Composite Tape Splicing for High-Strength Flexible Pipe Armour
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Solution Overview
Problem
Flexible pipes used for subsea fluid transportation face challenges in deep and ultra-deep water environments due to high tension loads and pressure, leading to potential failure, and existing splicing methods for composite tape do not ensure consistent and strong joins, which can compromise the integrity of the pipe.
Innovation Solution
A method and apparatus for splicing composite tape by overlapping sections and applying heat and pressure to achieve a lap shear strength of at least 11 MPa, using a process that can be controlled and repeated for consistent results, involving the use of press plates and potentially uneven heat and pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing splicing methods are used for composite tape, then the manufacturing process can be completed, but the join strength and consistency are insufficient, compromising pipe integrity
Solution Approach 1:
The patent applies parameter changes by controlling and optimizing the heat and pressure parameters during the splicing process. By adjusting temperature, pressure, and time parameters, the method achieves consistent lap shear strength of at least 11 MPa in the joined overlapping tape section, thereby improving both reliability and strength of the composite tape joins.
Solution Approach 2:
The patent replaces traditional mechanical splicing methods with a thermally-assisted joining process. Instead of relying solely on mechanical fastening or bonding, the invention uses controlled heat and pressure application to fuse the composite tape sections, achieving superior and more consistent join strength and reliability.
2Strength
If thicker and stronger materials are used for armour layers, then load response and performance improve, but pipe weight increases
Solution Approach 1:
The patent uses composite materials for the armour layers, combining different materials to achieve high strength-to-weight ratio. The composite tape provides the necessary load response and performance while minimizing weight increase compared to using thicker monolithic materials.
Solution Approach 2:
The patent applies local quality by reinforcing specific areas of the pipe with composite armour layers where high strength is needed, rather than uniformly increasing thickness throughout. This allows optimized load response in critical areas while controlling overall pipe weight.
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 method provides improved strength and consistency in the joins between composite tape sections, enhancing the reliability and durability of flexible pipes operating in extreme conditions.
Implementation Method 1
applying heat and pressure to the overlapping tape section to form a joined overlapping tape section
Implementation Method 2
applying heat and pressure to the overlapping tape section to form a joined overlapping tape section
Data Source
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AI summary
A method of manufacturing an armour layer of a flexible pipe for transporting fluid from a subsea location and apparatus are provided. The method comprises winding a first length of composite tape to form a first section of the armour layer and positioning an end region of the first length of composite tape over an end region of a second length of composite tape to form an overlapping tape section. Heat and pressure is applied to the overlapping tape section to form a joined overlapping tape section in which the first length of tape is joined to the second length of tape such that the joined overlapping tape section has a lap shear strength of at least 11 MPa. The joined overlapping tape section and the second length of composite tape are wound to form a second section of the armour layer.