Flexible Pipe Helical Insert Vibration Control
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Solution Overview
Problem
Flexible pipes used for conveying hydrocarbons through water bodies often experience flow disruptions and vibrations due to the helical interstice in the inner carcass, leading to manufacturing challenges and increased costs, particularly with T-shaped inserts that require complex equipment and storage issues.
Innovation Solution
A flexible pipe design featuring a helical insert formed by bending a second tape, with a T-shaped cross-section and wings that protrude to close off the interstice, allowing for easier manufacturing and reduced vibration risks, using a method that includes profiling and winding the insert and carcass around a mandrel to simplify the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a T-shaped insert is used to close off the helical interstice, then vibration and pulsation risks are reduced, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The T-shaped insert is segmented into two separate components: the helical insert and the wings. The helical insert is formed by bending a first tape into a helical shape, while the wings are formed by bending a second tape. These segments are then assembled together through interlocking, eliminating the need for complex T-shaped insert manufacturing while achieving the same vibration reduction effect.
Solution Approach 2:
The wings are nested within the helical interstice structure, with the helical insert positioned inside the inner sheath and the wings extending radially outward. This nested arrangement allows the components to be assembled in a straightforward sequence without requiring complex integration processes.
2Ease of manufacture
If a T-shaped insert is manufactured and stored on drums, then the insert is available for assembly, but storage space requirements and handling complexity increase
Solution Approach 1:
The insert is segmented into two separate tapes that can be stored independently on standard drums. This segmentation allows each tape to be stored in a compact, manageable form without requiring special storage infrastructure, significantly reducing the storage area needed compared to storing complete T-shaped inserts.
Solution Approach 2:
The tapes are prepared and stored in advance in a compact form, ready for quick assembly when needed. This preliminary preparation eliminates the need for complex on-site manufacturing of T-shaped inserts while minimizing storage requirements through efficient tape winding on drums.
3Ease of manufacture
If welding equipment and assembly equipment are added to the production line, then T-shaped inserts can be manufactured, but device complexity and manufacturing cost increase
Solution Approach 1:
The manufacturing process is segmented into two independent tape preparation lines that feed into a simple assembly station. This eliminates the need for complex welding equipment and T-shaped insert manufacturing apparatus, requiring only basic bending and interlocking mechanisms that are already present in standard pipe production lines.
Solution Approach 2:
The helical insert and wings are designed to interlock through their own geometric features without requiring external joining processes like welding. The helical ribs on the insert engage with corresponding features on the wings, allowing self-assembly through simple mechanical interlocking that reduces equipment requirements.
Data Source
AI summary
This flexible fluid transport pipe includes an inner polymer sheath defining a fluid circulation passage with a central axis; at least one armor layer positioned outside the inner sheath; an inner carcass, positioned in the inner sheath, the inner carcass comprising a first bent tape defining a helical interstice emerging toward the central axis. The pipe includes a helical insert with a T-shaped cross-section comprising a rod inserted in the helical interstice and two wings protruding on either side of the rod to inwardly close off the helical interstice. The helical insert is formed from a second bent tape.