Flexible Pipe Layer Design for Deep Water Strength
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Solution Overview
Problem
Traditional flexible pipes used in deep and ultra-deep water environments face challenges with increased weight and material costs due to the need for thicker, stronger materials to withstand extreme pressures and temperatures, which limits their performance and efficiency.
Innovation Solution
A flexible pipe body layer is designed with a carcass layer formed from a tape with semi-randomly oriented stainless steel fibers and stainless steel faceplates, providing high strength, stiffness, and energy absorption while maintaining a reduced weight and cost-effective manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker and stronger materials are used to manufacture armour layers or carcass layer, then the strength and robustness of the layer increases, but the weight of the flexible pipe increases
Solution Approach 1:
The patent applies composite materials by combining metal faceplates with fiber reinforcement layers to create a hybrid structure. The faceplates provide compressive strength and structural integrity, while the fibers (such as aramid, carbon, or glass fibers) contribute tensile strength and stiffness. This composite approach allows the armour layer to achieve high strength-to-weight ratio, satisfying the requirement for strength while minimizing weight increase.
Solution Approach 2:
The patent implements local quality by varying the thickness and material composition of different layers within the armour structure. The metal faceplates are positioned at specific locations to provide localized protection against crushing loads, while the fiber layers are distributed to handle tensile stresses. This non-uniform distribution of materials optimizes the overall performance by providing strength where needed while reducing weight in less critical areas.
2Strength
If thicker and stronger materials are used to manufacture armour layers or carcass layer, then the strength and robustness of the layer increases, but the material cost increases
Solution Approach 1:
The composite structure allows for cost optimization by selecting materials based on their specific functional requirements. Rather than using expensive thick metal throughout, the design employs thinner metal faceplates combined with high-performance fibers that provide equivalent or superior strength at lower cost. This material substitution strategy reduces overall material costs while maintaining required strength levels.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the thickness, material composition, and structural configuration of the armour layers to achieve the minimum required strength at optimal cost. By carefully selecting fiber types, faceplate thicknesses, and layer arrangements, the design finds the cost-effective balance point where sufficient strength is achieved without excessive material expenditure.
3Adaptability or versatility
If the flexible pipe operates in deep water environments, then the pipe can access oil resources at greater depths, but the external pressure and temperature increase the risk of pipe blockage and structural failure
Solution Approach 1:
The composite armour structure provides enhanced reliability in deep water by combining the crush resistance of metal faceplates with the tensile strength of fibers. This combination creates a structurally robust pipe that can withstand the high external pressures and thermal stresses of deep water environments, preventing collapse and blockage while maintaining operational integrity.
Solution Approach 2:
The patent employs curved or profiled cross-sectional shapes in the armour layer construction, such as circular or oval profiles, which are geometrically optimal for withstanding external pressure. The curved geometry distributes compressive loads more evenly across the structure, preventing stress concentration and reducing the risk of structural failure under deep water pressure conditions.
Data Source
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AI summary
A flexible pipe body and method of producing a flexible pipe body are disclosed. The flexible pipe body includes a layer comprising a tape element formed from at least a first sub-layer (415)sandwiched be¬ tween two further sub-layers (417, 419), wherein the first sub-layer has a lower density than at least one of the two further sub-layers.