Flexible Pipe Polymer Composition for Wear Resistance
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Solution Overview
Problem
Existing flexible pipes used in deep offshore oil exploration face challenges with polymer layers that lack sufficient wear and environmental stress rupture resistance, especially under severe abrasion and chemical attack, and are costly compared to high-performance semi-crystalline polymers like PEEK.
Innovation Solution
A flexible pipe design featuring a polymer composition comprising a blend of poly(aryl ether ketone) and poly(aryl ether sulfone) with a weight ratio of 35% to 95%, without epoxy resin modified by aromatic polyamine, which is well-suited for extrusion into long tape form, providing improved compressive strength, temperature resistance, and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-performance semi-crystalline polymers like PEEK are used to achieve sufficient wear and environmental stress rupture resistance, then reliability is improved, but cost increases
Solution Approach 1:
The patent employs a composite polymer material consisting of poly(aryl ether ketone) and poly(aryl ether sulfone) in a weight ratio of 35:65 to 95:5. This composite achieves wear resistance and environmental stress rupture resistance comparable to high-performance semi-crystalline polymers like PEEK, while offering better cost-effectiveness and extrudability. The composite formulation allows the material to meet the reliability requirements for flexible pipe polymer layers without the high cost associated with pure PEEK.
2Reliability
If high-performance semi-crystalline polymers like PEEK are used to achieve environmental stress rupture resistance, then reliability is improved, but extrudability worsens
Solution Approach 1:
The patent changes the chemical composition parameters by selecting specific aromatic polymeric materials - poly(aryl ether ketone) and poly(aryl ether sulfone) - that possess both the required environmental stress rupture resistance and superior extrudability. The molecular structure and physical properties of these polymers are optimized to enable easy extrusion into long tape form while maintaining the reliability needed for demanding flexible pipe applications.
3Adaptability or versatility
If polymer layers are made independent and un-bonded to allow bending, then flexibility is improved, but adhesion between layers deteriorates
Solution Approach 1:
The patent uses a homogeneous polymer composition of poly(aryl ether ketone) and poly(aryl ether sulfone) for the polymer layers. This homogeneous material provides consistent properties throughout the layer, ensuring adequate adhesion between independent layers while maintaining the flexibility required for bending. The uniform composition allows layers to move relative to one another without compromising interlayer bonding.
Data Source
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AI summary
Flexible pipe (fP) suitable for transporting hydrocarbons, said flexible pipe comprising at least one polymer layer (L) composed of a polymer composition (C) comprising: at least one poly(aryl ether ketone) (P1), and at least one poly(aryl ether sulfone) (P2), wherein: the weight of the poly(aryl ether ketone ) (P1), based on the total weight of the poly(aryl ether ketone) (P1) and the poly(aryl ether sulfone) (P2), is from 35 % to 95 %, and the polymer composition (C) is free of epoxy resin modified by at least one aromatic polyamine, or comprises the said epoxy resin modified by at least one polyamine in a weight amount of at most 10 %, based on the total weight of the polymer composition (C). Method for producing the flexible pipe (fP).