carcass strip 810 is wound so that the first portion of each coil of the elongated strip element 820 is positioned into a corresponding gap region between adjacent coils of the carcass strip 810. Additionally or alternatively, another strip element may be wound on the elongated strip in addition to or in place of the carcass strip. A portion of the further section 860 provides a mating region 870 that extends the first free edge of the elongated strip to the middle region 840 of the elongated strip cross-section for receiving the radially innermost surface of the carcass strip.

[0128] Fig. 9 A cross-sectional view of a plane extending along the length of an alternative shaft member 900 for making a flexible pipe body is shown. The plane contains the central axis of the shaft / spindle body. The shaft member 900 has a profiled cross section over at least a portion of the length of the shaft body, the profiled cross section comprising a plurality of spaced, repeating constant radius cross-sectional areas 910. The shaft member 900 also has at least one helical extension variation 920 in the form of a helical recess in the surface of the shaft member. Alternatively or additionally, the helical extension variation comprises a helical protrusion. The helical extension variation is provided for spacing the coils of the elongated strip element during use. Alternatively, a plurality of notches or recesses in the shaft member 900 that are periodically spaced along a helical path may be utilized. Fig. 9 and Fig.10 A constant modification in the outer surface of the shaft body in the form of a constant helically extending recess is shown.

[0129] The cross-sectional constant radius regions 910 are provided by smooth surface regions of the outer surface extending helically along the length of the shaft member. These surface regions coincide with an imaginary cylindrical surface 930 corresponding to the radially outermost boundary of the shaft member 900. The imaginary cylindrical surface 930 is coaxial with the central longitudinal axis of the shaft member.

[0130] It will be appreciated that the outer surface of the shaft member may taper from a point at least part way along the length of the shaft member towards the free end of the shaft member. By such a gradual reduction in the diameter of the shaft member towards the free end of the shaft member, the elongated strip coil may gradually relax from the end of the shaft member, thereby eliminating the risk of the elongated strip and the shaft member sticking, which may result in inconsistent form or pitch. When the shaft member tapers in this manner, at least a portion of the imaginary surface 930 may be frustoconical or bullet-shaped.

[0131] Fig.10 Shows the use of Fig. 9 The shaft member shown is part of a method 1000 for manufacturing a flexible pipe body. The carcass strip 1010 and the elongated strip 1020 are simultaneously wrapped around the shaft member 1030. Fig.10 In FIG. 1 , the shaft member 1030 is shown with at least one helical extension variation 1040 in the form of a helical recess in the outer surface 1050 of the shaft member. Alternatively or additionally, the helical extension variation comprises a helical protrusion. The helical extension variation is provided for spacing the coils of the elongated strip element 1020.

[0132] When the elongated strip is placed on the outer surface of the shaft member, the spiral recess 1040 helps to position at least the first section of the elongated strip. The spiral recess extends along a corresponding portion of the entire length of the shaft member at a predetermined pitch. The profiled portion may be the entire length or only a portion of the entire length. The end of the shaft body may taper inwardly to assist in releasing the wound coil when the wound coil is removed from the end of the shaft member. The pitch of the spiral recess is predetermined by the required overlap between adjacent coils of the elongated strip and / or the required position of the gap between the coils of the carcass strip 1010 (i.e., the pitch is designed to substantially match the pitch of the carcass pitch). The width of the spiral recess is less than the width of the elongated strip. This allows the spiral recess to help tilt or bend the elongated strip because the first section of the strip abuts the radially rearward surface of the shaft member, while a portion of the remaining section of the elongated strip abuts the radially outer surface 1050 outside the recess 1040 relative to the radially rearward surface. This helps to provide the tape at the tilt angle required to position adjacent elongated tape coils on the outer surface of the shaft member.

[0133] As the elongated strip and carcass strip are wound around the shaft member, the shaft member turns in the same direction as the winding direction of the strip and at the same rotational speed. A crawler track system is typically used to pull the manufactured tube body carcass from the shaft member at a rate equal to the production line manufacturing speed. Here, as the winding of the strip progresses, the carcass and elongated strip are thereby guided (by their travel adjacent to the rotating helical extension variation) toward the end of the shaft member 1030.

[0134] As the winding of the strips 1010, 1020 progresses, at least one press roller 1060 compresses the coils of the carcass strip 1010 and the coils of the elongated strip 1020, thereby deforming and interlocking adjacent coils of the S-shaped carcass strip 1010 and positioning at least a portion of each elongated strip coil into the gap between adjacent carcass strip coils. The press is an example of a portion of a manufacturing node that, along with the rotating profiled rollers and coil rollers, helps form the layers. When the carcass strip is compressed by the press roller 1060, another section of the elongated strip provides a mating area where a portion of the carcass strip is positioned. The mating area may extend between the first portion and the middle region of the elongated strip.

[0135] Fig.10 It is also shown that when the folded strip of carcass strip 1020 is wrapped around the elongated strip 1020, it has a footprint 1070. The footprint 1070 covers a plurality of consecutive elongated strip coils. Optionally, the footprint 1070 covers at least three coils of the elongated strip 1020.

[0136] Fig.11 Shows Fig.10 A magnified view of the method shown, focusing on the helical extension variation 1040. Fig.11 The helical extension variation 1040 shown in the profiled cross section of is a recess in the outer surface of the shaft, which would otherwise be a smooth cylindrical outer surface. The recess has a common cross-section 1100 that extends helically at a common pitch along a portion of the shaft. Therefore, the recess is effectively repeated along the length of the shaft member 1030. The common cross-section 1100 has a radial inner surface area 1110 relative to the imaginary cylindrical outer surface, which separates the cross-sectional area 1120 of constant radius. The common cross-section also includes a first end 1130 and another end 1140 of the helical extension variation or helical recess. Optionally, the radial inner surface area 1110 is substantially flat, or the radial inner surface area is varied or textured.

[0137] The first recess end 1130 of the recess comprises an abrupt radially inward step extending into the outer surface at an angle of approximately 90 degrees to the outer surface of the shaft member 1030. Alternatively, the inward step may extend into the outer surface of the shaft member at less than 90 degrees. The other recess end 1140 is provided by an inclined surface region of the recess extending between the radially innermost surface regions 1110 of the recess, rising to a point where it meets an imaginary cylindrical surface, thereby coinciding with the constant radial cross-sectional region 1120.

[0138] The width of the helical recess is less than the width of the elongated strip. This allows the helical recess to facilitate tilting or curving the elongated strip because a first section 1150 of the strip 1020 contacts an abutment surface 1160 within the recess, while a portion of the remaining section 1170 of the elongated strip abuts a radially outer surface 1180 outside of the recess 1040 relative to the abutment surface. Optionally, the abutment surface 1160 is a radially trailing surface of the shaft member. The tilting or curvature helps provide the strip coils 1120 at the tilt angle required to position adjacent elongated strip coils on the outer surface of the shaft member at a desired helical pitch.

[0139] A portion of the remaining section 1170 of the elongated strip 1020 may abut the inclined surface 1140 of the recess, which will also help to tilt or bend the elongated strip. The first section 1150 of the elongated strip 1020 may extend between the remaining edge of the elongated strip and the middle region of the cross-section of the elongated strip. The first section may also include at least a portion of the middle region. Portions of the first section may be disposed only proximate to the abutment surface 1160.

[0140] The recess is an example of a variation that can be produced in an otherwise smooth cylindrical surface of a mandrel for supporting the carcass layer of a flexible pipe body. The repetition of the variation makes the shaft particularly useful for manufacturing elements that are themselves highly repetitive in their structure. Using a shaft with a variation rather than a simple smooth cylindrical surface provides new opportunities for producing winding layers that are not possible with other prior art support structures. The variation (whether it is a recess or a protrusion, or a combination of a recess in an otherwise cylindrical surface and a protruding element extending beyond the other cylindrical surface) helps to align a portion of the lead-in coil in a different direction than would otherwise be possible with conventional technology. This opens up opportunities for winding structures that could not be manufactured before.

[0141] As the elongated strip and carcass strip are wound around the shaft member, the shaft member turns in the same direction as the winding direction of the strip and at the same rotational speed. As the winding of the strip progresses, the carcass and elongated strip are thereby guided (by their progression along the rotating helical extension variation) toward the end of the shaft member 1230. The helical recesses help push the wound carcass and elongated strip along and away from the shaft member.

[0142] Fig.12 A cross-sectional view of a plane extending along the length of a further alternative flexible pipe body 1200 during its manufacture is shown. Fig.12 Shown with Fig.10 and Fig.11 The manufacturing process is similar to at least a portion of the manufacturing process shown in FIG. 1 , except that the helical recess in the shaft member has a relative Fig.11 The common cross-section of the spiral recesses shown is opposite to the common cross-section. This allows the manufacture of a flexible pipe body with a preferred flow direction. That is, the shaft member can be profiled to facilitate the flexible pipe body for fluid flow in different directions.

[0143] Fig.12 The carcass strip 1210 is shown being wrapped around the shaft member 1230 simultaneously with the elongated strip 1220. Additional or alternative strip elements may be wrapped together with the elongated strip. Fig.10 , the shaft member 1230 is shown with at least one helical extension variation 1240 in the form of a helical recess in the outer surface of the shaft member 1230. Alternatively or additionally, the helical extension variation comprises a helical protrusion. The helical extension variation is provided for spacing the coils of the elongated ribbon element 1220. Alternatively, it is possible to utilize a plurality of notches or recesses in the shaft member 1230 that are periodically spaced along the helical path.

[0144] The shaft member 1230 has a profiled portion having a cross section comprising a plurality of spaced apart, repeating constant radius cross-sectional areas. These cross-sectional constant radius areas are provided by smooth surface areas of the outer surface extending helically along the length of the shaft member. These surface areas coincide with an imaginary cylindrical surface corresponding to the radially outermost boundary of the shaft member 1230. The imaginary cylindrical surface is coaxial with the central longitudinal axis of the shaft member.

[0145] Fig.12 The spiral extension variation shown in the profiled cross section in has a common cross section that is repeated along the length of the shaft member 1230. The common cross section has a radial inner surface area relative to the imaginary cylindrical outer surface that separates the first end and the other end of the recess. Optionally, the radial inner surface area is substantially flat, or the radial inner surface area is varied or textured.

[0146] The first end of the recess includes an abrupt radially inward step extending into the outer surface at an angle of approximately 90 degrees to the outer surface of the shaft member 1230. Alternatively, the inward step may extend into the outer surface of the shaft member at an angle less than 90 degrees. The other recess end is provided by an inclined surface region of the recess extending between the radially innermost surface regions of the recess, rising to a position where it meets an imaginary cylindrical surface.

[0147] When the elongated strip is placed onto the outer surface of the shaft member, the spiral recess 1240 helps to position at least a portion of the first section of the elongated strip. The spiral recess 1240 extends along the length of the shaft member 1230 at a predetermined pitch. The pitch of the spiral recess is predetermined by the desired overlap between adjacent coils of the elongated strip and / or the desired position of the gap between the coils of the carcass strip 1210 (i.e., the pitch is designed to substantially match the pitch of the carcass pitch). The width of the spiral recess is less than the width of the elongated strip. This allows the spiral recess to help tilt or bend the elongated strip because the first section of the strip abuts the radially rearward surface of the shaft member, while a portion of the remaining section of the elongated strip abuts the radially outer surface outside the recess relative to the radially rearward surface. This helps to provide the strip at the tilt angle required to position adjacent coils of the elongated strip on the outer surface of the shaft member. A portion of the remaining section of the elongated strip may abut the inclined surface of the recess, which will also help to tilt or bend the elongated strip 1220. The first section may extend between the remaining free edge of the elongated strip and the middle region of the cross-section of the elongated strip. The first section may also include at least a portion of the middle region. Portions of the first section may only be disposed proximate to the radially rearward surface associated with the recess.

[0148] As the winding of the strips 1210, 1220 progresses, at least one compression roller 1250 compresses the coils of the carcass strip 1210 and the coils of the elongated strip 1220, thereby deforming and interlocking at least two adjacent coils of the S-shaped carcass strip 1210 and positioning at least a portion of each elongated strip coil into the gap between adjacent carcass strip coils. When the carcass strip is compressed by the compression roller 1250, another section of the elongated strip provides a mating area for a portion of the carcass strip to be positioned. The mating area may extend between the first portion and the middle region of the elongated strip.

[0149] Fig.13 Another example of a shaft member 1310 for supporting an elongate strip of material during manufacture of a flexible pipe body is shown. Fig.13 The shaft member shown has Figures 9 to 12 Different common cross-sections of shaft components are shown. Fig.11 The common cross section of the helical extension variant 1330 in FIG. 1 has a protrusion 1320 having a radially outwardly curved surface 1340 extending from a constant radius cross-sectional area to an abrupt radially inward step. Optionally, the inward step extends from the radially outer boundary of the protrusion 1320 to the constant radius area at approximately 90 degrees to the outer surface of the shaft member 1310. Alternatively, the inward step may extend from the radially outer boundary of the protrusion to the constant radius area at an angle less than 90 degrees to the outer surface of the shaft member. The regions of the common cross section of the helical extension variants may be adjacent to each other.

[0150] Fig.13 The raised portion 1320 of the common cross-section of the shaft member in Figure 1 helps to tilt or bend the elongated strip because a first section of the strip abuts the constant radius region of the shaft member, set back from the raised portion and the radially outward curved surface 1340, while a portion of the remaining section of the elongated strip abuts at least a portion of the radially outward curved surface 1340. This helps to provide the strip at the tilt angle required to position adjacent elongated strip coils on the outer surface of the shaft member.

[0151] For the avoidance of doubt, Figures 7 to 13 Only half of a cross section through a portion of the elongated shaft member and the flexible tube body is shown. Also for the avoidance of doubt, all shafts shown may optionally include one or more lubrication passages 1350 comprising one or more radially extending passages 1360 terminating in respective exit holes 1370 that facilitate lubrication of the interface region between the outer surface of the shaft and the radially innermost surface of the element wound on the shaft. This facilitates release of the coil from the shaft during manufacturing.

[0152] 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, integral bodies or steps. Throughout the detailed description and claims of this specification, the singular encompasses the plural unless the context requires otherwise. In particular, where the indefinite article is used, the specification should be understood as contemplating plural as well as singularity unless the context requires otherwise.

[0153] Features, integers, features or groups described in conjunction with a particular aspect, embodiment or example of the invention are to 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 appended claims, abstracts 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 the features and / or steps are mutually exclusive combinations. The invention is not limited to any details of any of the foregoing embodiments. The invention extends to any novel feature or novel combination of features disclosed in this specification (including any appended claims, abstracts and drawings), or to any novel step or novel combination of steps of any method or process so disclosed.

[0154] 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. An apparatus for supporting an elongate strip element during the manufacture of a flexible pipe body, comprising: An elongated shaft member comprising an outer surface including a profiled surface region extending along at least a portion of the shaft member and having a profiled cross section including repeating flat constant radius cross section regions provided by helically extending smooth surface regions of the outer surface located on an imaginary cylindrical surface coaxial with a central longitudinal axis of the shaft member, disposed between spaced apart strip-aligned cross section regions provided by continuously repeating helically extending variations of the outer surface located on the imaginary cylindrical surface.

2. The device according to claim 1, further comprising: Each strip-aligned cross-sectional area comprises a recessed area or a raised area or a combination of recessed and raised areas in or from the outer surface relative to the imaginary cylindrical surface.

3. The device according to claim 2, further comprising: The strip-aligning cross-sectional area comprises a recess in the outer surface, and the variation comprises a helical recess having a common cross-section that helically extends at least 720 degrees and thereby repeatedly extends along the profiled area of ​​the outer surface of the shaft member.

4. The device according to claim 3, further comprising: The common cross-section of the recess includes a first recess end and another recess end spaced apart from the first recess end, the first recess end including a step extending radially inwardly at an abrupt change extending into the outer surface of the shaft member adjacent to the first end at approximately 90 degrees, and the other recess end including a position where an inclined surface of the recess rising from the bottom of the recess meets the imaginary cylindrical surface.

5. The device according to claim 4, further comprising: The common cross-section of the recess also includes a constant radius area, which has a constant depth radially inside the imaginary cylindrical surface and extends from the bottom of the sudden step to the starting part of the inclined surface as the inclined surface rises from the bottom of the recess toward the imaginary cylindrical surface.

6. The apparatus according to any preceding claim, further comprising: The shaft cross section includes a cross section of an outer surface of one semi-cylindrical side of the shaft member at a plane passing through and including the central longitudinal axis of the shaft member.

7. Apparatus according to any preceding claim, wherein the helical extension variations have a constant cross section and a constant pitch.

8. Apparatus according to any preceding claim, wherein the elongate shaft member comprises a mandrel supported at least at one end of the mandrel.

9. The apparatus according to any preceding claim, further comprising: at least one fluid communication passage extending axially along and within a respective lubrication area of ​​the shaft member and including a passage portion extending to the outer surface of the shaft member; and At least one lubrication hole is located at the outer surface of the shaft member and at a respective end of a respective channel portion for selectively providing lubricant at a respective location at the interface region on the outer surface of the elongated shaft member.

10. A method of manufacturing a flexible pipe body, comprising the steps of: helically wrapping the elongated ribbon element around a profiled region of the outer surface of the elongated shaft member; orienting a first section of the tape cross-section of the elongated tape element adjacent to the helically extending smooth surface region of the outer surface while winding the elongated tape element; as well as Via a helical extension variant to the outer surface, a further section of the strip cross section is aligned obliquely to the smooth surface area of ​​the outer surface.

11. The method according to claim 10, further comprising: A lead-in coil of the elongated tape element is wound between the outer surface and another portion of an immediately preceding coil of the elongated tape element.

12. The method of claim 10 or claim 11, wherein orienting the first section of the elongated tape element further comprises: The first section of the elongated tape element is positioned adjacent the helically extending smooth surface region of the outer surface.

13. The method according to any one of claims 10 to 12, further comprising: Another strip is spirally wound on at least one already wound coil of the slender strip element, thereby positioning a first portion of the coil of the other slender strip element at least partially in a gap between another adjacent strip coil of the other strip, and positioning another portion of an adjacent coil of the elongated strip element adjacent to the coil of the elongated strip element at least partially in the gap.

14. The method according to any one of claims 10 to 13, further comprising: Another strip is helically wound around at least one coil of the elongated strip element, thereby nesting an area of ​​the coil of the other strip within a mating area of ​​a previous coil of the elongated strip element, the mating area being arranged obliquely to the smooth surface area before interlocking adjacent coils of the other strip.

15. The method according to any one of claims 10 to 14, further comprising: When helically winding the slender strip element, the end of the cross-section of the introduced coil of the slender strip element corresponding to the free edge of the slender strip element is positioned against the abutment surface provided by the stepped edge of the spiral recess in the outer surface of the shaft member, thereby determining the spacing relationship and therefore the pitch of adjacent coils for the slender strip element.

16. The method according to any one of claims 10 to 15, further comprising: When the elongated tape element is helically wound, the region of the cross section of the lead-in coil of the elongated tape element is supported via the inclined surface of the recess, thereby positioning the remaining portion of the cross section of the elongated tape element not disposed in the recess in a desired configuration.

17. The method according to any one of claims 10 to 16, further comprising: The elongated tape element is helically wound on the outer surface whereby at least a portion of a plurality of successively wound adjacent coils of the elongated tape element is provided beneath a footprint of an incoming coil of the further tape when the further tape is wound.

18. The method according to claim 17, further comprising: When winding the further tape, at least a portion of at least three consecutively wound adjacent coils of the elongated tape element is provided below a footprint of an incoming coil of the further tape.

19. A method according to claim 18, wherein the further strip comprises a carcass strip and adjacent coils of the wound carcass strip self-interlock following application of compression pressure downstream of the footprint.

20. Use of an elongated shaft member for manufacturing a flexible pipe body, the elongated shaft member comprising: an outer surface including a profiled surface region extending along at least a portion of the shaft member and having a profiled cross section including repeating flat constant radius cross sectional regions provided by helically extending smooth surface regions of the outer surface located on an imaginary cylindrical surface coaxial with a central longitudinal axis of the shaft member, disposed between spaced apart strip-aligned cross sectional regions provided by continuously repeating helically extending variations of the outer surface located on the imaginary cylindrical surface.

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