Co-extruded Thermal Insulation for Flexible Pipe Armour
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Solution Overview
Problem
Flexible pipes used in deep and ultra-deep water environments face issues such as corrosion of armour layers due to water permeation and potential blockage from paraffin formation, exacerbated by existing thermal insulation methods that require multiple manufacturing processes and are prone to corrosion when damaged.
Innovation Solution
A thermal insulation layer is extruded directly over the outer tensile armour layer, forming a continuous, sealed layer that prevents water vapour convection and liquid ingress, reducing the risk of corrosion and blockage by maintaining a higher temperature within the pipe and acting as an additional barrier against seawater.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermal insulation is applied using helically wound tapes, then thermal insulation is provided to prevent paraffin formation, but the manufacturing process becomes complex requiring two separate processes (extrusion and winding)
Solution Approach 1:
The patent combines the thermal insulation layer with the outer sheath layer into a single extrusion process. The insulation material (syntax foam) and sheath material are co-extruded in one operation, eliminating the separate winding process required by prior art while maintaining thermal insulation effectiveness.
Solution Approach 2:
The outer sheath layer serves dual functions: it provides the required mechanical protection and structural integrity of the pipe, and simultaneously provides thermal insulation to prevent paraffin formation. This multi-functional design eliminates the need for separate insulation components.
2Temperature
If thermal insulation is applied using helically wound tapes, then thermal insulation is provided, but the insulation layer is not continuous allowing water vapour migration and condensation
Solution Approach 1:
By co-extruding the insulation material with the sheath material in a single continuous process, the patent creates an uninterrupted, seamless insulation layer that completely prevents water vapour migration pathways, eliminating condensation risks.
Solution Approach 2:
The co-extrusion process creates a homogeneous, uniform insulation layer without joints, seams, or discontinuities. This homogeneous structure ensures consistent thermal protection and complete blocking of water vapour pathways throughout the entire pipe length.
3Reliability
If the outer shield layer is damaged, then seawater can ingress into the annulus, but with proper insulation design the risk of corrosion can be reduced
Solution Approach 1:
The patent incorporates thermal insulation material (syntax foam) within the sheath layer structure, creating a built-in protective barrier before seawater can reach the armour layers. This pre-positioned insulation cushion prevents direct contact between seawater and metal components, reducing corrosion risk even if the outer shield is damaged.
Solution Approach 2:
The sheath layer is constructed as a composite structure incorporating both structural material and thermal insulation material (syntax foam). This composite design provides simultaneous mechanical protection and corrosion protection, creating a multi-functional barrier against seawater ingress.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively reduces corrosion risks, delays or eliminates the need for pipeline 'pigging', and enhances the operational lifespan of flexible pipes in extreme environments by providing continuous thermal insulation and preventing water condensation and ingress.
Implementation Method 1
a layer of thermal insulation should be provided around the barrier layer of a flexible pipe
Implementation Method 2
water vapour originating from water permeation through the inner barrier layer can freely migrate to the outer shield through the taped layer to form liquid where the temperature is lower
Implementation Method 3
water vapour originating from water permeation through the inner barrier layer can freely migrate to the outer shield through the taped layer to form liquid where the temperature is lower
Data Source
AI summary
Flexible pipe body, a method of manufacturing flexible pipe body and a method of providing a flexible pipe are disclosed. The flexible pipe body (100) includes a fluid retaining layer (102), at least one tensile armour layer (105), at least one extruded thermal insulation layer (108) over an outermost one of the at least one tensile armour layers (105) and an outer shield layer (107) over the insulation layer.