Unbonded Flexible Pipe Internal Protective Layer Wear Resistance
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Solution Overview
Problem
Existing flexible pipes used for transporting abrasive materials from great depths suffer from significant wear due to cutting and crushing mechanisms, leading to reduced service life and flow rate, especially when dealing with materials like rocks and sediments from seabed mining operations.
Innovation Solution
A flexible pipe design featuring a central passage with an internal protective layer made of an elastomeric matrix and longitudinal reinforcement, which provides resistance to wear and deformation, combined with a pressure sheath and tensile armor layers, to ensure mechanical strength and abrasion resistance over extended periods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible pipe is used to transport abrasive material from great depths, then the pipe can be deployed in deep water environments, but the pipe suffers from significant wear due to cutting and crushing mechanisms
Solution Approach 1:
The pipe employs a composite structure with an inner protective layer made of elastomeric material (such as rubber or thermoplastic elastomer) that provides superior abrasion and impact resistance. This inner layer is combined with an outer protective layer and intermediate layers, creating a multi-material composite pipe that maintains flexibility while resisting wear from abrasive materials transported through it.
2Reliability
If the pipe wall is made thicker to resist wear, then the service life is extended, but the flexibility and flow rate are reduced
Solution Approach 1:
The protective properties are concentrated in the inner layer that directly contacts the abrasive material, while outer layers focus on providing structural strength and environmental protection. This localized distribution of protective qualities allows the inner surface to be wear-resistant without requiring the entire pipe wall to be excessively thick, thereby maintaining flexibility and flow characteristics.
3Productivity
If a rigid pipe structure is used to maintain flow rate, then the flow efficiency is improved, but the pipe cannot be deployed in deep water environments
Solution Approach 1:
The pipe utilizes a flexible shell structure composed of multiple layers including elastomeric inner layers and reinforced outer layers. This flexible construction allows the pipe to bend and adapt to deep water deployment conditions while the layered reinforcement maintains sufficient structural integrity to preserve flow rate and prevent collapse under pressure.
4Strength
If the pipe layers are bonded together for structural strength, then the mechanical resistance is improved, but the flexibility during bending is reduced
Solution Approach 1:
The pipe is constructed as an unbonded flexible pipe with distinct, separable layers that are not chemically bonded to each other. Each layer (inner protective layer, intermediate layers, outer protective layer) can move independently during bending, allowing the pipe to flex easily while maintaining structural strength through the stacked configuration of multiple reinforcement layers.
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 pipe achieves enhanced mechanical resistance and extended service life by minimizing wear from abrasive materials, ensuring a stable flow rate and prolonged operational lifespan, even in harsh underwater conditions.
Implementation Method 1
resistance to wear and deformation
Implementation Method 2
resistance to wear from abrasive materials
Implementation Method 3
pressure sheath
Implementation Method 4
tensile armor layers
Data Source
Figure 1~2
Figure 3~4(e)
Figure 5~10
AI summary
The pipe comprises: - at least one tubular sheath (20) delimiting a passage (11) for the circulation of the abrasive material; - at least one tensile armour layer (34, 36) arranged externally with respect to the tubular sheath (20), the armour layer (34, 36) comprising a plurality of filiform armour elements (44). The pipe also comprises an internal protective layer (40) arranged inside the tubular sheath (20) in the circulation passage (11), the internal protective layer (40) comprising an elastomer matrix (50) and a longitudinal reinforcing assembly (52) embedded in the matrix (50).