Flexible Pipe Sensor Integration via Crush-Resistant Housing
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Solution Overview
Problem
Existing methods for monitoring strain, temperature, and acoustics in flexible pipes face challenges in incorporating and removing fibre optic conduits during manufacturing and end fitting assembly, leading to increased production time and potential material stress.
Innovation Solution
A method involving wrapping a crush-resistant elongate body housing a fibre element radially between tensile armour elements around a fluid retaining layer, with the fibre element being locally bonded and protected by a flowable matrix material that is cured later for secure placement, allowing easy assembly and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conduits are bonded into the wire's groove prior to applying the armour layer, then strain monitoring is achieved, but production time is extended and assembly difficulty increases
Solution Approach 1:
The conduit is positioned in the groove and bonded before the armour layer is applied. This preliminary action allows the conduit to be securely placed and bonded while the armour layer is subsequently wrapped around it, protecting the conduit and establishing reliable strain monitoring capability without requiring separate post-assembly steps
Solution Approach 2:
The conduit integration process is merged with the armour layer application process. The conduit is positioned in the groove and bonded, then the armour layer is wrapped around it in a continuous manufacturing sequence, combining multiple functions (conduit placement, bonding, and armour application) into a unified process that improves productivity
2Reliability
If conduits are bonded into the wire, then strain monitoring is achieved, but removing them from the groove is difficult and induces stress
Solution Approach 1:
The conduit is designed as a separate, removable component that can be independently extracted from the groove after the pipe assembly is complete. This segmentation allows the conduit to be securely bonded during manufacturing for strain monitoring, yet easily removed later for interrogator connection without inducing stress in the wire or armour layers
Solution Approach 2:
The conduit is preliminarily positioned and bonded in the groove during manufacturing to establish strain monitoring capability, but the bonding is designed to allow easy removal afterward. This preliminary placement enables both secure integration during assembly and easy extraction during end fitting installation
3Ease of manufacture
If a groove is formed into the wire to carry the conduit, then conduit placement is enabled, but wire preparation becomes difficult with hard or soft wire
Solution Approach 1:
The groove is formed only in the specific location where the conduit needs to be placed, with dimensions and geometry optimized for that local function. This localized groove formation enables conduit placement without requiring complex modifications to the entire wire structure, accommodating variations in wire hardness at the groove location while maintaining overall wire integrity
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
Enables cost-effective and convenient incorporation of fibre optic technology into flexible pipes for continuous monitoring of parameters like strain and temperature, reducing assembly stress and extending the pipe's functionality.
Implementation Method 1
a flowable matrix material that is cured later for secure placement
Data Source
AI summary
Apparatus and method of manufacturing a flexible pipe body are disclosed. The method may include providing a fluid retaining layer; wrapping a plurality of tensile armour elements around the fluid retaining layer; and wrapping a crush resistant elongate body that houses at least one fibre element around the fluid retaining layer and radially between two of the plurality of tensile armour elements. Matrix material provided in the elongate body may be cured subsequent to fitting the pipe body to an end fitting.