Cutter for flexible pipe, method of cutting flexble pipe and method for recycling flexible pipe

Abstract

A method for recycling flexible body, apparatus for repeatedly separating lengths of flexible pipe body for subsequent recycling material from the flexible pipe body, and a method of providing a plurality of separated sections, as separated lengths, of flexible pipe body are disclosed. The method comprises: providing flexible pipe body to an input guide location, urging flexible pipe body from the input guide location to a separation location proximate to a separator member, via the separator member providing separated lengths of flexible pipe body by separating a free end region of incoming flexible pipe body from a remainder portion of the flexible pipe body, and locating at least one separated length of flexible pipe body at a collection location.

Description

[0001] CUTTER AND CUTTING

[0002] The present invention relates to a method and apparatus for automatically recycling pipe body. In particular, but not exclusively, the present invention relates to automated processing of a continuous length of perused flexible pipe body to form shorter standardised individual lengths of flexible pipe body that can be used in a recycling process.

[0003] Traditionally long lengths of pipes are used to transport fluids for a range of different applications across a range of technical fields. For example, flexible pipe is utilised to transport production fluids, such as oil and / or gas and / or water, from one location (such as a Christmas tree at a wellhead) to another location (such as a subsea or topside device). Flexible pipe is particularly useful in connecting a sub-sea location (which may be deep underwater, say 1000 metres or more) to a sea level location. The pipe may have an internal diameter of typically up to around 0.6 metres (e.g. diameters may range from 0.05 m up to 0.6 m). A flexible pipe is generally formed as an assembly of flexible pipe body and one or more end fittings. The pipe body is typically formed as a combination of layered materials that form a pressurecontaining conduit. The pipe structure allows large deflections without causing bending stresses that impair the pipe’s functionality over its lifetime.

[0004] There are different types of flexible pipe such as unbonded flexible pipe, which is manufactured in accordance with American Petroleum Institute (API) Specification 17J; bonded flexible pipe; non-metallic flexible pipe, which may be manufactured in accordance with API 15S; and the like. Examples of types of non-metallic flexible pipe include Reinforced Thermoplastic Pipe (RTP), Thermoplastic Composite Pipe (TCP), and the like. Pipe body is generally built up as a combined structure including polymer layers and / or composite layers and / or metallic layers. For example, pipe body may include polymer and metal layers, or polymer and composite layers, or polymer, metal and composite layers. Layers may be formed from a single piece such as an extruded tube or by helically winding one or more wires at a desired pitch or by connecting together multiple discrete hoops that are arranged concentrically side-by-side. Depending upon the layers of the flexible pipe used and the type of flexible pipe some of the pipe layers may be bonded together or remain unbonded.

[0005] When flexible pipes are no longer needed in the field, they are sometimes recovered and redeployed in other fields I oil wells. However, eventually flexible pipes reach their end-of-life state. At this point it is no longer economical or advisable to reuse the flexible pipe further andthey are decommissioned. As a result, tens of thousands of tonnes of end-of-life flexible pipe will be disposed of each year, typically either as waste or for recycling.

[0006] The potential for recycling flexible pipe is still being explored. Conventionally the process of recycling reels of flexible pipe is labour intensive and time consuming. This is compounded by the considerable length of a flexible pipe and its multi-component and / or multi-material structure. Processing flexible pipes for recycling takes worker hours and expensive machinery away from other important tasks. This reduces the viability of recycling flexible pipe which is undesirable. At the same time, more flexible pipe is being disposed each year. There is thus a need for improved processes and machinery to fully realise the potential for safely and efficiently recycling flexible pipes including the flexible pipe body itself.

[0007] One approach for cutting flexible pipe body is performed using a tool such as a band-saw or high speed rotating saw or abrasive disc (examples of which would be types of Stihl saw). Tools may be hand-held devices (as may be the case with Stihl saws). A human operator may be put at risk when operating equipment in close proximity to the location where the cutting operations are taking place. There is therefore also a need to find safe apparatus and a method to handle and separate lengths of pipe body after they have been in hydrocarbon operation.

[0008] It is an aim of the present invention to at least partly mitigate one or more of the above-mentioned problems.

[0009] It is an aim of certain embodiments of the present invention to simplify the recycling process for flexible pipe body.

[0010] It is an aim of certain embodiments of the present invention to provide apparatus for automating at least part of the recycling process for flexible pipe body.

[0011] It is an aim of certain embodiments of the present invention to reduce the labour and capital requirements for recycling flexible pipe body.

[0012] It is an aim of certain embodiments of the present invention to provide apparatus and a method for increasing the viability of recycling flexible pipe body. Non-metallic flexible pipe in particular is in some instances completely recyclable.It is an aim of certain embodiments of the present invention to provide apparatus and a method for increasing safety when cutting decomissioned flexible pipe body into a plurality of lengths after it has been in operation and contains hydrocarbon residues.

[0013] It is an aim of certain embodiments of the present invention to provide apparatus for separating a segment of flexible pipe body into a plurality of lengths that can be more easily recycled. For example, the individual lengths can be drained of any left-over bore fluid and more manageably deconstructed into their constituent parts.

[0014] It is an aim of certain embodiments of the present invention to provide a method for decommissioning flexible pipe body that reduces the duration of time that any worker is in the “firing line” - where there is a risk of injury.

[0015] It is an aim of certain embodiments of the present invention to provide a method for decommissioning flexible pipe body that standardises output recyclable material.

[0016] According to a first aspect of the present invention there is provided a method for recycling flexible pipe body, comprising the steps of:

[0017] providing flexible pipe body to an input guide location;

[0018] urging flexible pipe body from the input guide location to a separation location proximate to a separator member;

[0019] via the separator member, providing separated lengths of flexible pipe body by separating a free end region of incoming flexible pipe body from a remainder portion of the flexible pipe body; and

[0020] locating at least one separated length of flexible pipe body at a collection location.

[0021] Aptly the method further comprises:

[0022] recycling at least one material of at least one layer of the flexible pipe body via performing at least one processing step continuously or repeatedly or batch-by-batch on a separated length subsequent to collection of the separated length at the collection location.

[0023] Aptly the method further comprises:

[0024] providing flexible pipe body comprises urging a free end region of flexible pipe body that is wound on a reel member, away from the reel member to the input guide location.

[0025] Aptly the method further comprises:urging the flexible pipe body comprises feeding the free end region into a caterpuller station that comprises at least one pair of opposed drive rollers; and

[0026] via the pair of drive rollers, pulling the flexible pipe body from a reel member through the caterpuller station and pushing a terminal section comprising a free end region of the flexible pipe body past the separation location proximate to the separator member.

[0027] Aptly the method further comprises:

[0028] applying a predetermined compressive force via a pair of opposed rollers to an outer surface of the flexible pipe body wherein the predetermined compressive force is sufficient to permanently deform the flexible pipe body.

[0029] Aptly the method further comprises:

[0030] pulling the flexible pipe body and pushing the terminal section comprises applying a predetermined compressive force via the pair of drive rollers to an outer surface of a covered portion of the flexible pipe body and optionally wherein the predetermined compressive force is sufficient to permanently deform the covered portion.

[0031] Aptly the method further comprises:

[0032] permanently deforming the flexible pipe body comprises providing the predetermined compressive force with sufficient magnitude to reduce a radius of the outer surface of flexible pipe body in a single axis by 10% or optionally by 20%, or 30%, or 50%, or 75%, or 90%.

[0033] Aptly the method further comprises:

[0034] the separator member comprises a hydraulic cutter or guillotine or saw and the separator member is operable to slice through the flexible pipe body in a plane orthogonal or oblique to an axial direction of motion associated with the lengthwise motion of the flexible pipe body thereby separating the free end region of the flexible pipe body from the remainder portion of the flexible pipe body.

[0035] Aptly the method further comprises:

[0036] locating at least one separated length comprises one-by-one, locating a plurality of separated lengths each having a common axial length, in a stacked formation.

[0037] Aptly the method further comprises:

[0038] tipping a plurality of separated lengths subsequent to separation of the separated lengths from a remainder of the flexible pipe body thereby draining remnants of previously transported material from a lower open end of the tipped separated lengths.Aptly the method further comprises:

[0039] continuously and automatically and one-by-one urging a predetermined length of the flexible pipe body past the separator member in an in-line process and repeatedly separating a presented end region of incoming flexible pipe body from a remainder portion of the flexible pipe body and optionally pausing inline motion of flexible pipe body during a separation step during which a length of flexible pipe body is separated.

[0040] Aptly the method further comprises:

[0041] providing the flexible pipe body, as a segment of pre-used flexible pipe body decommissioned from a previously used pipeline or flow line or riser, on a reel member.

[0042] Aptly the method further comprises:

[0043] urging the flexible pipe body along a straight travel pathway between the input guide location, the separation location and the collection location.

[0044] Aptly the method further comprises:

[0045] the flexible pipe body is a segment of flexible pipe body from a decommissioned pipeline or flow line or umbilical or riser.

[0046] Aptly the method further comprises:

[0047] removing at least one end fitting from a terminal end region of the flexible pipe body prior to winding the decommissioned flexible pipe body onto a reel member or urging the free end region of incoming flexible pipe body from the reel member to the input guide location prior to winding the decommissioned flexible pipe body onto the reel member.

[0048] Aptly the method further comprises:

[0049] flushing and or cleaning at least a bore region of each separated length of flexible pipe body subsequent to locating separated lengths at the collection location and optionally subsequent to transferring separated lengths from the collection location to a storage location or a treatment location.

[0050] According to a second aspect of the present invention there is provided apparatus for repeatedly separating lengths of a segment of flexible pipe body for subsequently recycling material from the flexible pipe body, comprising:an input guide member for providing an inlet, that comprises at least one guide surface, through which a segment of flexible pipe body is locatable in a lengthwise configuration;

[0051] an urging member for urging the flexible pipe body in a lengthwise direction from the inlet towards a collection location;

[0052] a separator member disposed in a travel pathway of the flexible pipe body between the urging member and the collection location and disposable to separate a presented free end region of the flexible pipe body from a remainder of the flexible pipe body; and

[0053] a gathering member, disposed at the collection location, that comprises a separated length support surface.

[0054] Aptly, the separator member comprises a guillotine or saw or hydraulic cutter, comprising a pair of jaw elements, disposed to create a slice through the flexible pipe body in a plane orthogonal to a primary drive axis along which the flexible pipe body is urged in a lengthwise orientation.

[0055] Aptly, the urging member comprises a caterpuller station that includes at least one pair of opposed drive rollers that are selectively rotatable to pull flexible pipe body disposed between outer drive surfaces of the rollers from a reel member and towards a collection location in a lengthwise direction.

[0056] Aptly, the gathering member comprises at least one hydraulic ram for selectively urging the separated length support surface between a collection position and a storage position.

[0057] Aptly, at least the urging member and separator member and gathering member are disposed in an in-line orientation whereby flexible pipe body is urgeable lengthwise in a straight pathway from the urging member to the gathering member support.

[0058] According to a third aspect of the present invention there is provided a method of providing a plurality of separated sections, as separated lengths, of flexible pipe body, comprising steps of:

[0059] providing a segment of flexible pipe body, that has an overall length of greater than 50m, lengthwise to an inlet guide member;

[0060] via an urging member, urging a free end region of the flexible pipe body towards a collection position;via a separator member, separating the free end region, comprising a section of the flexible pipe body having a section length greater than 1m, from a remainder of the flexible pipe body with the free end region located at the collection location;

[0061] repeatedly separating separated sections of flexible pipe body via the separator member; and

[0062] repeatedly transferring separated sections at a collection location to a storage location.

[0063] Aptly the method further comprises:

[0064] repeatedly and continuously and automatically urging flexible pipe body from a reel member through a caterpuller station that pulls flexible pipe body from the reel member; via the caterpuller station, presenting a presented free end region of the flexible pipe body beyond a separation point associated with the separator member;

[0065] pausing inline motion of flexible pipe body whilst the separation member separates a separated length from a remainder portion of the flexible pipe body; and

[0066] subsequent to separating a separated length recommencing inline motion to present a further presented free end region for separation.

[0067] Certain embodiments of the present invention provide a method for continuously processing flexible pipe body that is quicker at accumulating small lengths of flexible pipe body from a reel of flexible pipe body compared to conventional techniques.

[0068] Certain embodiments of the present invention provide apparatus for safely separating lengths of flexible pipe body after it has been in operation and contains hydrocarbon residues. This may be achieved by helping to ensure separation operations do not generate sparks which could ignite hydrocarbon gases removes - or at least reduces - the risk of a fire during decommissioning operations.

[0069] Certain embodiments of the present invention provide a controllable process for repeatedly separating lengths of a segment of flexible pipe body. Having predetermined input and output locations enables the process to be easily integrated into a larger decommissioning operation.

[0070] Certain embodiments of the present invention provide apparatus that simplifies the recycling process for flexible pipe body by automating certain steps.

[0071] Certain embodiments of the present invention provide a method that reduces the labour and capital requirements for recycling flexible pipe body. This increases the viability of recyclingflexible pipe body. Previously-deemed unrecyclable flexible pipe body may be considered recyclable once the method is implemented.

[0072] Certain embodiments of the present invention provide apparatus for separating a segment of flexible pipe body into a plurality of lengths that can be more easily recycled. For example, the individual lengths can be drained of any left-over bore fluid and more manageably deconstructed into their constituent parts.

[0073] Certain embodiments of the present invention provide a method for recycling flexible pipe body that produces standard lengths of flexible pipe body that can be processed further. Introducing standard lengths of recyclable material increases the potential for further automation in the recycling operation.

[0074] Certain embodiments of the present invention provide a method for decommissioning flexible pipe body that reduces the duration of time that any worker is in the “firing line” - where there is a risk of injury.

[0075] Embodiments of the present invention will now be described hereinafter, by way of example only, with reference to the accompanying drawings in which:

[0076] Figure 1 illustrates flexible pipe body;

[0077] Figure 2 illustrates certain uses of flexible pipe body;

[0078] Figure 3A illustrates a plan view of a flexible pipe separating process;

[0079] Figure 3B illustrates a side view of the flexible pipe separating process;

[0080] Figure 4 illustrates a caterpuller location;

[0081] Figure 5 illustrates a separation location;

[0082] Figure 6 illustrates part of a collection location;

[0083] Figure 7 illustrates a collection location;

[0084] Figures 8A-D illustrate a flexible pipe recycling process;Figure 9 illustrates an alternative collection location; and

[0085] Figure 10 illustrates reinforced thermoplastic pipe.

[0086] In the drawings like reference numerals refer to like parts.

[0087] Throughout this description, reference will be made to a flexible pipe. It is to be appreciated that certain embodiments of the present invention are applicable to use with a wide variety of flexible pipe. For example certain embodiments of the present invention can be used with respect to flexible pipe body and / or associated end fittings of the type which is manufactured according to American Petroleum Institute (API) 17J. Such flexible pipe is often referred to as unbonded flexible pipe. Other embodiments are associated with other types of flexible pipe, such as non-metallic flexible pipe, which includes reinforced thermoplastic pipe (RTP), thermoplastic composite pipe (TCP), and the like.

[0088] It will be understood that the illustrated flexible pipes are an assembly of a portion of flexible 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 illustrates how pipe body 100 containing a central bore 105 is formed from a combination of layered materials that form a pressure-containing conduit. Although a number of particular layers are illustrated in Figure 1, it is to be understood that certain examples are broadly applicable to coaxial pipe body structures including two or more layers manufactured from a variety of possible materials. Pipe body may include one or more layers containing composite materials, forming a tubular composite layer. It is to be further noted that the layer thicknesses are shown for illustrative purposes only. As used herein, the term “composite” is used to broadly refer to a material that is formed from two or more different materials, for example a material formed from a matrix material and reinforcement fibres.

[0089] A tubular composite layer is thus a layer having a generally tubular shape formed of composite material. Alternatively, a tubular composite layer is a layer having a generally tubular shape formed from multiple components one or more of which is 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 by a winding process in which adjacent windings of tape which themselves have a composite structure are consolidated together with adjacent windings. The composite material, regardless of manufacturing technique used, may optionally include a matrix or body of material having a first characteristic in which further elements having different physical characteristics are embedded. That is to say elongate fibreswhich are aligned to some extent or smaller fibres randomly orientated can be set into a main body or spheres or other regular or irregular shaped particles can be embedded in a matrix material, or a combination of more than one of the above. Aptly the matrix material is a thermoplastic material, aptly the thermoplastic material is polyethylene or polypropylene or nylon or PVC or PVDF or PFA or PEEK or PTFE or alloys of such materials with reinforcing fibres manufactured from one or more of glass, ceramic, basalt, carbon, carbon nanotubes, polyester, nylon, aramid, steel, nickel alloy, titanium alloy, aluminium alloy or the like or fillers manufactured from glass, ceramic, carbon, graphene, metals, buckminsterfullerenes, metal silicates, carbides, carbonates, oxides or the like.

[0090] The pipe body 100 illustrated in Figure 1 includes an internal pressure sheath 110 which acts as a fluid retaining layer and has a polymer layer that ensures internal fluid integrity. The layer provides a boundary for any conveyed (bore) fluid that passes through the bore 105. It is to be understood that this layer may itself comprise a number of sub-layers. It will be appreciated that when a carcass layer 120 is utilised the internal pressure sheath is often referred to by those skilled in the art as a barrier layer. In operation without such a carcass (so-called smooth bore operation) the internal pressure sheath may be referred to as a liner. A barrier layer 110 is illustrated in Figure 1.

[0091] It is noted that a carcass layer 120 is a pressure resistant layer that provides an interlocked construction that can be used as the innermost layer to prevent, totally or partially, collapse of the internal pressure sheath 110 due to pipe decompression, external pressure, and tensile armour pressure and mechanical crushing loads. The carcass is a crush resistant layer. It will be appreciated that certain examples are thus applicable to ‘rough bore’ applications (with a carcass). Aptly the carcass layer is a metallic layer. Aptly the carcass layer is formed from stainless steel, corrosion resistant nickel alloy or the like. The carcass layer is radially positioned within the barrier layer.

[0092] The carcass layer is a “layer” in the sense that a radially innermost and outermost surface are created in single pass at a single manufacturing node. The single manufacturing node may include multiple tape handling sections axially close together so that they are effectively a single node. The node aptly extends over an axial distance of less than 2.5m. Aptly the node has a length of 1m or less. Manufacture of the carcass layer will be discussed in more detail hereinbelow.

[0093] The pipe body includes a pressure armour layer 130 that is a pressure resistant layer that provides a structural layer that increases the resistance of the flexible pipe to internal andexternal pressure and mechanical crushing loads. The layer also structurally supports the internal pressure sheath. Aptly as illustrated in Figure 1 the pressure armour layer is formed as a tubular layer. Aptly for unbonded type flexible pipe the pressure armour layer which provides an interlocked construction of wires with a lay angle close to 90°. Aptly in this case the pressure armour layer is a metallic layer. Aptly the pressure armour layer is formed from carbon steel, aluminium alloy, stainless steel or the like. Aptly the pressure armour layer is formed from a pultruded composite interlocking layer. Aptly the pressure armour layer is formed from a composite formed by extrusion or pultrusion or deposition. A pressure armour layer is positioned radially outside an underlying barrier layer.

[0094] The flexible pipe body also includes a first tensile armour layer 140 and a second tensile armour layer 150. Each tensile armour layer is used to sustain tensile loads and optionally also internal pressure. Aptly for some flexible pipes the tensile armour windings are metal (for example steel, stainless steel or titanium or the like). For some composite flexible pipes the tensile armour windings may be polymer composite tape windings (for example provided with either thermoplastic, for instance nylon, matrix composite or thermoset, for instance epoxy, matrix composite). For unbonded flexible pipe the tensile armour layer is formed from a plurality of wires (to impart strength to the layer) that are located over an inner layer and are helically wound along the length of the pipe at a lay angle typically between about 10° to 55°. Aptly the tensile armour layers are counter-wound in pairs. Aptly the tensile armour layers are metallic layers. Aptly the tensile armour layers are formed from carbon steel, stainless steel, titanium alloy, aluminium alloy or the like. Aptly the tensile armour layers are formed from a composite, polymer, or other material, or a combination of materials.

[0095] Aptly the flexible pipe body includes optional layers of tape 160 which help contain underlying layers and to some extent prevent abrasion between adjacent layers. A tape layer may optionally be a polymer or composite or a combination of materials, also optionally comprising a tubular composite layer. Tape layers can be used to help prevent metal-to-metal contact to help prevent wear. Tape layers over tensile armours can also help prevent “birdcaging” of the tensile armour wires.

[0096] The flexible pipe body also includes optional layers of insulation 165 and an outer sheath 170, which comprises a polymer layer used to protect the pipe against penetration of seawater and other external environments, corrosion, abrasion and mechanical damage. Any thermal insulation layer helps limit heat loss through the pipe wall to the surrounding environment. An annulus region 180 is defined as the space between the internal pressure sheath 110 and the outer sheath 170. In other words, in the flexible pipe body illustrated in Figure 1, the pressurearmour layer 130, the first tensile armour layer 140, the further tensile armour layer 150, the optional layers of tape 160, and the optional layers of insulation 165 are located in the annulus region 180. The flexible pipe body has an outer surface 185 provided by an outer surface of the outer sheath 170. It will be appreciated that alternatively, the annulus region 180 may contain any or none of the layers present in the flexible pipe body illustrated in Figure 1.

[0097] Figure 2 illustrates a riser assembly 200 suitable for transporting production fluid such as oil and / or gas and / or water from a sub-sea location 221 to a floating facility 222. Aptly production fluid may refer to the product of a subsea well outputted at high pressure via a wellhead. In Figure 2 the sub-sea location 221 includes a sub-sea flow line 225. The flexible flow line 225 comprises a flexible pipe, wholly or in part, resting on the sea floor 230 or buried below the sea floor and used in a static application. The floating facility may be provided by a platform and / or buoy or, as illustrated in Figure 2, a ship. The riser assembly 200 is provided as a flexible riser composing three flexible pipes 240 connecting the ship to the sea floor installation.

[0098] Each flexible pipe 240 has a segment of the flexible pipe body 100 terminated at each end by respective end fittings 245. The end fittings 245 are joined end to end providing an uninterrupted path for bore fluid to be transported along. Aptly each flexible pipe includes at least one portion, referred to as a segment or section, of pipe body 100 together with the end fitting 245 located at at least one end of the flexible pipe. A respective end fitting 245 may be used to terminate each end of the flexible pipe body 100. The end fitting 245 may be a mechanical device that forms the transition between the flexible pipe body and a connector. The different pipe layers as shown, for example, in Figure 1 are terminated in the end fitting in such a way as to transfer the load between the flexible pipe and the connector.

[0099] It will be appreciated that there are different types of riser, as is well-known by those skilled in the art. In some instances the invention may be used with any type of riser, such as a freely suspended (free-hanging, catenary riser), a riser restrained to some extent (buoys, chains), totally restrained riser or enclosed in a tube (I or J tubes). Some, though not all, examples of such configurations can be found in API 17J. Figure 2 also illustrates how portions of flexible pipe can be utilised as a jumper 250.

[0100] Figures 3A and 3B provide a diagrammatic overview of a flexible pipe separating plant 300 and process. The plant 300 illustrated therein may be used for repeatedly separating lengths of a segment of flexible pipe body 100 for subsequently recycling material from the flexible pipe body 100. In Figure 3A, a plan view of the plant 300 is illustrated whilst Figure 3Billustrates a side view 301 (looking upwards in reference to Figure 3A). It will be appreciated that whilst Figures 3A and 3B are described in relation to one type of flexible pipe body 100, they may equally be applied to any type of flexible pipe body with the necessary adjustments as desired. The plant is provided by multiple stations each carrying out a respective process / step and arranged in order for an inline process. The plant maybe distributed wholly within a building or be set out in an outside site or partially undercover. The plant and the various machines of the inline stations provide apparatus for continuously unwinding flexible pipe body from a spool and chopping the longer length into shorter more manageable lengths. Aptly the process is automated in the sense that once started little human interaction is needed during the process of separating the whole length of flexible pipe body on a reel into many shorter lengths.

[0101] A segment of flexible pipe body 100 is held on a spool 305 before being fed along a straight travel pathway 310 initially in a leftwards operation direction 315 (as illustrated in Figures 3A and 3B) during which time the segment of flexible pipe body 100 is separated into a number of separated lengths 320I,2 of flexible pipe body 100 (two shown). The spool 305 is an example of a reel member. The spool 305 contains a segment of flexible pipe body 100. The segment of flexible pipe body 100 may be provided by a flexible pipe 240 once the end fitting(s) 245 have been removed. The spool 305 shown in Figure 3A holds 500m of flexible pipe body 100, although alternatively a full spool may hold between 100m and 2000m or more of flexible pipe body 100. The straight travel pathway 310 is an example of a primary drive axis along which the flexible pipe body 100 is urged in a lengthwise direction. Optionally the straight pathways may include gently curved regions (less than 5 degrees of change per metre). Also optionally the straight pathway is linear in the vertical and / or horizontal plane.

[0102] During its journey the flexible pipe body 100 passes a caterpuller location 325 followed by a separation location 330 and eventually, as a series of separated lengths 320, a collection location 335. Flexible pipe body 100 is urged from the spool 305 to the caterpuller location 325 via a cylindrical peg 340 at an input guide location 342. The cylindrical peg 340 is an example of an input guide member 340. The cylindrical peg 340 has a cylindrical guide surface 344 for directing flexible pipe body 100 towards the input guide location 342 of a caterpuller station 345, as the flexible pipe body 100 leaves the spool 305. Aptly the guide surface 344 may be flat, curved, grooved, or the like. The input guide location 342 helps to direct flexible pipe body 100 as it is unravelled from the spool 305 towards the caterpuller station 345. It will be appreciated that alternatively the cylindrical peg 340 may be replaced by a Y-shaped guide or another type of input guide member that can direct the path of flexible pipe body 100.The caterpuller station 345 shown in Figure 3 has three pairs of spaced-apart opposed drive rollers 350I-6 that urge flexible pipe body 100 along the straight travel pathway (drive axis) 310. The drive rollers 350 are orientated vertically although they could alternatively have any orientation. Each pair of drive rollers 350 has a gap therebetween which is just about wide enough to accommodate the flexible pipe body 100 (possibly with some distortion). Aptly the caterpuller station 345 may have one, two, three, four or more pairs of opposed drive rollers 350. For each pair a roller may be driven and another idle or alternatively both opposed rollers of a pair are driven rollers. Each drive roller 350 has a curved drive surface 352 that contacts the outer surface of the flexible pipe body 100 at a covered portion 354. Aptly the covered portion 354 of flexible pipe body 100 is defined between each pair of opposed drive rollers 350. The flexible pipe body 100 is effectively gripped, by the drive surface 352, between each pair of opposed drive rollers 350. As the drive rollers 350 rotate - clockwise for the upper three drive rollers 350I,3,S and anticlockwise for the lower three drive rollers 3502,4,6 as illustrated in Figure 3A - flexible pipe body 100 is urged in the operation direction 315. Alternatively, the direction of rotation of the drive rollers 350 and / or the operation direction 315 may be different.

[0103] Part of the flexible pipe body 100 is thereby urged, as an incoming flexible pipe body section 355 towards a hydraulic cutter 360 in the separation location 330. The hydraulic cutter 360 is an example of a separator member. Other examples of a separator member include a bandsaw, guillotine, or the like. The incoming flexible pipe body section 355 bridges the gap between the caterpuller station 345 and the hydraulic cutter 360 and passes between a pair of opposed jaws comprising an upper jaw 365i and a lower jaw 3652 (as illustrated in Figure 3B).

[0104] Alternate separator members such as rotating abrasive cutting wheels, high speed circular saws or the like may be used. It will be appreciated that certain alternative separator members may however come with a greater risk of creating sparks as a result of the cutting processes which could ignite hydrocarbon residues in the pipe body and cause a fire. In circumstances where this may be potentially problematical, in respect of these alternative separator members, in order to prevent ignition sources the various locations of the apparatus may be connected to earth, and / or certified for use in explosive atmosphere (for instance via ATEX approval). The various locations may include in particular the separator member 360 and / or separation location 330. Ventilation systems may on occasion also be used to ensure fumes from fluids in the flexible pipe body are removed from the area around the equipment and away from operators.The incoming flexible pipe body section 355 rests on the lower jaw 3652 as it continues to be urged leftwards past a cutting plane 370 in the operation direction 315. The cutting plane 370 is perpendicular to the straight travel pathway 310 defined by the opposing jaws 365I,2. It will be appreciated that the cutting plane 370 could alternatively be at an oblique angle to the straight travel pathway 310.

[0105] It will be appreciated that alternative hydraulic cutter arrangements may be incorporated such as four-way cutter / shears. Aptly a force of up to 1200 tons force (11.8 meganewtons) may be used to separate large diameter pipe sections. It will be appreciated that smaller pipes generally require much less force to separate.

[0106] The flexible pipe body 100 continues to move in the same direction along the travel pathway 310 at which point it reaches the collection location 335. A rotating table 375 is aligned such that flexible pipe body 100 moving from the hydraulic cutter 360 along the travel pathway 310 reaches the longitudinal centreline of the rotating table 375. The rotating table 375 is an example of a gathering member. The rotating table is effectively a V-shaped (or L-shaped, II-shaped, or the like) bucket with a mount that allows it to pivot about an axis parallel to the travel pathway 310. Due to the shape of the rotating table, flexible pipe body 100 naturally falls towards the centre line of the rotating table 375 which helps to correctly position the flexible pipe body 100 for separation. The rotating table 375 is supported by a box frame 378 (see Figure 3B). Aptly the box frame 378 may be replaced by any supporting structure. Once a presented free end region 380 of the flexible pipe body 100 having longitudinal length equal to the separated length 320 has passed the cutting plane 370, the flexible pipe body 100 is ready to be separated. Aptly the presented free end region 380 may comprise a common axial length of flexible pipe body 100. Each separated length 320 has a common axial length of 4m. Aptly the common axial length may be between 0.5m and 10m or the like.

[0107] Aptly it will be appreciated that a desired common axial length may vary by a small amount due to the ability to control tolerances on the separated lengths, but each length will be nominally the same desired common axial length. Aptly each separated length 320 may have the same common axial length within a 2mm tolerance. Aptly the tolerance may be 4mm, 10mm, 25mm, 50mm, 100mm, or the like. Aptly the common axial length may be a common axial length tolerance range, for example 4000mm ± 1%, 10000mm ± 2%, 500mm ± 0.5%, or the like.

[0108] Next, progression of the flexible pipe body 100 is halted by the caterpuller station 345. The opposed drive rollers 350I-6 are no longer driven and may by locked in position. Thus thepresented free end region 380 is held at a collection position 381. The jaws 365I-2 of the hydraulic cutter 360 are operated to slice through the flexible pipe body 100 in the cutting plane 370. Aptly the cutting plane 370 is orthogonal (or alternatively oblique) to the straight travel pathway 310. Aptly the straight travel pathway 310 is in an axial direction of motion associated with the lengthwise motion of the flexible pipe body. Thus the presented free end region 380 is separated from a remainder portion of the flexible pipe body 100 producing a second separated length 3202.

[0109] In the present example, the rate of movement of flexible pipe body 100 along the straight travel pathway 310 is not constant. Instead, flexible pipe body 100 is drawn in the operation direction 315 by the caterpuller station 345 at a speed of about 0.5 m / s for a few seconds until the full presented end region 380 has passed the cutting plane 370 of the hydraulic cutter 360. Aptly the speed may be between 0.1 m / s and 20 m / s. Then the caterpuller station 345 halts motion of the flexible pipe body 100 for around a second, holding the presented end region 380 in place whilst the hydraulic cutter 360 slices through the flexible pipe body 100. Aptly an operating time interval and a stationary time interval during which flexible pipe body 100 is urged and then halted may be three seconds and one second respectively. Aptly the operating time interval may be between 1 and 20 seconds. Aptly the stationary time interval may be between 0.25 and 10 seconds. Aptly a computer may control operation of the drive rollers 350, hydraulic cutter 360 and rotating table 375.

[0110] An optional computer 383 may be used to control any powered mechanical elements of the flexible pipe separating plant 300, providing either fully automated or fully human controlled operation as desired. The computer 383 has a processor for executing lines of instruction stored on a hard drive (alternatively flash storage, cloud storage, or the like). Optionally one or more sensors may be used to coordinate the operation of mechanical elements of the flexible pipe separating plant 300. Optionally preset time intervals may be used to coordinate the operation of mechanical elements of the flexible pipe separating plant 300. Optionally each mechanical element (drive rollers 350, hydraulic cutter 360, rotating table 375 and the like) may be manually energised by a human operator.

[0111] As an illustration, an automated program for the flexible pipe separating plant 300 may proceed as outlined below. It will be appreciated that any combination of the steps may be used. Also any direction (e.g. clockwise or anticlockwise) can be reversed as desired. An optional HALT command may be issued at any time to temporarily pause the program, for example, whilst the separated lengths 320 are removed from the collection location 335.Additional sensors may alternatively be used to detect and automatically pause the program when no more separated lengths 320 can be added.

[0112] STEP 1 Opposed drive rollers 350 energised (i.e. actively driving)

[0113] STEP 2 Detected presented end region 380 has desired axial length STEP 3 Opposed drive rollers 350 de-energised (i.e. actively stopping motion) STEP 4 Hydraulic cutter 360 initiated (flexible pipe body 100 sliced)

[0114] STEP 5 Detected hydraulic cutter 360 has finished slicing

[0115] STEP 6 Rotating table 375 initiated - clockwise rotation

[0116] STEP 7 Detected rotating table 375 reached storage position

[0117] STEP 8 Rotating table 375 halted

[0118] STEP 9 Detected separated length 320 deposited from rotating table 375 STEP 10 Rotating table 375 initiated - anticlockwise rotation

[0119] STEP 11 Detected rotating table 375 reached collection position

[0120] STEP 12 Return to STEP 1

[0121] Lastly, after the second separated length 3202 has been formed, the rotating table 375 pivots about its axis, tipping the second separated length 3202 into a storage position 382, into which it may roll under the influence of gravity. Alternatively, a walking-beam arrangement may be incorporated to move and collate the separated lengths 320 in the storage position 382. The skilled person will appreciate that other separated length handling processes may be implemented instead. The storage position 382 has enough space to store 10 separated lengths 320. At the storage position 382 there are three holding frame arms 385I-3 joined roughly perpendicularly to three corresponding holding frame walls 390I-3 that each extend vertically (upwards in Figure 3A). The holding frame arms 385 are fixed together by a holding frame base 392 (as shown in Figure 3B). Aptly there may be two, three, four or more holding frame arms 385 and / or holding frame walls 390. Together the holding frame arms 385 and the holding frame walls 390 contain the separated lengths 320 in the storage position 382 until retrieval. Figure 3A illustrates how the separated length 320 is urged downwards in a holding direction 395.

[0122] Once the second separated length 3202 has been deposited in the storage position 382, the caterpuller station 345 resumes operation and flexible pipe body 100 begins to move again in the operation direction 315. The process repeats until the storage position 382 is full or the spool of flexible pipe body 100 has been completely separated into smaller sections. Optionally the caterpuller station 345 may be halted to enable separated lengths 320 of flexible pipe body 100 to be retrieved, for example, by a fork-lift truck.The following Figures 4-7 illustrate some aspects of the flexible pipe separating apparatus in more detail.

[0123] Figure 4 illustrates an isometric perspective of the caterpuller location 325. As discussed previously the caterpuller station 345 includes six opposed drive rollers 350I-6 (two illustrated), although there could alternatively be any number of drive rollers. The drive rollers 350 are supported on a guide frame 410 inside the caterpuller station 345. It will be appreciated that the guide frame 410 may have any structure suitable for holding the drive rollers 350 in position and withstanding the weight of flexible pipe body 100.

[0124] The guide frame 410 is attached to a base frame 420 which provides a rigid and stable supporting structure. Two idle (non-driven) rollers 430 are attached to the base frame 420 on opposite sides. The idle rollers 430 may support the majority of the weight of the flexible pipe body. The idle rollers 430 thereby help to make flexible pipe body 100 gripped by the drive rollers 350I-6 easier to move. As the drive rollers 350I-6 urge flexible pipe body 100 in the operation direction 315 (leftwards in Figure 4), the idle rollers 430 rotate freely about respective axes of rotation as flexible pipe body 100 passes over them. Aptly there may be zero, one, two, three, four or more idle rollers 430.

[0125] In use the drive rollers 350I-6 pull flexible pipe body 100 from the spool 305 and urge it along the travel pathway 310. The caterpuller station 345 thus facilitates the automated operation of the separation process by positioning the flexible pipe body 100 correctly in the separation location 330. Optionally one or more sensors may be installed to detect the position of the flexible pipe body 100 and thus determine when the drive rollers 350 should stop rotating so that the presented free end region of flexible pipe body can be sliced from the remaining segment. Aptly the drive rollers 350 apply a predetermined compressive urging force to the covered portion 354 of the outer surface 185 of the flexible pipe body 100. Aptly the curved outer surface 352 of the drive rollers 350 provide the predetermined compressive force on the covered portion 354. Aptly the curved outer surface 352 of the drive rollers 350 provide the predetermined compressive force on the outer surface 185 of the flexible pipe body 100. Aptly the predetermined compressive force causes the covered portion 354 of flexible pipe body 100 to deform elastically. Aptly the covered portion 354 is deformed non-permanently. Aptly the predetermined compressive force helps the drive rollers 350 to grip the outer surface 185 of the flexible pipe body 100 to urge the flexible pipe body 100.Alternatively, the caterpuller station 345 may provide drive rollers 350 which have their rotation axis orientated horizontally, so that the drive rollers are positioned vertically one above another, one below and one above when gripping the flexible pipe body 100.

[0126] As a further alternative, the drive rollers 350 may alternatively be set to apply a predetermined compressive force sufficient to crush the flexible pipe body 100 so that it is no longer circular in cross section but forms a flattened tube which may then be cut into separated lengths 320. In this case the separated lengths may not roll into the storage position 382 and may instead slide or be manipulated into the desired storage configuration. Aptly the drive rollers 350 apply the predetermined compressive force to the covered portion 354 of the flexible pipe body 100. Aptly the predetermined compressive force causes the covered portion 354 of flexible pipe body 100 to permanently deform. Aptly the magnitude of the predetermined compressive force is sufficient to deform the covered portion. Aptly permanently deforming the covered portion 354 causes a flattened tube flexible pipe body to be output from the caterpuller location 325. Aptly crushing flexible pipe body causing permanent deformation comprises providing a force to reduce the radius of flexible pipe body 100 in a single axis by 10%. Aptly the radius is reduced in a single axis by 20%, or 30%, or 50%, or 75%, or 90% or the like. Aptly by reducing the radius of flexible pipe body 100 in a single axis only, the axial cross-section of the flexible pipe body 100 is changed from a circle to an oval, non-circular ellipse, or the like. Aptly the flexible pipe body 100 may be crushed by opposed rollers. Aptly the flexible pipe body 100 may be crushed by opposed rollers that are not located in the caterpuller location 325.

[0127] In a further alternative embodiment, automatic strapping or securing mechanisms may collate, group and secure a plurality of separated lengths 320 at the storage position 382 to make them more easily lifted and taken to a recycling location for further processing.

[0128] Figure 5 illustrates an isometric perspective of the separation location 330 and in particular of the hydraulic cutter 360. Aptly the hydraulic cutter 360 may be replaced with a guillotine, saw, or the like. Aptly the hydraulic cutter 360 may be any device suitable for cutting through flexible pipe body. It will be appreciated that depending on the specification of the flexible pipe body, the capability of the hydraulic cutter 360 will vary. In the present example the hydraulic cutter 360 is able to cut pipe with a diameter of up to 16 inches (406 mm) and can apply up to around 200 kN (kilo newtons) of force. Aptly 10, 50, 100, 500 or more kN of force can be applied by the jaws 365 of the hydraulic cutter 360.

[0129] The upper jaw 365i is connected to the lower jaw 3652 of the hydraulic cutter 360 via a jaw pivot 510. The jaw pivot 510 has an axis of rotation that is parallel with the travel pathway 310.Aptly the axis of rotation of the jaw pivot 510 is oblique to the travel pathway 310. The upper jaw 365i has an upper jaw cutting surface 515 with a protruding cutting edge 520 that produces a cut in use. The lower jaw 3652 has an inset region 530 that can accommodate at least the upper jaw cutting surface 515. The incoming flexible pipe body section 355 is urged between the jaws 365 as illustrated in Figure 5.

[0130] When the hydraulic cutter 360 is operated, the upper jaw 365i is driven in a clockwise (generally downwards in Figure 5) direction about the jaw pivot 510 until it engages with the lower jaw 3652. The cutting edge 520 of the upper jaw 365i is driven through the flexible pipe body 100 with sufficient force to cut through the layers of pipe body. This produces a slice 540 through the flexible pipe body 100 in a plane orthogonal (or alternatively oblique) to the travel pathway 310. The travel pathway 310 is aligned with the longitudinal axis of the flexible pipe body 100 in a primary drive axis along which the flexible pipe body is urged in a lengthwise orientation.

[0131] One non-limiting example of a suitable hydraulic cutter is the AGF CS40RS which may be used for pipes up to around 10 inches in diameter. This cutter is designed for attachment onto a manipulator arm of a large plant vehicle; however, it may be adapted into use for this type of application.

[0132] Figure 6 illustrates part of the collection location 335 in a plane perpendicular to the travel pathway 310. That is to say the travel pathway 310 appears to pass out of the page in Figure 6. Flexible pipe body 100 is proceeding along the straight travel pathway 310 on the rotating table 375 until enough pipe body has passed the hydraulic cutter 360 for slicing to proceed. The rotating table 375 has a V-shaped bucket 610 having a separated length support surface 615. The bucket 610 is attached to a bucket pivot 620 allowing the bucket 610 is rotate freely. The axis of rotation of the bucket pivot 620 is parallel to the travel pathway 310. Aptly the bucket 610 could be U-shaped, L-shaped, or the like. The shape of the bucket 610 helps to correctly align the flexible pipe body 100 to be colinear with the travel pathway 310. The bucket 610 is supported via its pivot 620 on an optional box frame 630. The box frame 630 helps to vertically position the bucket 610 where desired and to provide a base. The box frame 630 is a steel structure defining a cuboidal shape with angled reinforcement struts. Aptly the box frame 630 could be constructed from any suitable rigid material and with any geometry so desired.

[0133] A hydraulic ram 640 is also fixed to the box frame 630 for tipping the bucket 610. The hydraulic ram 640 is effectively composed of a cylinder and piston arrangement having a ram arm 650protruding from one longitudinal end that can be linearly actuated. The ram arm 650 is attached to the bucket 610 at a point which is spaced apart from the bucket pivot 620. The opposite end of the hydraulic ram to the ram arm has a ram pivot point 660 about which the hydraulic ram 640 can rotate freely. Thus as the ram arm 650 is extended out of the hydraulic ram 640, the bucket 610 is tipped (clockwise in Figure 6). As the bucket 610 of the rotating table 375 is operated a separated length 320 of flexible pipe body can be moved from the collection position 381 (aligned with the travel pathway 310) to the storage position 382. For example, the separated length 320 rolls under gravity from the collection position 381 into storage position 382.

[0134] Figure 7 illustrates the collection location 335 including the collection position 381 and the storage position 382. In particular, Figure 7 shows how, after the second separated length 3202 is sliced and thus separated from the remaining flexible pipe body 100, the separated length is moved in a holding direction 395 (rightwards in Figure 7).

[0135] The hydraulic ram 640 thus enables the rotating table 375 to selectively urge the separated length support surface 615 between the collection position 381 and the storage position 382, where the second separated length 3202 will be deposited near the first separated length 320i. At the storage position 382 up to ten separated lengths 320 can be temporarily held, supported by the holding frame arms 385 and the holding frame walls 390. Aptly the storage position 382 may have a larger or smaller capacity depending on the size of the separated lengths 320 (and thus external diameter of the flexible pipe body 100) and the dimensions of the holding frame.

[0136] Once the storage position 382 has been filled with separated lengths 320, a batch of separated lengths 320 (for example 10, but alternatively more or less than 10) are moved together to a recycling location for further processing. A forklift, for example, may be used to pick up and move the whole batch to another area on site. Alternatively the storage position 382 may be an input to another automated process. In this way, a spool of flexible pipe body could be automatically recycled without requiring any manual input.

[0137] The storage position 382 may also be angled (as will be later described in relation to Figure 9), and / or incorporate apparatus (such as under-rollers and a chain or belt-drive) to rotate the separated lengths 320 to encourage fluids retained in the pipe layers to escape under gravity. Optionally the fluids may then be collected in a collection tank or sump underneath the storage position (not shown). This assists in the recycling of the separated lengths 320 and captures the fluids for safe and appropriate disposal.Figures 8A-D illustrate a decommissioning process for flexible pipe 240 including separating and recycling components of the flexible pipe 240. Figures 8A-D are thus an example of the whole process, including retrieval (Figure 8A), transport and storage (Figure 8B), separation (Figure 8C) and recycling (Figure 8D).

[0138] Figure 8A illustrates part of the riser assembly 220 that is to be decommissioned. The riser assembly 220 is deployed subsea between the floating facility 222 and the subsea location 221. The riser assembly is made from two flexible pipes 240 that are joined end to end via end fittings 245. Aptly any number of flexible pipes regardless of their use and location could be decommissioned and recycled. In the present example the floating facility 222 is a pipe lay support vessel (PLSV) that retrieves the riser assembly 220. The flexible pipe body 100 is wound onto a spool. A riser assembly 220 such as the one illustrated will provide multiple spools of flexible pipe body which are stored on the PLSV 222 until they can be returned to shore. When delivered by the PLSV to an onshore base, the riser assembly end fittings 245 may be removed and the length of flexible pipe body 100 provided on a spool 305. Aptly the spool 305 may alternatively hold one or more flexible pipes 240, and the end fitting(s) 245 may be removed later in the process.

[0139] Figure 8B illustrates a spool 305 containing a pre-used segment of flexible pipe body 100 decommissioned from a previously used riser (or alternatively a flow line or pipeline or the like). The spool 305 shown in Figure 8B holds 500m of flexible pipe body 100. Aptly the spool 305 may hold between 100m and 2000m or more of flexible pipe body 100. A free end 810 of the flexible pipe body 100 extends from the spool 305.

[0140] The spool 305 is transported to an onshore processing site for separation and recycling. At the start of the recycling process, the spool 305 is positioned at the start of the flexible pipe separating plant 300 (as shown in Figure 3A for example). The spool 305 is mounted on a shaft that passes through a through-hole 820 in the spool 305, or alternatively on under-rollers on which the rim of the spool 305 sits. This allows the spool 305 to spin freely as flexible pipe body 100 is withdrawn. The free end 810 of the flexible pipe body is fed through the cylindrical peg 340 to the caterpuller location 325. The process of recycling / separating the spool 305 of flexible pipe body 100 begins, as outlined in Figures 3A-B.

[0141] Aptly, the spool 305 may hold one or more flexible pipes 240 having end fitting(s) 245. The end fittings 245 may be removed as the flexible pipe 240 is withdrawn from the spool 305 prior to the flexible pipe body 100 approaching the input guide location 342.Figure 8C illustrates five separated lengths 320i-s of flexible pipe body 100 produced by the flexible pipe separating plant 300. Aptly any type of flexible pipe body may be separated using the flexible pipe separating plant 300. Aptly the separated lengths 320 may be drained of any remnants of previously transported material. This can help prepare the lengths for the recycling process. It will be noted that the separated lengths 320 all have a common axial length. This standardisation simplifies storage, transport and facilitates further automated processing. At this stage the separated lengths may optionally be sprayed or flooded with or submerged in cleaning fluid to remove retained production chemicals.

[0142] Figure 8D illustrates how the separated lengths 320 may be recycled. The separated lengths 320 of flexible pipe body 100 may be sorted into different groups of recyclable materials. Certain materials such as recycled polymers 830 and recycled steel 840 are formed (for instance by being separated using magnets) and can be used to make other components. For example, each material may be combined with some “virgin material” that has been newly created, thereby forming a larger supply of usable recycled material.

[0143] The recycled steel 840 may be formed by melting down steel extracted from the separated lengths 320 in a furnace and purified to remove contaminants and imperfections. The recycled polymers 830 may be formed by shredding and melting or through chemical processing of polymer components found in the separated lengths 320. It will be appreciated that various recycling processes can be applied to the individual sorted materials produced by the separated lengths 320.

[0144] Figure 9 illustrates an alternative collection location 900 to the collection location 335 illustrated in the previous Figures. The alternative collection location 900 contains the rotating table 375 (as described previously) and box frame 378 along with an alternative holding frame. The alternative holding frame includes the previously-described holding frame base 392 which holds the three holding frame arms 385I-3 (not visible) together. The three holding frame arms 385I-3 are each attached to respective alternative holding frame walls 910I-3.

[0145] At an alternative storage position 920 the separated lengths 320 of flexible pipe body 100 are held at an oblique angle to the ground in the holding frame by three holding frame supports 93O1-3. Each holding frame support 930 is attached to a corresponding holding frame wall 910. By tipping the separated lengths 320, remnants of previously transported material can be drained from an open lower end of each tipped separated length due to gravity. This further simplifies the ensuing recycling process.Figure 10 illustrates a segment of reinforced thermoplastic pipe (RTP) body 1000 which may alternatively be processed in the flexible pipe processing plant 300. RTP body 1000 is an example of a type of flexible pipe body. RTP body 1000 is combined with one or more end fittings to create a RTP. Multiple RTPs can be joined together to form a pipeline. In some situations RTP may be used in place of flexible pipe 240, such as in Figure 2. In other instances RTP is used overland rather than subsea. Regardless of the use, RTP is decommissioned from time to time just like any flexible pipe. RTP body 1000 may be processed, separated, and / or recycled according to any of the previously-described techniques. Construction of RTP body 1000 will now be briefly outlined.

[0146] The bonded RTP body 1000 illustrated in Figure 10 includes a fluid retaining layer 1010 which is non-porous. Aptly, the fluid retaining layer 1010 is tubular in shape. The fluid retaining layer 1010 is a polymer layer that ensures internal fluid integrity and can provide a boundary for any conveyed fluid. It is to be understood that the fluid retaining layer 1010 may itself comprise a number of sub-layers in some embodiments.

[0147] The fluid retaining layer 1010 is made of high-density polyethylene (HDPE). It will be appreciated that alternatively the fluid retaining layer 1010 may be made of any polyethylene, including PEX and PE-RT, a polypropylene, or a polyamide, or other polymer, or the like. The fluid retaining layer 1010 in Figure 10 is formed by an extrusion process, although it will be appreciated by a person skilled in the art that the fluid retaining layer may be manufactured in other ways. The fluid retaining layer 1010 is the innermost layer of RTP body 1000 and thus defines a pipe bore 1015 of RTP body. Aptly, the internal diameter of the fluid retaining layer - which may also be referred to as the bore 115 - is 6 inches (152.4mm). It will be appreciated that alternatively the pipe bore 1015 may be larger or smaller in diameter. Aptly, the bore fluid is constrained to being within the bore 1015 of RTP body 1000.

[0148] The embodiment of RTP body 1000 shown in Figure 10 also includes a thermoplastic reinforcement layer 1020 which is coaxial and radially external to the fluid retaining layer 1010. The thermoplastic reinforcement layer may also be referred to as a reinforcement layer. The reinforcement layer 1020 provides structural support to RTP body 1000. In other words the reinforcement layer 1020 may help to improve the resistance of RTP body to internal or external pressures, tensile forces, torsion, or the like. It will be appreciated that alternatively, the reinforcement layer 1020 may be composed of a plurality of layers.The reinforcement layer 1020 is formed of pairs of tapes cross-wound around the fluid retaining layer 1010 with a lay angle of around + / - 55° (not shown). In other words, each pair of tapes is wound helically in clockwise and counterclockwise directions respectively. It will be appreciated that alternatively the lay angle may be between 10° and 90° depending on the reinforcement requirements of the reinforcement layer 1020. For example, a shallower lay angle may provide greater resistance to axial forces along RTP body. The tapes are made of HDPE which may optionally be reinforced with fibres of other materials. It will be appreciated that the fibre may itself be composed of multiple fibres threaded or otherwise bunched together. It will be appreciated that alternatively, the HDPE may be replaced by another polymer such as any polyethylene, a polypropylene, or a polyamide, or the like.

[0149] RTP body also includes an outer sheath 1030 which is a polymer layer used to protect the pipe against penetration of seawater and other external environments, corrosion, abrasion and mechanical damage. The outer sheath 1030 is coaxial to the reinforcement layer 1020 and the fluid retaining layer 1010. As shown in Figure 10, the outer sheath 1030 is in physical contact with the reinforcement layer 1020. The outer sheath is the outermost layer of RTP body 1000. The outer sheath 1030 is made of HDPE. The outer sheath 1030 is tubular in shape and is manufactured using an extrusion process. It will be appreciated that as an alternative, the outer sheath may be formed from any polyethylene, a polypropylene, or a polyamide. Aptly, a manufacturing process such as tape winding or the like may be used to make the outer sheath. Whilst the embodiment shown in Figure 10 has three layers: the fluid retaining layer 1010, the thermoplastic layer 1020, and the outer sheath 1030; it will be appreciated that alternatively, RTP body may have the fluid retaining layer 1010, a plurality of helically wound steel wires, and the outer sheath 1030. Aptly, the plurality of steel wires (not shown) may be located radially between the fluid retaining layer 1010 and the outer sheath 1030.

[0150] The pipe bore 1015 of RTP body 1000 is hollow. Bore fluid is able to flow in a direction broadly parallel with the central axis A-A of RTP body 1000. It will be appreciated that RTP body 1000 may be deformed by external or internal forces without breaking. External forces may deform RTP body 1000 and determine a shape adopted by the RTP.

[0151] Each RTP comprises at least one portion, referred to as a segment or section, of pipe body 1000 together with an end fitting located at at least one end of the RTP. The end fitting provides a mechanical device which forms the transition between RTP body and a connector. The different pipe layers as shown, for example, in Figure 10 are terminated in the end fitting in such a way as to transfer the load between RTP body and the connector.Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to” and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0152] Features, integers, characteristics 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 of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of the features and / or steps are mutually exclusive. The invention is not restricted to any details of any foregoing embodiments. The invention extends to any novel one, or novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0153] The reader’s attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS:

1. A method for recycling flexible pipe body, comprising the steps of:providing flexible pipe body to an input guide location;urging flexible pipe body from the input guide location to a separation location proximate to a separator member;via the separator member, providing separated lengths of flexible pipe body by separating a free end region of incoming flexible pipe body from a remainder portion of the flexible pipe body; andlocating at least one separated length of flexible pipe body at a collection location.

2. The method as claimed in claimed 1, further comprising:recycling at least one material of at least one layer of the flexible pipe body via performing at least one processing step continuously or repeatedly or batch-by- batch on a separated length subsequent to collection of the separated length at the collection location.3 The method as claimed in claim 1 and 2, further comprising:providing flexible pipe body comprises urging a free end region of flexible pipe body that is wound on a reel member, away from the reel member to the input guide location.4 The method as claimed in any preceding claim, further comprising:urging the flexible pipe body comprises feeding the free end region into a caterpuller station that comprises at least one pair of opposed drive rollers; and via the pair of drive rollers, pulling the flexible pipe body from a reel member through the caterpuller station and pushing a terminal section comprising a free end region of the flexible pipe body past the separation location proximate to the separator member.5 The method as claimed in any preceding claim, further comprising:applying a predetermined compressive force via a pair of opposed rollers to an outer surface of the flexible pipe body wherein the predetermined compressive force is sufficient to permanently deform the flexible pipe body.The method as claimed in any preceding claim, further comprising:the separator member comprises a hydraulic cutter or guillotine or saw and the separator member is operable to slice through the flexible pipe body in a plane orthogonal or oblique to an axial direction of motion associated with the lengthwise motion of the flexible pipe body thereby separating the free end region of the flexible pipe body from the remainder portion of the flexible pipe body.The method as claimed in any preceding claim, further comprising:locating at least one separated length comprises one-by-one, locating a plurality of separated lengths each having a common axial length, in a stacked formation.The method as claimed in any preceding claim, further comprising:tipping a plurality of separated lengths subsequent to separation of the separated lengths from a remainder of the flexible pipe body thereby draining remnants of previously transported material from a lower open end of the tipped separated lengths.The method as claimed in any preceding claim, further comprising:continuously and automatically and one-by-one urging a predetermined length of the flexible pipe body past the separator member in an in-line process and repeatedly separating a presented end region of incoming flexible pipe body from a remainder portion of the flexible pipe body and optionally pausing inline motion of flexible pipe body during a separation step during which a length of flexible pipe body is separated.The method as claimed in any preceding claim, further comprising:providing the flexible pipe body, as a segment of pre-used flexible pipe body decommissioned from a previously used pipeline or flow line or riser, on a reel member.The method as claimed in any preceding claim, further comprising:urging the flexible pipe body along a straight travel pathway between the input guide location, the separation location and the collection location.The method as claimed in any preceding claim wherein the flexible pipe body is a segment of flexible pipe body from a decommissioned pipeline or flow line or umbilicalor riser and optionally the method further comprises removing at least one end fitting from a terminal end region of the flexible pipe body prior to winding the decommissioned flexible pipe body onto a reel member or urging the free end region of incoming flexible pipe body from the reel member to the input guide location prior to winding the decommissioned flexible pipe body onto the reel member.

13. The method as claimed in any preceding claim, further comprising:flushing and or cleaning at least a bore region of each separated length of flexible pipe body subsequent to locating separated lengths at the collection location and optionally subsequent to transferring separated lengths from the collection location to a storage location or a treatment location.

14. Apparatus for repeatedly separating lengths of a segment of flexible pipe body for subsequently recycling material from the flexible pipe body, comprising:an input guide member for providing an inlet, that comprises at least one guide surface, through which a segment of flexible pipe body is locatable in a lengthwise configuration;an urging member for urging the flexible pipe body in a lengthwise direction from the inlet towards a collection location;a separator member disposed in a travel pathway of the flexible pipe body between the urging member and the collection location and disposable to separate a presented free end region of the flexible pipe body from a remainder of the flexible pipe body; anda gathering member, disposed at the collection location, that comprises a separated length support surface.

15. The apparatus as claimed in claim 14, further comprising:the separator member comprises a guillotine or saw or hydraulic cutter, comprising a pair of jaw elements, disposed to create a slice through the flexible pipe body in a plane orthogonal to a primary drive axis along which the flexible pipe body is urged in a lengthwise orientation.

16. The apparatus as claimed in claim 14 or claim 15, further comprising:the urging member comprises a caterpuller station that includes at least one pair of opposed drive rollers that are selectively rotatable to pull flexible pipe bodydisposed between outer drive surfaces of the rollers from a reel member and towards a collection location in a lengthwise direction.

17. The apparatus as claimed in any one of claims 14 to 16, further comprising:the gathering member comprises at least one hydraulic ram for selectively urging the separated length support surface between a collection position and a storage position.

18. The apparatus as claimed in any one of claims 14 to 17, further comprising:at least the urging member and separator member and gathering member are disposed in an in-line orientation whereby flexible pipe body is urgeable lengthwise in a straight pathway from the urging member to the gathering member support.

19. A method of providing a plurality of separated sections, as separated lengths, of flexible pipe body, comprising steps of:providing a segment of flexible pipe body, that has an overall length of greater than 50m, lengthwise to an inlet guide member;via an urging member, urging a free end region of the flexible pipe body towards a collection position;via a separator member, separating the free end region, comprising a section of the flexible pipe body having a section length greater than 1m, from a remainder of the flexible pipe body with the free end region located at the collection location;repeatedly separating separated sections of flexible pipe body via the separator member; andrepeatedly transferring separated sections at a collection location to a storage location.

20. The method as claimed in claim 19, further comprising:repeatedly and continuously and automatically urging flexible pipe body from a reel member through a caterpuller station that pulls flexible pipe body from the reel member;via the caterpuller station, presenting a presented free end region of the flexible pipe body beyond a separation point associated with the separator member;pausing inline motion of flexible pipe body whilst the separation member separates a separated length from a remainder portion of the flexible pipe body; andsubsequent to separating a separated length recommencing inline motion to present a further presented free end region for separation.-31 -

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