Multilayer Spoolable Composite Pipe Barrier Against Aromatic Swelling

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Solution Overview

Problem

Spoolable composite pipes used in the oil and gas industry face degradation in mechanical properties such as modulus and strength when exposed to high temperatures and aromatic hydrocarbons, leading to reduced performance in sour environments.

Innovation Solution

The development of spoolable composite pipes with an inner extruded tubular liner made of thermoplastic and a backer layer of polypropylene, which acts as a permeation barrier, along with a reinforcement layer, allowing the pipes to operate at temperatures up to 110°C and handle hydrocarbons with up to 35% aromatic content, while maintaining mechanical integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If spoolable composite pipes use a polypropylene backer layer, then ease of manufacture and cost are improved, but the backer material swells and degrades when exposed to aromatic hydrocarbons at high temperatures

Engineering Contradiction:

Improveease of manufactureVSAvoidmechanical integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent introduces an inner extruded tubular liner made of thermoplastic material as an intermediary barrier between the hydrocarbon fluid and the polypropylene backer layer. This liner prevents direct contact between the aromatic hydrocarbons and the polypropylene, eliminating the swelling and degradation issue while maintaining the ease of manufacture benefits of using polypropylene in the composite pipe structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a composite structure combining two different materials: a thermoplastic inner liner and a polypropylene backer layer. This composite approach allows each material to perform its optimal function - the thermoplastic provides chemical resistance and barrier properties against aromatic hydrocarbons, while the polypropylene provides structural support and manufacturing advantages.

Inventive Principle:

Principle #40Composite materials

2Productivity

If the pipes operate at high temperatures (up to 110°C), then productivity and operational capability are improved, but the mechanical properties of the backer material degrade

Engineering Contradiction:

Improveoperational capabilityVSAvoidmechanical properties

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The thermoplastic inner liner serves as a protective intermediary that shields the polypropylene backer layer from the combined effects of high temperature and aromatic hydrocarbons. This barrier allows the pipe to operate at elevated temperatures (up to 110°C) without the backer material experiencing thermal degradation, thus maintaining mechanical strength while improving operational capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If the pipes are used in sour environments with high aromatic content (up to 35%), then adaptability is improved, but swelling and degradation of the backer material occurs

Engineering Contradiction:

ImproveadaptabilityVSAvoidcomposition stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The thermoplastic inner extruded tubular liner acts as a chemical barrier that prevents aromatic hydrocarbons from reaching and interacting with the polypropylene backer layer. This intermediary protection allows the pipe to adapt to sour environments with high aromatic content (up to 35%) while maintaining the compositional stability and preventing swelling of the backer material.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 effectively prevents swelling and degradation of the backer material, retaining mechanical properties and providing a robust barrier against hazardous gases, thus ensuring the pipes' performance and longevity in harsh oil and gas flowline conditions.

Implementation Method 1

The inner extruded tubular liner acts as a permeation barrier to prevent migration of hazardous gases

Methodology Applied

Scientific EffectPermeation barrier: Permeation

Implementation Method 2

The inner extruded tubular liner acts as a permeation barrier to prevent migration of hazardous gases and to reduce diffusion of aromatics into the backer material

Methodology Applied

Scientific EffectDiffusion barrier: Diffusion

Data Source

PatentUS20240377002A1Multilayer permeation barrier for spoolable composite pipes

Publication Date: 2024.11.14 SAUDI ARABIAN OIL CO

AI summary

Spoolable composite pipes, a method of producing spoolable composite pipes, and a method for transporting a hydrocarbon fluid are provided. The spoolable composite pipes have an inner extruded tubular liner, a backer layer surrounding the inner extruded tubular liner, and a reinforcement layer surrounding the backer layer. The backer layer includes a polypropylene, and the inner extruded tubular liner includes a thermoplastic. The production method includes co-extruding the inner extruded tubular liner with the backer layer, providing the reinforcement layer, and extruding the cover layer around the reinforcement layer. The method for transporting a hydrocarbon fluid includes providing the spoolable composite pipe and introducing the hydrocarbon fluid with an aromatic content of up to about 35% by volume based on the total hydrocarbons content.