Flexible Pipe Barrier Layer Composite for High Temperature Resistance
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Solution Overview
Problem
Flexible pipes used for conveying oil or gas face challenges in achieving a balance between temperature resistance and flexibility, as existing materials often result in permanent deformation under strain and limited longevity due to trade-offs between these properties.
Innovation Solution
A multi-layer flexible pipe design incorporating a carcass layer, a barrier layer with polyphenylenesulphide (PPS) that provides a tensile elongation at yield greater than 5% at 23°C, a hoop strength layer, and an external fluid barrier layer, along with a method of extrusion process using heated zones to form a continuous hollow profile, ensuring high temperature resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If thermoplastic materials with high temperature resistance are used for the barrier layer, then temperature resistance is improved, but elongation at yield decreases causing permanent deformation
Solution Approach 1:
The barrier layer uses a composite material consisting of PPS as the base polymer combined with elastomeric components. This composite structure allows the material to maintain the high temperature resistance of PPS while the elastomeric phase provides enhanced elongation at yield, resolving the contradiction between temperature resistance and flexibility.
Solution Approach 2:
The invention modifies the chemical composition parameters of the barrier layer by incorporating specific elastomeric components into the PPS matrix. This parameter change transforms the material properties to achieve both high temperature resistance (>150°C) and sufficient elongation at yield (>5% at 23°C), eliminating the traditional trade-off.
2Ease of operation
If the pipe is designed to flex for laying and site operations, then ease of operation is improved, but reliability decreases due to permanent deformation and failure
Solution Approach 1:
The elastomeric-modified PPS composite in the barrier layer provides both the flexibility needed for bending during laying and site operations, and the structural integrity to prevent permanent deformation. This allows the pipe to be flexed repeatedly without compromising its 20+ year service life reliability.
Solution Approach 2:
The enhanced elongation at yield of the barrier layer material provides a cushioning effect that absorbs flexing stresses before they can cause permanent deformation. This beforehand cushioning allows the pipe to withstand bending during installation and operation without compromising long-term reliability.
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 flexible pipe can operate continuously at temperatures over 150°C for extended periods, maintaining flexibility and chemical resistance, thereby extending its service life beyond twenty years without chemical degradation.
Implementation Method 1
a method of extrusion process using heated zones to form a continuous hollow profile
Data Source
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AI summary
An apparatus and method are disclosed relating to a multi-layer flexible pipe for conveying a target fluid. The pipe includes a core layer arranged to provide an inner bore along which a fluid can flow and at least one barrier layer having a tensile elongation at yield of greater than 5% at a temperature of 23°C.