Flexible Pipe Seal Integrity Testing Rig
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Solution Overview
Problem
Current end fittings for flexible pipes used in deep and ultra-deep water environments face challenges in reliably testing the integrity of seals under pressures equivalent to those experienced in sub-sea conditions, leading to potential leaks and uncertainty in seal effectiveness.
Innovation Solution
A seal testing rig is employed to simulate hydrostatic pressures by using an end cap and collar members to apply pressure to the sealing rings, allowing for the verification of seal integrity up to pressures of 5 MPa or more without compromising the pipe structure, using a method that includes swaging actions and O-rings to ensure reliable sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional seal testing methods are used on flexible pipes in deep water environments, then the pipe structure remains simple and easy to manufacture, but the seal integrity cannot be reliably verified under operational pressures
Solution Approach 1:
The pipe body is divided into multiple sealed chambers (first chamber and second chamber) separated by sealing rings. This segmentation allows independent testing of each seal location by pressurizing one chamber while the other remains at atmospheric pressure, enabling reliable seal integrity verification without requiring the entire pipe to withstand extreme pressures simultaneously.
Solution Approach 2:
A testing apparatus with collar members and internal pressure sheaths acts as an intermediary device to apply controlled pressures to the pipe body chambers. The apparatus includes pressure application mechanisms that can independently pressurize specific chambers to simulate operational conditions without requiring the full pipe structure to endure the maximum operational pressure simultaneously.
2Reliability
If high pressures equivalent to sub-sea conditions are applied to test seals, then seal integrity can be verified, but the pipe structure may be compromised or damaged
Solution Approach 1:
The pipe body is divided into multiple sealed chambers (first chamber and second chamber) separated by sealing rings. This segmentation allows independent testing of each seal location by pressurizing one chamber while the other remains at atmospheric pressure, enabling reliable seal integrity verification without requiring the entire pipe to withstand extreme pressures simultaneously.
Solution Approach 2:
The testing apparatus applies pressure partially - only to the specific chamber being tested - rather than pressurizing the entire pipe structure. The collar members and internal pressure sheaths confine the pressure to localized regions, allowing seal testing at pressures equivalent to operational conditions without subjecting the entire pipe to damaging stress levels.
3Reliability
If multiple sealing rings are used in end fittings, then seal reliability improves, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The pipe body is divided into multiple sealed chambers (first chamber and second chamber) separated by sealing rings. This segmentation allows independent testing of each seal location by pressurizing one chamber while the other remains at atmospheric pressure, enabling reliable seal integrity verification without requiring the entire pipe to withstand extreme pressures simultaneously.
Solution Approach 2:
The sealing rings are pre-installed and pre-positioned within the end fittings during manufacturing, and the pipe body layers are pre-assembled with the sealing system before field deployment. This preliminary assembly allows for quality control and testing to be performed on the sealing system before the pipe is put into service, ensuring reliability without increasing field installation complexity.
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
This method provides a reliable means to test the integrity of sealing rings before deployment, ensuring the longevity and performance of flexible pipes in extreme environments by confirming the seals' ability to withstand operational pressures, thereby reducing the risk of leaks and extending the pipe's lifespan.
Implementation Method 1
A seal testing rig is employed to simulate hydrostatic pressures by using an end cap and collar members to apply pressure to the sealing rings
Implementation Method 2
using a method that includes swaging actions and O-rings to ensure reliable sealing
Data Source
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AI summary
An assembly and method of testing the integrity of a sealing ring of a flexible pipe are disclosed. The method includes locating a first sealing ring adjacent a first collar member and a layer of flexible pipe body; energising the first sealing ring by urging the sealing ring towards a primary pressure-retaining end fitting component, or by urging the pressure- retaining component towards the sealing ring; locating a second sealing ring adjacent the first collar member and a second collar member; energising the second sealing ring by urging the sealing ring towards the pressure-retaining component, or by urging the pressure-retaining component towards the sealing ring; and pressurising the region between the first sealing ring and the second sealing ring through a port extending towards the region to a predetermined pressure of 5 MPa or greater.