Flexible Pipe Carcass Layer with Insulated Interlocked Annular Elements
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Solution Overview
Problem
Traditional methods for manufacturing carcass layers in flexible pipes are time-consuming, costly, and limited in material choices and thermal insulation, with existing techniques restricting the operating envelope and offering inadequate thermal protection.
Innovation Solution
A carcass layer with interlocked annular elements and a channel region that can be filled with insulating or strengthening materials, allowing for tailored physical properties and improved thermal insulation, enabling the use of diverse materials and enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a profiled tape is used to form the carcass layer by helically wrapping and interlocking, then the structural strength and pressure resistance are improved, but the manufacturing complexity and cost increase due to the time-consuming profile generation process
Solution Approach 1:
The carcass layer is divided into discrete annular elements rather than being formed from a continuous profiled tape. Each element can be manufactured independently using simpler processes, then assembled together to form the complete carcass layer, reducing manufacturing complexity while maintaining structural strength
Solution Approach 2:
The annular elements are formed from composite materials including a metallic layer and a polymer layer. This composite construction provides the necessary structural strength and pressure resistance while allowing for simpler manufacturing processes compared to traditional profiled tape
2Strength
If metal materials are used for the carcass tape windings, then the structural strength is improved, but the thermal insulation performance deteriorates due to high thermal conductivity
Solution Approach 1:
The annular elements are constructed as composites with a metallic layer providing structural strength and a polymer layer providing thermal insulation. This composite structure resolves the contradiction by combining materials with complementary properties - the metal ensures strength while the polymer reduces thermal conductivity to protect overlying layers from heat
Solution Approach 2:
Different regions of the annular elements have different material properties optimized for their specific functions. The metallic portion provides localized strength where needed, while the polymer portion provides localized thermal insulation, allowing each material to perform its optimal function in the appropriate location
3Adaptability or versatility
If traditional rolling methods are used to generate profiled tape, then the material malleability is maintained, but the manufacturing time and cost increase significantly
Solution Approach 1:
By segmenting the carcass layer into discrete annular elements, the manufacturing process avoids the time-consuming continuous profile generation required by traditional rolling methods. Each element can be formed more efficiently and assembled rapidly, significantly improving productivity while the composite material design maintains the necessary adaptability and malleability for installation
Data Source
AI summary
Flexible pipe body for transporting fluids from a sub-sea location includes a carcass layer comprising adjacent interlocked annular elements each comprising a body portion that extends around an inner circumference of a bore region and a channel region provided within the body. A method of manufacturing flexible pipe body is also disclosed.