Corrosion-free welding connection for reinforcing

Abstract

A connection system (100) for reinforcing a thermoplastic polymer (RTP) pipe includes a first pipe (110) having a first end (111) and a reinforced thermoset resin (RTR) coupler (120) positioned adjacent the first end (111) of the first pipe (110). The RTR coupler (120) has an annular body (201) with a first socket extension (204) extending into the first end (111) of the first conduit (110) and a first thermoplastic tie layer (210) disposed between the first socket extension (204) and the first end (111) of the first conduit (110). A first set of wedges (140) is positioned circumferentially around an outer surface of a first end (111) of the first duct (110) and a first flange (150) is fitted around the first set of wedges (140), where the first set of wedges (140) is wedged between the first end (111) and the first flange (150).

Description

Background Art

[0001] Reinforced thermoplastic polymer (RTP) pipes are widely used in the oil and gas and petrochemical industries for transporting various fluids, such as water, crude oil, natural gas, and chemicals. FIG1 illustrates a typical layer structure of an RTP pipe. As shown, a typical RTP pipe 10 includes an inner thermoplastic liner 12, a fiber reinforcement layer 14 layered around the inner thermoplastic liner 12, and an outer thermoplastic jacket 16 layered around the fiber reinforcement layer 14. The inner thermoplastic liner can be made of, for example, polyethylene, polyvinyl chloride, polypropylene, polyurethane, polyamide, and / or polyvinylidene fluoride, using an extrusion process to form a tubular pipe shape. The fiber reinforcement layer 14 can be made of, for example, polyethylene, aromatic polyamide, polyester, polyamide, glass, carbon, and / or metal fibers, by winding or braiding a certain length of fiber around the thermoplastic liner. The outer thermoplastic jacket 16 can be made of, for example, polyethylene, polyvinyl chloride, polypropylene, polyurethane, and / or polyamide, using an extrusion process.

[0002] Compared to other non-metallic pipes, such as reinforced thermosetting resin (RTR) pipe, RTP pipe exhibits a degree of flexibility that allows it to be spooled, thereby allowing significant lengths of RTP (e.g., hundreds of meters of seamless pipe) to be delivered on a reel. Because the spooling capability of RTP pipe allows for the production of long, seamless lengths of pipe, the need for connectors is reduced, as only one connector may be required every several hundred meters. For example, in contrast to RTP pipe, RTR pipe is typically produced in rigid sections of approximately 10-12 meters in length and shipped to the site before being finally assembled (joined) to each other to the required length.

[0003] While the number of joints required for RTP pipe may be reduced, joints remain the weak link in the pipeline and are far more likely to leak than anywhere else in the pipeline.

[0004] There have been many attempts to develop RTP connections that exhibit both high mechanical properties and good sealing characteristics and corrosion resistance to the fluids being conveyed. The design of RTP connections and their associated technologies are typically proprietary to individual RTP suppliers, with little or no standardization (unlike other types of composite piping technologies, such as RTR).

[0005] Generally speaking, known RTP connections can be grouped into three main categories: metal connections, fiber-reinforced thermoset connections, and thermoplastic couplings. Metal connections offer excellent mechanical and thermal resistance, but are susceptible to corrosion damage over time when exposed to the transported hydrocarbons or harsh environmental conditions. Fiber-reinforced thermoset connections, such as glass-reinforced epoxy (GRE), show acceptable mechanical and thermal properties but cannot be directly welded to RTP pipes because thermoset polymers cannot be welded. Thermoplastic couplings (typically non-reinforced) are used to join thermoplastic pipes by heat welding (e.g., electrofusion). However, the relatively low mechanical and thermal performance of the resulting connection results in a limited operating range for the system, so the system's pressure rating is typically limited to the pressure rating of the coupling itself. Summary of the Invention

[0006] This Summary is provided to introduce a selection of concepts that are further described below in the Detailed Description. This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

[0007] In one aspect, embodiments of the present disclosure relate to a connection system for reinforced thermoplastic polymer (RTP) pipe. The connection system may include a first pipe having a first end and a reinforced thermosetting resin (RTR) coupler positioned adjacent the first end of the first pipe. The RTR coupler includes an annular body having a first pipe seat extension extending into the first end of the first pipe; and includes a first thermoplastic bonding layer disposed between the first pipe seat extension and the first end of the first pipe. The connection system may also include a mechanical connection system for combination with the coupler. Such a mechanical connection system may include a first set of wedges positioned circumferentially around an outer surface of the first end of the first pipe, and a first flange assembled around the first set of wedges, wherein the first set of wedges are wedged between the first end and the first flange.

[0008] In another aspect, embodiments of the present disclosure relate to a method for connecting RTP pipes using a coupling having an annular body with a first socket extension, the first socket extension comprising a first thermoplastic material disposed about an outer surface. The method may include fitting a first end of a first pipe about the first socket extension, wherein the first pipe has an inner surface made of the pipe thermoplastic material, and applying heat to the fitted first end to thermoplastically weld the inner surface of the first end to the first thermoplastic material of the first socket extension.

[0009] In yet another aspect, embodiments of the present disclosure relate to a pipe connection device. The connection device may include an annular body having an inner surface defining an inner diameter of the annular body, a first radial extension extending radially from the inner surface, a first socket extension extending axially from a first side of the first radial extension, and a first thermoplastic tie layer bonded around an outer surface of the first socket extension, wherein the first thermoplastic tie layer includes a thermoplastic material and a susceptor material, and wherein the annular body is formed of a reinforced thermoset resin (RTR) material.

[0010] Other aspects and advantages of the claimed subject matter will be apparent from the following description and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] FIG1 shows the structure of a traditional RTP pipeline.

[0012] Figure 2A An exploded view of a connection system according to an embodiment of the present disclosure is shown.

[0013] Figure 2B Shown in a partially assembled configuration Figure 2A connection system.

[0014] Figure 2C Shown Figure 2A and Figure 2B Cross-sectional view of the connection system in the assembled configuration.

[0015] Figure 3 A partial cross-sectional view of a connection system according to an embodiment of the present disclosure is shown.

[0016] Figure 4A A cross-sectional view of a coupling according to an embodiment of the present disclosure is shown.

[0017] Figure 4B Another example of a coupling according to an embodiment of the present disclosure is shown.

[0018] Figure 4C Another example of a coupling according to an embodiment of the present disclosure is shown.

[0019] Figure 4D Another example of a coupling according to an embodiment of the present disclosure is shown.

[0020] Figure 5 The step of tightly fitting the assembly parts of the method according to the present disclosure is shown.

[0021] Figure 6 An example of a heating step for forming a thermoplastic weld according to the method of the present disclosure is shown.

[0022] Figure 7An example of a mechanical connection step of a method according to the present disclosure is shown.

[0023] Figure 8 An example of a connection system according to an embodiment of the present disclosure is shown. DETAILED DESCRIPTION

[0024] In the following detailed description of the embodiments of the present disclosure, many specific details are set forth to provide a more thorough understanding of the present disclosure. However, it is apparent to one of ordinary skill in the art that the present disclosure can be practiced without these specific details. In other instances, well-known features are not described in detail to avoid unnecessarily complicating the description.

[0025] Throughout this application, ordinal numbers (e.g., first, second, third, etc.) may be used as adjectives for elements (i.e., any nouns in this application). The use of ordinal numbers does not imply or create any particular order of elements, nor does it limit any element to being a single element, unless explicitly disclosed, such as with the terms "first," "last," "single," and other such terms. Rather, the use of ordinal numbers is intended to distinguish between elements. By way of example, a first element is different from a second element, and a first element may contain more than one element and come after (or before) a second element in the ordering of the elements.

[0026] exist Figures 2A to 8 In the following description of the drawings, the components described with respect to the drawings may, in the various embodiments disclosed herein, be equivalent to one or more components of the same name described with respect to any other drawings. For the sake of brevity, the description of these components may not be repeated for each drawing. Therefore, each and each embodiment of the components of each drawing is incorporated by reference and is assumed to be optionally present in each other drawing with one or more components of the same name. In addition, according to the various embodiments disclosed herein, any description of the components in the drawings should be interpreted as optional embodiments, and the optional embodiments can be implemented to exclude, combine, or replace the embodiments described with respect to the corresponding components of the same name in any other drawings.

[0027] In one aspect, embodiments disclosed herein relate to a corrosion-free system and method for mechanically coupling (to withstand axial and hoop stresses) and sealing (to prevent fluid ingress through the joint) two RTP (reinforced thermoplastic polymer) pipe ends. The connectors, systems, and methods disclosed herein include coupling and sealing RTP pipes by leveraging the structural characteristics of reinforced thermoset materials and the weldability and sealing properties of thermoplastic materials. The connection systems and methods according to embodiments of the present disclosure can mitigate corrosion issues evident in metal connections, mitigate failures due to mechanical or thermal loads that can occur in thermoplastic connections, and provide optimal sealing, as observed with systems capable of thermoplastic welding.

[0028] Connection system

[0029] According to an embodiment of the present disclosure, a connection system for joining two RTP (reinforced thermoplastic polymer) pipes may include an RTR (reinforced thermosetting resin) coupler positioned between the ends of the two RTP pipes. RTP pipe refers to a pipe formed from concentric layers of multiple materials, typically including an inner liner and an outer jacket, both made of thermoplastic materials. The coupler may include a body made from the RTR material, wherein the connecting end of the RTR coupler is modified to be weldable to the RTP pipe using a thermoplastic bonding layer. In certain embodiments, the coupler may be made entirely from the RTP material, which may eliminate the need for adding a sacrificial connecting layer for welding to the liner (assuming the two thermoplastic parts are weld-compatible). By providing a thermoplastic connecting end of the coupler assembled against the thermoplastic material of the connected RTP pipes, the thermoplastic connecting end may melt with the adjoining thermoplastic material of the RTP pipes to "weld" the connecting end of the coupler to the ends of the RTP pipes, thereby connecting the RTP pipes together.

[0030] According to embodiments disclosed herein, in addition to using thermoplastic welding to connect the RTP pipe to the coupling, the connection system disclosed herein may also include mechanical connection components. For example, the connection system disclosed herein may include a mechanical connection system of a wedge and a flange that is secured between the coupling and the RTP pipe around the welded connection end.

[0031] Figures 2A to 2C An example of a connection system according to an embodiment of the present disclosure that utilizes thermoplastic welding and a mechanical connection system to secure the end of an RTP pipe to a coupling is shown. In particular, Figure 2A shows an exploded perspective view of the connection system 100 before connection, Figure 2B A perspective view of the connection system 100 is shown in a partially assembled configuration, and Figure 2C A cross-sectional view of the connection system 100 is shown after connection.

[0032] As shown, the connection system 100 includes a first RTP pipe 110 having a first end 111, a second RTP pipe 112 having a second end 113, and a coupling 120. The first end 111 and the second end 113 of the RTP pipe are open and sized to match the coupling 120. Figures 2A to 2CIn the figure, for simplicity, the multiple material layers of the RTP pipe are not shown. However, the first RTP pipe 110 and the second RTP pipe 112 include multiple material layers arranged concentrically around each other, wherein the inner surface 114 and the outer surface 115 of the RTP pipe are both formed by layers of thermoplastic material (an inner liner layer and an outer jacket layer, respectively). The thermoplastic material forming the inner surface 114 and / or the outer surface 115 of the RTP pipe can be selected from at least one of polyethylene (PE), polyvinylidene fluoride (PVDF), polyphenylene sulfide (PPS), polyaryletherketone (PAEK), polyamide (PA), polyetheretherketone (PEEK), acrylonitrile-butadiene-styrene (ABS), polypropylene (PP), or other thermoplastic polymers known in the art.

[0033] The coupling 120 generally includes an annular body having a radial extension 121 and two socket extensions 122 extending in opposite axial directions, wherein the socket extensions 122 are sized and shaped to mate with the open ends 111, 113 of the RTP pipes 110, 112. According to embodiments of the present disclosure, the radial extensions can extend in a direction that is generally perpendicular to the direction in which adjacent socket extensions extend. However, other embodiments may include radial extensions that extend at different angles relative to the direction in which the socket extensions extend. As discussed in more detail below, the shape and orientation of the radial extensions can be configured to correspond to mating surfaces of components (e.g., flanges) used to mechanically connect the pipes to the coupling in a mechanical connection system.

[0034] The coupling body can be formed from an RTR material, which can include reinforcing fibers (e.g., glass, carbon fibers, or other reinforcing fibers known in the art) in a resin matrix, such as a thermosetting polymer (e.g., polyester, vinyl ester, epoxy, or other thermosetting polymers known in the art). By bonding a layer of thermoplastic material to the socket extension 122, the socket extension 122 is functionalized to have a thermoplastic joining surface covered with the RTR material, wherein the thermoplastic joining surface on the socket extension 122 is designed to interface with the thermoplastic joining surface on the RTP pipes 110, 112. In this manner, a thermoplastic bonding layer 130 can be disposed between the socket extension 122 and the ends 111, 113 of the RTP pipes 110, 112.

[0035] For example, Figure 2AAs shown in , the thermoplastic bonding layer 130 can be bonded around the outer surface of the base extension 122 to provide a thermoplastic bonding surface on the coupler 120. When the thermoplastic bonding surface is provided around the exterior of the base extension 122, the functionalized base extension 122 can be inserted into the ends 111, 113 of the RTP pipe so that the outer thermoplastic bonding surface of the base extension 122 interfaces with the inner thermoplastic bonding surface of the RTP pipe ends 111, 113. Figure 2C As shown in FIG, the adjoining thermoplastic joining surfaces may be melted to thermoplastic weld the base extension 122 to the ends of the RTP pipes 110, 112. The method of providing the thermoplastic joining surface on the RTR material of the base extension is described below.

[0036] According to embodiments of the present disclosure, a thermoplastic tie layer (e.g., thermoplastic tie layer 130) may be made of the same thermoplastic material as the inner lining of the connected RTP pipe, or made of a different thermoplastic material that is thermoplastic weldable with the connected RTP pipe.

[0037] By integrating a thermoplastic connecting surface on an RTR coupling body made of RTR material, a coupling having relatively higher strength, chemical resistance, and temperature resistance (provided by the RTR material) compared to RTP material can be provided with an integrated weldable interface to permanently connect and seal with the RTP pipe. Thus, according to embodiments of the present disclosure, a coupling having a body made of RTR material and a thermoplastic connecting surface can be designed to have sufficient strength in the axial direction to transfer increased loads from one pipe to another. Following the discussion of the connection system overview, additional examples and a more detailed discussion of couplings according to embodiments of the present disclosure, as well as methods of manufacturing such couplings, are provided below.

[0038] In other embodiments, the coupling body (including its socket extension) can be formed entirely of RTP material, which can eliminate the need for adding a sacrificial bonding layer for welding to the RTP pipe (when the coupling and pipe thermoplastics are weld-compatible). However, commercial thermoplastics generally exhibit lower mechanical and thermal resistance than thermoplastics, and specialty thermoplastic polymers such as PPS, PVDF, PEEK, etc., have higher strength and / or thermal resistance than commercial thermoplastics, often at the expense of cost.

[0039] Figures 2A to 2CThe connection system 100 shown in FIG. 1 also includes a mechanical connection system to mechanically connect the RTP pipes 110, 112 to the coupling 120 in addition to thermoplastic welding the RTP pipes 110, 112 to the coupling 120. As shown, the mechanical connection system includes an assembly of wedges 140, 142 and flanges 150, 152 that are secured and tightened around the ends 111, 113 of the RTP pipes 110, 112 to mechanically connect the ends 111, 113 of the RTP pipes 110, 112 to the coupling 120.

[0040] According to embodiments of the present disclosure, after the socket extension of the coupler has been thermoplastic welded to the RTP pipe, a set of wedges may be arranged around the coupler / pipe connection. Figure 2B As shown in , after the socket extension 122 of the coupler 120 is thermoplastically welded to the RTP pipes 110, 112, the wedges are arranged into a first set of wedges 140 positioned circumferentially around the outer surface of the first end 111 of the first pipe 110 and a second set of wedges 142 positioned circumferentially around the outer surface of the second end 113 of the second pipe 112. The wedges can be equally spaced around the outer circumference of the pipe ends. In addition, the wedges can be sized and provided in different quantities depending on the size of the pipes being connected. For example, two or three or more wedges can be provided around the pipe ends. In some embodiments, such as Figure 2B As shown in FIG, when the wedge members 140, 142 are assembled around the coupling / pipe connection, the wedge members 140, 142 are sized and shaped to fit adjacent to each other (with no circumferential spacing between adjacent wedge members). In this embodiment, the assembled set of wedge members 140, 142 extends around the entire outer circumference of the coupling / pipe connection without any circumferential spacing between adjacent wedge members.

[0041] The size of the wedge can be selected, for example, based on the size of the pipe being connected and / or the desired pressure rating of the connection. For example, the wedge length (as measured in a direction parallel to the central axis of the connected pipe) can be designed based on the pipe diameter and pressure rating, where a relatively larger diameter pipe with a relatively higher pressure rating will use a relatively longer wedge to transfer a greater load.

[0042] After the wedge has been assembled around the coupling / pipe thermoplastic connection, the flange can be assembled around the assembled wedge. Figure 2CAs shown in FIG, after the wedges 140, 142 are assembled around the coupling / pipe thermoplastic connection, a first flange 150 is assembled around the first set of wedges 140 so that the first set of wedges 140 are wedged between the first end 111 of the first pipe 110 and the first flange 150, and a second flange 152 is assembled around the second set of wedges 142 so that the second set of wedges 142 are wedged between the second end 113 of the second RTP pipe 112 and the second flange 152.

[0043] Flanges 150, 152 are designed to compress and tighten wedges 140, 142, ensuring that pipe ends 111, 113 are securely and permanently connected. For example, in the illustrated embodiment, each flange 150, 152 has an inclined inner surface that corresponds to and abuts the inclined outer surface of wedges 140, 142. The inclined surfaces are configured to have a thicker end portion of the wedge positioned closer to the radial extension 121 of the coupling annular body and a thinner end portion of the wedge positioned further away from the radial extension 121 of the coupling annular body. When flanges 150, 152 are tightened together (in a direction toward the radial extension 121 of the annular body), the inclined inner surfaces of flanges 150, 152 exert a force on wedges 140, 142 in an axial direction toward the radial extension 121 of the annular body and in a radial direction inward toward the pipe base extension 122. In this manner, the flanges 150 , 152 squeeze the wedges 140 , 142 , which compress the ends 111 , 113 of the RTP pipes 110 , 112 between the wedges 140 , 142 and the header extension 122 .

[0044] At least one connector is used to connect the second flange 152 to the first flange 150 to hold and secure the flanges 150, 152 together about the wedge members 140, 142 and the radial extension 121 of the coupler 120. For example, in the illustrated embodiment, a plurality of correspondingly positioned holes are formed through the flanges 150, 152 and the coupler 120 such that when the flanges 150, 152 are positioned about and aligned with the coupler 120, circumferentially spaced through holes 160 are formed through the flange-coupler assembly. Connectors (e.g., bolt and nut assemblies) can then be inserted through the through holes 160 to secure the first and second flanges 150, 152 against opposing sides of the radial extension 121 of the coupler 120. Thus, as Figure 2C As shown in , a connection system may include a coupling having a partial annular body sandwiched between a first flange and a second flange, wherein the first flange and the second flange are connected together by a connector extending through the partial annular body.

[0045] According to embodiments of the present disclosure, the flange can have various sizes and shapes that can be tightened around the grouped wedges. In addition, the flange can have a coupling connection side of different shapes or sizes to match or correspond to the radial extension of the coupling. For example, a mating interlocking feature can be provided on the coupling connection side of the flange and the radial extension of the coupling, wherein the interlocking feature can lock to connect the flange to the coupling. As another example, a threaded extension can be integrally formed along the coupling connection side of the flange, wherein the threaded extension can be aligned with a hole positioned circumferentially around the radial extension of the coupling. The threaded extension of the flange can be inserted through the hole in the radial extension of the coupling, and a nut can be tightened to the threaded extension to tighten the flange to the coupling.

[0046] In addition, if Figure 2C As shown in FIG, when the connection system is assembled, the coupler 120 is positioned between the first end 111 of the first pipe 110 and the second end 113 of the second pipe 112, wherein a flow path is formed through the RTP pipe and the coupler. When the connection system is designed with a pipe base extension 122 that is inserted into the interior of the RTP pipes 110, 112, such as Figure 2C As shown in FIG, depending on the thickness of the tube base extension 122, the flow path can have a reduced diameter along the coupling portion of the flow path. In addition, when the RTP pipes 110, 112 are connected to the coupling 120, as shown in FIG. Figure 2C As shown in FIG, the RTP pipes 110 , 112 and the header extension 122 are coaxial about the central axis 101 .

[0047] In some embodiments, such as Figure 3 As shown in FIG, the connection system 100 may utilize flanges 150, 152 having one or more discharge ports 154 formed therethrough. Figure 3 As shown in , a discharge port 154 extends through each of the first flange 150 and the second flange 152, wherein the discharge port 154 fluidly connects the exterior of each flange 150, 152 with the interface between the flange and the annular body of the coupling 120. In particular, in the illustrated embodiment, the coupling 120 includes a radial extension 121 that extends radially outward and is sandwiched between the two flanges 150, 152 so that the discharge port 154 interfaces with the radial extension 121 of the coupling 120. The exterior of the discharge port 154 can be fluidly connected to a gas collection system, a storage container, or other components located outside the flange (not shown). In this way, fluid trapped between the flange and the coupling 120 can flow through the discharge port 154 to another fluid connection system, for example, to be stored, reused, and / or redirected back into the pipeline.

[0048] also, Figure 3 The connection system 100 shown in FIG includes O-ring seals 170, 172 positioned along the inner surfaces of the flanges 150, 152 to prevent the ingress of external fluids. For example, in the embodiment shown, the first O-ring seal 170 is positioned between the radial ends of the flanges 150, 152 and the radial extension 121 of the coupling, and the second O-ring seal 172 is positioned between the axial ends of the flanges 150, 152 and the RTP pipes 110, 112. Although Figure 3 While an O-ring seal is shown, other seals may be used to prevent fluid from entering the flange connection, including, for example, a sealing compound such as grease.

[0049] A vent port 154 may be formed through the flanges 150, 152 at a location between the sealing components. In RTP pipes, a small portion of the transported gas sometimes permeates through the inner liner and then travels axially along the pipe annulus (e.g., in unbonded pipes) to ultimately reach the pipe-to-pipe connection. Accordingly, a vent port may be added to the connection, such as at Figure 3 to collect the permeated gas (eg, for collection or reinjection).

[0050] According to certain embodiments of the present disclosure, the wedges and flanges can be made of non-metallic materials (e.g., with pipes having lower pressure requirements). For example, the wedges and / or flanges can be made of RTR materials, such as glass reinforced epoxy or carbon reinforced epoxy, or of RTP materials, such as short or continuous fiber reinforced thermoplastics, carbon reinforced PEEK, or carbon reinforced PPS. By using non-metallic materials to form the wedges and flanges, the connection system 100 can be completely non-metallic, which provides immunity to external corrosion. In addition, an all-non-metallic connection can be significantly lighter than its metal equivalent, which can provide logistical advantages (e.g., for transportation, loading and unloading, etc.). In other embodiments, the wedges and / or flanges can be metal.

[0051] Such as Figures 2A to 3 The connection system shown in FIG can have sufficient strength in the axial direction to transfer loads from one pipe to another. Some of the axial loads passing through the connected pipes 110, 112 can be transferred by the thermoplastic weld surfaces between the coupling 120 and the RTP pipes 110, 112, while the majority of the axial loads can be transferred by the wedges 140, 142 in the mechanical connection system.

[0052] Figures 2A to 3The embodiment shown in shows a connection system that generally includes: (1) a coupling made of a reinforced thermoset body with modified surface ends to allow "weldability" with the thermoplastic layer of the RTP pipe to be joined; (2) a series of wedges assembled around the circumference of the outer surface of the RTP pipe; (3) an optional sealing component to prevent external fluid from entering the RTP structure; and (4) an external flange to allow complete assembly of the system using bolts. Therefore, in Figures 2A to 3 In the embodiment shown in FIG, the connection system uses a mechanical connection system that includes a series of flanges and wedges, and optional sealing components, to achieve a tight mechanical interlock between the coupler and the RTP pipe. However, other mechanical connection systems are contemplated without departing from the scope of the present disclosure. For example, a different type of flange connection can be used to tighten the flange around the wedge, or a different type of mechanical fastening component can be used, such as a radially adjustable / tightening component (e.g., as used with a hose clamp). By integrating the mechanical connection system with the thermoplastic welding connection system, the connection system can have both improved strength and sealing performance.

[0053] Furthermore, the connection system utilizing a combination of thermoplastic welding and mechanical connection components according to embodiments of the present disclosure can be used for different types of pipe connections, such as turn connections or terminal connections. For example, Figure 4A An example of a connection system 180 according to an embodiment of the present disclosure for a pipe terminal connection is shown, wherein the connection system 180 connects the end of an RTP pipe 181 to another device 182 (e.g., a manifold, a device junction, a storage container, or other device having a flow path port). As shown, the connection system 180 includes a coupler 183, a single set of wedges 185, and a single flange 186. The coupler 183 has an annular body with a radial extension 179 and a single socket extension 184 extending from a first side of the radial extension 179. A terminal connection side is positioned along the radial extension 179 opposite the first side, wherein the terminal connection side is configured to mate with or correspond to a device connection 187. In some embodiments, the terminal connection side of the coupler can be a flat surface that can be positioned flush against a corresponding flat surface of the device connection.

[0054] The end of the RTP pipe 181 is thermoplastically welded to the pipe base extension 184 of the coupling 183. A set of wedges 185 is assembled around the outer circumference of the coupling / pipe thermoplastic connection, and a flange 186 is tightened around the set of wedges 185 so that the wedges 185 are sandwiched between the flange 186 and the coupling / pipe thermoplastic connection. The coupling 183 and the flange 186 are connected to an equipment connection 187 (e.g., a metal flange connection) using connectors 188 (e.g., bolts or screws).

[0055] In other embodiments, a connection system utilizing a combination of thermoplastic welding and mechanical connection components according to embodiments of the present disclosure can be used to divert connections. In such embodiments, the connection system can include a coupling having an annular body with a diverting portion along at least one direction of a flow path formed therethrough, wherein one or both axial ends of the coupling can have a pipe socket extension for thermoplastic welding to an end of an RTP pipe. For example, Figure 4B An example of a coupler 189 is shown having an annular body 190 with a turn formed between two ends of the annular body 190. In the illustrated embodiment, the annular body 190 includes radial extensions formed at its ends, with a socket extension 191 extending from each radial extension at the ends of the annular body 190. In other embodiments, a socket extension may be formed at only one end of the annular body, while the other end of the annular body may have a radial extension with a terminal connection side (e.g., a flange end) for terminal connection.

[0056] In certain embodiments, a connection system utilizing a combination of thermoplastic welding and mechanical connection components according to embodiments of the present disclosure can be used for a multi-way connection (e.g., a three-way connection or a four-way connection). In such embodiments, the connection system can include a coupler having an annular body that forms an intersection of multiple flow paths. For example, Figure 4C An example of a coupler 192 for a three-way connection is shown, wherein an annular body 193 of the coupler 192 forms an intersection between three branching flow paths. In the illustrated embodiment, the coupler 192 is T-shaped. A socket extension 194 may extend from one or more ends of the annular body along different branches, wherein an RTP pipe end may be thermoplastic welded to each socket extension, and a mechanical connection system may be connected about the thermoplastic weld body. In the illustrated embodiment, a radial extension may be formed at each branch end of the annular body, and a socket extension 194 may extend from each radial extension. In other embodiments, at least one branch end of the coupler may have a radial extension with a terminal connection side (without a socket extension) that may be connected to an equipment connection. For example, in some embodiments, a socket extension may be formed at two branches of the annular body, and one branch of the annular body may be a flange end for a terminal connection.

[0057] As another example, Figure 4DA coupling 195 is shown that can be used for a four-way connection. Coupling 195 has a cross ("+") shape, wherein an annular body 196 of the coupling forms an intersection between four branching flow paths. A socket extension 197 can extend from one or more ends of the annular body along different branches, wherein an RTP tubing end can be thermoplastic welded to each socket extension, and a mechanical connection system can be connected around the thermoplastic weld. In the illustrated embodiment, a radial extension can be formed at each branch end of the annular body, and a socket extension 194 can extend from each radial extension. In other embodiments, at least one branch end of the coupling can have a radial extension with a terminal connection side (without a socket extension) that can be connected to an equipment connection.

[0058] Other joint types are contemplated in which a socket extension of the coupler can be thermoplastically welded to the RTP pipe end, and a mechanical connection system can be connected around the thermoplastic welded joint to thermoplastically and mechanically connect the RTP pipe to the coupler.

[0059] RTR connector

[0060] According to embodiments of the present disclosure, the coupling can accommodate any pipe size and is completely independent of the pipe design. Consequently, the coupling according to embodiments of the present disclosure is particularly suitable for retrofitting existing RTP installations. Furthermore, the coupling can be sized and shaped to fit the pipe being joined and to coordinate with the mechanical connection system. In this way, the coupling can integrate the mechanical connection system into the connection between the RTR coupling and the joined pipe.

[0061] Figure 5 A detailed cross-sectional view of an example of a coupling 200 according to an embodiment of the present disclosure is shown. Coupling 200 has an annular body 201 having an inner surface defining an inner diameter 209, wherein the annular body includes a central radial extension 202 extending a radial distance 203 from the inner surface, a first socket extension 204 extending axially from a first side 206 of the radial extension 202, and a second socket extension 205 extending axially from a second side 207 of the radial extension 202 opposite the first side.

[0062] The annular body 201 (including the radial extension 202, the first socket extension 204, and the second socket extension 205) is integrally formed from an RTR material. The RTR material can be selected from, for example, glass-reinforced polyester (GRP), glass-reinforced vinyl ester (GRV), and glass-reinforced epoxy (GRE). According to embodiments of the present disclosure, the RTR coupler body can be manufactured integrally (e.g., using a wire winding process).

[0063] A plurality of through-holes 208 are spaced circumferentially about the radial extension 202 and extend across the width of the radial extension from a first side 206 of the radial extension to an opposite second side 207 of the radial extension. The through-holes 208 can be spaced from the outermost surface of the radial extension and circumferentially spaced from each other so that sufficient material is provided around the through-holes to prevent or inhibit cracking. For example, the through-holes 208 can be radially positioned along the radial extension at a distance ranging from approximately 50% to 90% of the radial distance 203 from the inner surface to the radial extension 202. Depending on, for example, the RTR material forming the radial extension, the size of the radial extension (radial distance and width), and the size of the through-holes, the through-holes can be positioned at other radial locations along the radial extension. Further, according to embodiments of the present disclosure, the through-holes can be positioned at the same radial distance and at equally spaced locations circumferentially around the radial extension.

[0064] A first thermoplastic tie layer 210 is bonded around the outer surface of the first base extension 204, and a second thermoplastic tie layer 211 is bonded around the outer surface of the second base extension 205. Both the first thermoplastic tie layer 210 and the second thermoplastic tie layer 211 are made of a thermoplastic material and a susceptor material. For example, in the illustrated embodiment, each of the first thermoplastic tie layer 210 and the second thermoplastic tie layer 211 is made of a top layer 212, 213 of susceptor material deposited on a base layer 214, 215 of thermoplastic material. In certain embodiments, the thermoplastic tie layers may be made of a susceptor-thermoplastic composite, in which the susceptor material may be dispersed in a thermoplastic matrix.

[0065] The thermoplastic material forming the thermoplastic tie layers 210, 212 can be the same as or different from the thermoplastic material forming the inner lining and / or outer jacket of the RTP pipes being joined by the coupling. However, according to embodiments of the present disclosure, the thermoplastic material forming the tie layers 210, 212 can be selected to be weldable to the adjacent thermoplastic layers of the RTP pipe (e.g., having very similar melting / solidifying temperatures and being melt compatible, i.e., mixing well when melted). In addition, such thermoplastic materials must be carefully selected to ensure their functionality throughout the life of the pipe (typically 25 years). For example, the material can be selected from those qualified (e.g., according to ISO 23936) to meet service specifications in terms of design temperature, pressure, and chemical compatibility with the environment (sour gases, liquids, aromatic content, etc.).

[0066] In general, the selection of the most suitable thermoplastic material for the tie layer may depend on: welding compatibility with the RTP pipe material on one side and mechanical adhesion affinity with the RTR material of the coupling on the other side; chemical compatibility and tolerance to the conveyed fluid; the melting temperature should not exceed the maximum temperature that causes significant degradation of the thermoset material during the friction deposition process or the secondary welding process (field induction); and sufficient mechanical and permeation barrier properties.

[0067] Examples of thermoplastics that can be used for the tie layer include, but are not limited to, polyolefins (e.g., polypropylene or polyethylene), polyvinylidene fluoride (PVDF), polytetrafluoroethylene (PTFE), polyphenylene sulfide (PPS), polyaryletherketone (PAEK), polyethyleneimine (PEI), high-density polyethylene (HDPE), raised-temperature polyethylene (PE-RT), aliphatic polyketones (PK), polyetheretherketone (PEEK) (and other polyaryletherketones), polyetherketoneketone (PEKK), polyamide 12 (PA12), polyketone (POK) and its carbon bead or short fiber reinforced grades, as well as other thermoplastic resins commonly used in the oil and gas industry.

[0068] During the RTR coupler manufacturing phase, or after the RTR coupler body is manufactured and distributed to the installation site, a thermoplastic layer (which may include a susceptor, if desired) can be bonded to the connecting (sealing) surface of the RTR coupler (e.g., the outer surface surrounding the socket extension). Various methods can be used to apply and bond the bonding layer to the thermoset RTR coupler body. For example, a thermoplastic powder can be thermally sprayed onto the sealing surface of the thermoset RTR coupler body (with adequate surface preparation, such as sandblasting), or a thermoplastic implant can be applied while the thermoset RTR coupler body is in a partially cured (or uncured) state, followed by co-curing at a desired temperature (below the melting temperature of the thermoplastic) to bond the thermoplastic bonding layer to the RTR coupler body. In one or more embodiments, the deposition of the bonding layer can be performed during the manufacturing phase in a factory. Since the surface preparation of the substrate typically affects the final quality of the coating, a clean and controlled environment (e.g., dust-free, temperature-regulated, etc.) is advantageous, which is more easily achieved at the manufacturing site.

[0069] In certain embodiments, the thermoplastic joining layer can be friction welded (e.g., using a friction welding tool) around a mating surface of an RTR coupling body (e.g., an outer surface of a socket extension), wherein the RTR coupling body is a single, integrally formed body of RTR material. For example, the thermoplastic joining layer can be friction welded to the mating surface of the RTR coupling body using a rotational friction welding process, wherein one component (e.g., a sleeve forming the thermoplastic joining layer) can be rotated against the other component being joined (e.g., the RTR coupling) to induce sufficient friction work to heat and thermally weld the components together. In such embodiments, the geometry of the RTR coupling can include a tapered socket extension, which can correspond to the geometry of the thermoplastic joining layer sleeve such that the thermoplastic joining layer sleeve can be rotated against the tapered socket extension and axially loaded against the tapered socket extension.

[0070] For example, Figure 5 The coupling 200 shown in FIG. 1 includes first and second socket extensions 204, 205 having a tapered thickness 216 in a direction from an inner end proximate to an annular body 201 to an outer end distal to the annular body 201. According to embodiments of the present disclosure, the tapered geometry of the socket extensions can be retained after the thermoplastic bonding layer is applied, or the tapered geometry of the socket extensions can be machined away after or during the application of the thermoplastic bonding layer. For example, the tapered socket extension geometry can be provided on the coupling body by machining the tapered thickness or during manufacture of the coupling body.

[0071] Prior to friction welding, the faying surfaces of the friction weld bodies may be subjected to surface preparation in the factory (e.g., by sandblasting / grinding) to provide sufficient roughness and contact forging force to promote heat generation in the rotary friction process and to facilitate deposition of the thermoplastic joining layer onto the reinforced thermoset coupling end. Surface preparation is important in friction welded components because it not only contributes to the manner of adhesion between the faying materials, but also to the friction characteristics of the faying surfaces and, therefore, to the rate at which frictional heat is generated during the joining process.

[0072] In certain embodiments, after the thermoplastic material has been friction welded to the RTR coupling body, a top layer of the susceptor may be deposited around the base layer of thermoplastic material. Figure 5As shown in FIG, a base layer 214, 215 of thermoplastic material is friction welded to the RTR coupling body 201 and machined to the desired bond lining thickness. After curing of the base layers 214, 215, a top layer 212, 213 of susceptor material (e.g., carbon fiber or copper wire) is deposited on top of the thermoplastic base layers 214, 215. As discussed further below, the susceptor material can be used for a secondary welding process (which occurs in the field during installation). Using an appropriate welding process (e.g., electrofusion or induction), the circulation of electrical current within the susceptor material will generate sufficient heat through the Joule effect to melt and fuse the thermoplastic joining layers 210, 211 to the RTP pipe.

[0073] The susceptor material can be selected from at least one of silicon carbide, molybdenum, graphite, stainless steel, aluminum, and other conductive materials. The type and location of the susceptor material can be selected to prevent preferential leakage paths and reduce the permeation resistance of the connection, whether through adjacent continuous carbon fibers, between locally contacting short fibers, or conductive particles. In other words, the type and location of the susceptor material in the thermoplastic tie layer can be selected so that the electroosmotic network is not a permeating network.

[0074] method

[0075] According to embodiments of the present disclosure, a coupling having at least one socket extension made of an RTR material can be used to connect the axial ends of an RTP pipe. For example, a connection method according to embodiments of the present disclosure can generally include providing a coupling having an annular body with one or more socket extensions having a thermoplastic bonding layer disposed around its outer surface. An end of an RTP pipe can then be assembled around each socket extension, wherein the RTP pipe has an inner surface made of a thermoplastic material. Heat can then be applied to the assembled pipe ends to thermoplastically weld the inner surface of the RTP pipe end to the thermoplastic bonding layer of the socket extension.

[0076] In one or more embodiments, after thermoplastic welding the coupling to the RTP pipe, a mechanical connection system may be secured around the thermoplastic weld to mechanically secure the RTP pipe to the coupling.

[0077] Reference below Figures 6 to 8 Examples of methods according to embodiments of the present disclosure are discussed.

[0078] like Figure 6As shown in FIG, a method according to an embodiment of the present disclosure includes providing a coupler 300 having an annular body 301 with a first socket extension 302 and a second socket extension 303 extending in opposite axial directions. The annular body 301 is made of an RTR material, wherein the first and second socket extensions 302, 303 each have a thermoplastic tie layer 304 disposed around the outer surface of the socket extensions. The thermoplastic tie layer 304 has an integrated susceptor material 305. For example, a thin layer of susceptor material (e.g., carbon fiber or copper wire) can be deposited on top of a thermoplastic base layer to provide the thermoplastic tie layer, or the susceptor material can be dispersed within a thermoplastic matrix.

[0079] Then, the first end of the first RTP pipe 310 can be assembled around the first pipe base extension 302, and the second end of the second RTP pipe 311 can be assembled around the second pipe base extension 303. The RTP pipes 310 and 311 include an inner thermoplastic liner 312 (forming the inner surface of the pipe), at least one fiber reinforcement layer 313 layered around the inner thermoplastic liner 312, and an outer thermoplastic jacket 314 layered around the fiber reinforcement layer 313. The thermoplastic bonding layer 304 can be made of the same thermoplastic material as the inner surface of the RTP pipes 310 and 311, or made of a thermoplastic material with properties (e.g., melting temperature) sufficiently close to achieve welding compatibility with the inner surfaces of the RTP pipes 310 and 311. According to an embodiment of the present disclosure, before the coupling 300 and the RTP pipes are tightly assembled together, the mating surfaces of the RTP pipes 310 and 311 and the thermoplastic bonding layer 304 can be cleaned (e.g., using alcohol).

[0080] According to embodiments of the present disclosure, an RTR coupling with an integrated thermoplastic bonding layer (including a welding susceptor) on the connection side can be manufactured in a factory, such as discussed above, and then shipped to the installation site, ready for use. At the installation site, the RTP pipe end can be tightly assembled onto the "functionalized" RTR coupling so that the thermoplastic inner surface of the RTP pipe is in close contact with the thermoplastic bonding layer bonded to the RTR coupling, such as Figure 6 . Subsequently, the assembled "functionalized" RTR coupling and RTP pipe can be joined by applying sufficient heat (e.g., by electrofusion, induction welding, resistance welding processes, or other types of welding suitable for thermoplastic welding) to cause the thermoplastic layers to melt and fuse to each other. Upon cooling, a fully bonded and sealed joint is formed.

[0081] For example, Figure 7As shown in FIG, once the RTP pipe ends are in place, an induction welding system 320 is positioned around the assembled ends to melt, fuse, connect, and seal the inner RTP liner 312 to the thermoplastic bonding layer 304 of the coupling 300. The induction welding system 320 includes an induction coil 322 wrapped around and spaced apart (e.g., a few millimeters) from the pipe outer jacket 314. For example, the induction coil can be encapsulated in a non-ferrous material (e.g., plastic) to control the distance between the induction coil and the pipe and / or ensure the coil remains coaxial with the pipe. When an electrical current is applied, a magnetic field is generated that induces an electrical current in the susceptor material 305, which triggers (via the Joule effect) heating of the susceptor material 305 and melting of the surrounding thermoplastic material (thermoplastic bonding layer 304 and RTP inner thermoplastic liner 312). For example, the energy used for induction welding can be approximately 1.5 kilowatts for 5 seconds to melt the thermoplastic bonding and liner interface. Optimized coil design and parameter tuning may be performed to reduce energy consumption of the induction welding process.After the induction process for thermoplastic welding is completed, the induction welding system 320 is removed.

[0082] After cooling from the thermoplastic weld, the thermoplastic weld between the RTP pipes 310 , 311 and the coupling 300 is established, and the two RTP pipes 310 , 311 are sealed and coupled together.

[0083] According to embodiments of the present disclosure, after thermoplastic welding the RTP pipe to the coupling, a mechanical connection system can be used to mechanically connect the RTP pipe to the coupling. In certain embodiments, the mechanical connection system can include a flange that can be connected around the RTP pipe and connected to the coupling via a connector (e.g., bolts or screws).

[0084] For example, Figure 8 As shown in FIG, after thermoplastic welding the RTP pipes 310, 311 to the coupling 300, as shown in FIG. Figure 7As shown in FIG, a mechanical connection system including flanges 330, 331 and wedges 340, 341 is used to lock a coupler / pipe thermoplastic connection. To achieve the mechanical connection, a first set of wedges 340 are assembled circumferentially around the outer surface of the end of a first RTP pipe 310, and a second set of wedges 341 are assembled circumferentially around the outer surface of the end of a second RTP pipe 311. Various techniques can be used to hold the wedges around the outer surface of the coupler / pipe connection until the flanges can be properly assembled around the set of wedges. For example, in some embodiments, the wedges can be held circumferentially around the outer surface of the coupler / pipe connection by interlocking adjacent wedges together (e.g., by interlocking features, such as grooves / protrusions formed on the sides of the wedges). In some embodiments, the wedges can be held circumferentially around the outer surface of the coupler / pipe connection using temporary anchoring or adhesives.

[0085] The first flange 330 is then positioned around the first set of wedges 340 to sandwich the first set of wedges 340 between the first flange 330 and the first RTP pipe 310 , and the second flange 331 is positioned around the second set of wedges 341 to sandwich the second set of wedges 341 between the second flange 331 and the second RTP pipe 311 .

[0086] According to embodiments of the present disclosure, a flange can be slid onto the end of the RTP pipe (in an orientation suitable for the connection later around the RTR coupler) before the RTP pipe is tightly assembled into the coupler. By pre-installing the flange around the end of the RTP pipe, the flange can simply be slid into position around the connection of the coupler after the thermoplastic welding process. In other embodiments, the mechanical connection system can include flange segments or clamps that can be assembled and tightened around the end of the RTP pipe with or without wedges after the thermoplastic welding process.

[0087] Reference again Figure 8After the wedges 340, 341 are sandwiched between the RTP pipes 310, 311 and the flanges 330, 331, the flanges 330, 331 are pushed toward each other to tighten the wedges 340, 341 against the RTP pipes 310, 311 (via force transfer across the correspondingly inclined abutting surfaces between the wedges and the flanges). A series of connectors 350 (e.g., bolts, end caps, nuts, screws, etc.) are used to tighten the first flange 330 against the first side of the coupling body and the second flange 331 against the second side of the coupling body. For example, as shown, bolts are inserted through through-holes extending through the first flange 330, the annular body of the coupling 300, and the second flange 331, wherein nuts are tightened on the bolts to tighten the first and second flanges 330, 331 against the coupling 300. During tightening, the flanges 330, 331 exert radial pressure on the regularly spaced wedges 340, 341 (in the circumferential direction), thereby tightening the RTP pipe end around the coupling socket extension. According to embodiments of the present disclosure, the inner surface of the wedges can be designed to have a certain roughness to prevent slippage between the wedges and the RTP pipe.

[0088] Furthermore, in certain embodiments, assembling a mechanical connection system around the RTP pipe and coupler connection may include assembling one or more sealing components between the mechanical connection components. Figure 8 As shown in FIG, after the thermoplastic welding step cools and the coupler and RTP pipe are fully sealed, and after the thermoplastic welding equipment is removed, the mechanical connection system is established by assembling O-rings 360, 362 between flanges 330, 331 and the coupler / pipe connection. The O-rings can be assembled around the connected RTP pipe before the RTP pipe is tightly assembled to the coupler. In other embodiments, different types of sealing components (e.g., sealing compounds) can be assembled around the RTP pipe after the RTP pipe is tightly assembled to the coupler. The sealing components can be used to prevent external fluids from entering the RTP structure.

[0089] exist Figure 8 In the embodiment of FIG, pipe O-ring 360 is assembled around the RTP pipes 310, 311 before the RTP pipes 310, 311 are tightly assembled into the coupling 300. After the thermoplastic welding step, pipe O-ring 360 is then sandwiched between the flanges 330, 331 and the outer surfaces of the RTP pipes 310, 311 to seal the interface between the flanges 330, 331 and the RTP pipes 310, 311. In some embodiments, the pipe O-ring can be pre-assembled to the inner surface of the flange.

[0090] In addition, Figure 8In the embodiment of FIG. 5 , the coupling O-ring 362 is assembled around the RTP pipes 310, 311 or around the coupling 300 before the RTP pipes 310, 311 are tightly assembled to the coupling 300. After the thermoplastic welding step, the coupling O-ring 362 is then sandwiched between the flanges 330, 331 and the body of the coupling 300 to seal the interface between the flanges 330, 331 and the coupling 300. In some embodiments, the coupling O-ring can be pre-assembled to the coupling. In some embodiments, the coupling O-ring can be pre-assembled to the coupling. Figure 8 The connector 350 in FIG. 1 is radially inwardly positioned around the connector to seal the interface between the connector and the flange to prevent potential fluid ingress through the flange connector.

[0091] According to embodiments of the present disclosure, the coupling / pipe connection can be reversible, for example, for pipe repair or for reuse of the coupling or RTP pipe. The coupling / pipe connection can be disconnected by first disassembling any mechanical connection system surrounding the coupling / pipe connection and then heating the coupling / pipe connection until the thermoplastic weld between the RTP pipe and the coupling melts, at which point the RTP pipe and coupling can be pulled apart.

[0092] For example, Figure 8 The coupling / pipe connection shown in FIG can be disconnected by first removing the flanges 330, 331 (by disconnecting the connector 350) and the wedges 340, 341 from the connection. Heat can then be applied around the ends of the RTP pipes 310, 311 to unweld the thermoplastic weld (e.g., using the same induction welding system used to make the thermoplastic weld or a different heating system). The ends of the RTP pipes 310, 311 can then be removed from the pipe base extension of the coupling 300. After disassembly, the coupling can be reused for the same purpose, or the thermoplastic bonding layer can be removed / machined and a new thermoplastic bonding layer can be deposited again.

[0093] Embodiments of the present disclosure may provide at least one of the following advantages.

[0094] Traditional metal RTP joints have good strength properties but eventually corrode, resulting in additional maintenance costs, and their sealing performance often relies on O-rings, which require regular maintenance. Traditional non-metallic RTP joints can exhibit good sealing properties but are limited in pressure resistance due to the inherent mechanical and durability weaknesses of common thermoplastic materials. Alternatively, traditional non-metallic RTP joints can exhibit good mechanical properties when relying on fiber-reinforced thermoset connectors, but their sealing capabilities are limited by their reliance on O-rings.

[0095] In contrast to the limitations of conventional RTP pipe connections, the embodiments disclosed herein can provide optimal sealing performance due to a fully thermoplastic circumferential seal achieved sequentially from friction welding (thermoplastic bonding layer to thermoset coupling) and thermoplastic welding (thermoplastic bonding layer to RTP pipe). The embodiments disclosed herein can also provide optimal mechanical performance because structural loads can be transferred through the thermoplastic interlayer between the RTR coupling and the RTP pipe liner and between the mechanical connection system (e.g., through a wedge assembled around the outer jacket of the RTP pipe). The fiber-reinforced thermoset (RTR) material of the RTR coupling can be designed to have sufficient strength to transfer axial loads.

[0096] Embodiments of the present disclosure may also reduce or eliminate the risk of corrosion because the internal fluid flowing through the flow path formed through the RTP pipe and the coupling does not come into contact with any metal parts. Furthermore, in embodiments utilizing a mechanical connection system made with one or more or all non-metallic parts (e.g., RTR flanges, RTR wedges, etc.), the risk of corrosion around the exterior of the RTP pipe connection may also be reduced or eliminated.

[0097] Furthermore, by using a connection system according to embodiments of the present disclosure, the coupling can be easily removed by heating, for example, for maintenance purposes or reuse.

[0098] Although only a few exemplary embodiments have been described in detail above, it will be readily apparent to those skilled in the art that many modifications are possible in the exemplary embodiments without departing substantially from the present invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims.

Claims

1. A connection system comprising: a first conduit having a first end; a reinforced thermosetting resin (RTR) coupling positioned adjacent the first end of the first conduit, the RTR coupling comprising: an annular body having a first socket extension extending into the first end of the first conduit; and a first thermoplastic bonding layer disposed between the first tube base extension and the first end portion of the first tube; a first set of wedges positioned circumferentially around an outer surface of the first end of the first pipe; and A first flange is assembled around the first set of wedges, wherein the first set of wedges are wedged between the first end and the first flange.

2. The system of claim 1 , wherein the annular body of the RTR coupling includes a radial extension extending in a direction perpendicular to the first header extension, wherein the first flange is connected to the radial extension of the RTR coupling by at least one connector.

3. The system of claim 1 or 2, wherein the first set of wedges and the first flange are non-metallic.

4. The system of any one of claims 1 to 3, wherein the first pipe comprises an inner liner made of a thermoplastic material, and wherein the first thermoplastic bonding layer is made of the thermoplastic material of the inner liner.

5. The system of any one of claims 1 to 4, wherein the first thermoplastic bonding layer comprises a susceptor material.

6. The system according to any one of claims 1 to 5, further comprising: a second pipe having a second end, wherein the second end is mounted on a second pipe seat extension of the annular body of the RTR coupler; a second thermoplastic bonding layer disposed between the second tube base extension and the second end portion of the second tube; a second set of wedges positioned circumferentially about the outer surface of the second end portion of the second conduit; and A second flange is assembled around the second set of wedges, wherein the second set of wedges are wedged between the second end and the second flange.

7. The system of claim 6, wherein the annular body of the RTR coupling forms an intersection between a plurality of branching flow paths, wherein: A first flow path is formed through the first tube base extension, A second flow path is formed through the second base extension, and Additional flow paths are formed through additional branches of the annular body.

8. The system of any one of claims 1 to 7, wherein the second side of the annular body is connected to an equipment connection to provide a terminal connection for the first conduit.

9. The system of any one of claims 1 to 8, further comprising a drain port extending through the first flange, wherein the drain port fluidly connects an exterior of the first flange and an interface between the first flange and the annular body.

10. A method comprising: A reinforced thermosetting resin (RTR) coupling is provided, the RTR coupling comprising: an annular body having a first tube seat extension, wherein said first socket extension comprises a coupler thermoplastic material disposed about an outer surface; fitting a first end of a first conduit about the first header extension, wherein the first conduit has an inner surface formed from a conduit thermoplastic material; and Heat is applied to the assembled first end portion to thermoplastically weld the inner surface of the first end portion to the coupler thermoplastic material of the first header extension.

11. The method according to claim 10, further comprising: After applying heat: assembling a first set of wedges circumferentially around an outer surface of the first end portion; positioning a first flange about the first set of wedges to sandwich the first set of wedges between the first flange and the first end of the first pipe; and The first flange is secured against a first side of the annular body.

12. The method according to claim 11, further comprising: removing the first flange and the first set of wedges from the RTR coupling; applying heat around the first end of the first pipe to desolder the thermoplastic weld; and The first end of the first pipe is removed from the first socket extension of the RTR coupler.

13. The method of any one of claims 10 to 12, wherein the coupler thermoplastic material comprises a joining thermoplastic material and a susceptor material, and applying heat comprises: positioning an induction coil around the first end; sending an electric current through the induction coil to generate a magnetic field across the first end portion and induce electrical heating of the susceptor material; A heated susceptor material is used to melt and bond the joining thermoplastic material and the tubing thermoplastic material of the inner surface of the first end portion.

14. The method of any one of claims 10 to 12, wherein providing the RTR coupling comprises: Integrally forming the annular body and the first header extension into a single body of RTR material; and A joining thermoplastic is friction welded around the outer surface of the first header extension to form the coupler thermoplastic.

15. A connecting device comprising: The annular body comprises: an inner surface defining an inner diameter of the annular body; a first radial extension extending a radial distance from the inner surface; a first header extension extending axially from a first side of the first radial extension; and a first thermoplastic bonding layer bonded around an outer surface of the first header extension; wherein the first thermoplastic bonding layer comprises a thermoplastic material and a susceptor material, and The annular body is formed of reinforced thermosetting resin (RTR) material. 16 . The connection device of claim 15 , wherein the first socket extension has a tapered thickness from an inner end proximate to the first radially extending portion to an outer end distal to the first radially extending portion.

17. The connection device according to claim 15 or 16, wherein the annular body further comprises a second socket extension portion extending axially from a second side of the first radial extension portion.

18. A connection device according to claim 15 or 16, wherein the annular body is formed at an intersection between multiple branch flow paths, wherein a first flow path is formed through the first tube seat extension, a second flow path is formed through a second tube seat extension extending from a second radial extension of the annular body, and additional flow paths are formed through additional branches of the annular body.

19. The connecting device according to claim 15 or 16, wherein the annular body further comprises: a second radial extension formed at a second end of the annular body; and A direction turning portion is provided between the first radially extending portion and the second radially extending portion.

20. The connection device according to any one of claims 15 to 19, wherein the first radially extending portion further comprises a terminal connection side opposite the first side, the terminal connection side being a flat surface.

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