Composite Hose Coupling Insert for Corrosion-Resistant End Terminations
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Solution Overview
Problem
Existing hose constructions for oil and gas field applications face premature failure due to the use of expensive metallic couplings that are not cost-effective and lack sufficient corrosion resistance for handling highly corrosive fluids.
Innovation Solution
A hose construction featuring a tubular insert made from a polymer mixed with chopped reinforcement fibers, such as PEEK or PEKK, combined with a metallic ferrule, which forms an annular hose receiving space for secure connection, allowing for deformation to create a corrosion-resistant, cost-effective coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic couplings are used for hose constructions, then the coupling provides sufficient strength and structural integrity, but the coupling suffers from premature failure due to corrosion in highly corrosive fluid environments
Solution Approach 1:
The coupling combines a polymer matrix with chopped reinforcement fibers to create a composite insert that exhibits both high strength and superior corrosion resistance. The fiber reinforcement provides mechanical integrity while the polymer matrix provides corrosion resistance, resolving the contradiction between strength and corrosion performance.
Solution Approach 2:
The invention changes the material composition parameters by incorporating 20-40 wt% chopped fibers into the polymer matrix, transforming the material properties to achieve both required strength and corrosion resistance simultaneously, rather than using traditional metallic materials.
2Object-affected harmful factors
If Inconel corrosion resistant material is used for couplings, then the coupling provides adequate corrosion resistance, but the material cost becomes extremely expensive
Solution Approach 1:
The invention replaces expensive Inconel material with a cost-effective polymer composite that provides comparable or superior corrosion resistance. The composite material uses common polymers and fibers that are significantly cheaper than nickel-based superalloys like Inconel.
Solution Approach 2:
By using composite materials made from polymer and fiber reinforcements, the invention achieves the required corrosion resistance at a fraction of the cost of Inconel, while maintaining or improving performance characteristics.
3Strength
If a metallic insert is used in the coupling, then the insert provides required strength for ferrule deformation, but the metallic insert is susceptible to corrosion from transported fluids
Solution Approach 1:
The insert is constructed as a composite material combining polymer matrix with chopped reinforcement fibers (20-40 wt%). This composite provides both the required mechanical strength to withstand ferrule deformation and superior corrosion resistance against transported fluids, eliminating the corrosion vulnerability of metallic inserts.
Solution Approach 2:
The reinforcement fibers are distributed throughout the polymer matrix to provide localized strength enhancement exactly where needed during ferrule deformation, while the polymer matrix provides uniform corrosion resistance across the entire insert surface.
4Object-affected harmful factors
If polymeric hose is used for transporting corrosive fluids, then the hose provides good chemical resistance, but the coupling remains the weak point for premature failure
Solution Approach 1:
The coupling insert is made from the same polymer material as the hose, ensuring homogeneous chemical resistance throughout the entire hose-coupling assembly. This eliminates the interface between dissimilar materials where corrosion could initiate, making the entire system uniformly resistant to corrosive fluids.
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
The solution provides superior corrosion resistance and extended lifespan for hose constructions in severe environments, resisting fluids like H2S, CO2, and aromatics, while being temperature-resistant up to 160°C and reducing material costs.
Implementation Method 1
The ferrule is then swaged or deformed inwardly trapping the hose against the insert in order to form the fluid tight connection
Implementation Method 2
the ferrule is deformed inwardly against the hose to form a secure connection
Data Source
AI summary
A hose construction having a coupling secured to an end of a hose, with the coupling including a tubular insert formed with a polymer mixed with chopped reinforcement fiber and including first and second ends, with the first end being inserted in the hose, and the second end including a connector interface. A tubular metallic ferrule is connected to the tubular insert adjacent to the second end in order to form an annular hose receiving space between an outer surface of the insert and an inner surface of the ferrule. The end of the hose is received in the annular hose receiving space, and the ferrule is deformed inwardly against the hose to form a secure connection. The tubular insert formed of a non-metallic material has high strength and is resistant to corrosion due to contact with the materials being transported.