Multi-layered Pipe Forming Machine for On-site Pipeline Construction
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Solution Overview
Problem
The hydrocarbon industry faces challenges in efficiently manufacturing and constructing long, high-pressure pipelines due to the complexity of welding large-diameter and thick-walled metal pipes, especially in arctic regions, where environmental conditions limit operation time, and existing methods like extruded plastic or fiber-wrapped pipes are not suitable for high-pressure applications and are difficult to join with metal pipes.
Innovation Solution
The development of multi-layered pipes formed by machines that simultaneously create multiple metal tubes around an inner tube, using a control system to feed metal stocks to forming devices, allowing for on-site construction of long pipelines with reduced welding requirements, using machines that can operate proximate to installation sites and handle large-diameter and thick-walled pipes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal pipes are manually welded together on-site to form long pipelines, then the pipeline can be constructed with high strength and reliability, but the construction time and complexity increase significantly due to the large number of welded joints required
Solution Approach 1:
The pipe is divided into multiple layers (inner metal tube, intermediate layer, outer metal tube) that are formed separately and then assembled together. This segmentation allows each layer to be manufactured independently with optimized processes, reducing the overall construction time while maintaining the strength benefits of metal pipes.
Solution Approach 2:
The multi-layered pipe structure nests different materials and functions within concentric layers. The inner metal tube provides structural strength, the intermediate layer provides corrosion resistance and flexibility, and the outer metal tube provides additional protection. This nested structure combines the advantages of different materials while reducing the need for extensive welding.
2Stress or pressure
If large-diameter and thick-walled metal pipes are transported to installation sites, then the pipeline can handle high-pressure hydrocarbon transportation, but the transportation and handling difficulties increase
Solution Approach 1:
The pipe structure is segmented into multiple layers that can be manufactured in smaller, more manageable sections. These segmented layers can be transported more easily to remote installation sites and then assembled on-site, reducing transportation difficulties while maintaining the pressure handling capability of thick-walled construction.
Solution Approach 2:
The pipe uses a composite structure combining metal tubes with intermediate layers of other materials. This composite construction achieves the required pressure handling capability without requiring excessively thick metal walls, thereby reducing the overall weight and transportation difficulty of the pipe sections.
3Device complexity
If extruded plastic pipes or fiber-wrapped pipes are used to continuously form pipe, then the manufacturing complexity and welding requirements are reduced, but the suitability for high-pressure applications and ability to join with metal pipes deteriorate
Solution Approach 1:
The pipe structure combines metal tubes with intermediate layers of other materials to create a composite pipe that maintains the high-pressure suitability of metal while incorporating the manufacturing advantages of continuous forming processes. The composite structure allows for reduced welding requirements while maintaining pressure integrity.
Solution Approach 2:
The pipe is structured with separable layers that can be manufactured using different processes optimized for each layer's requirements. This segmentation allows the metal layers to provide pressure integrity while the intermediate layers can be formed using continuous processes, reducing overall manufacturing complexity.
4Strength
If conventional welding methods are used to join pipe segments, then the pipeline joints can be made with high strength, but the quality assurance becomes difficult using conventional in-field methods
Solution Approach 1:
The multi-layered structure provides nested protection where the intermediate layer between metal tubes acts as a buffer and stress distributor at joint locations. This nested construction enhances joint strength while the distinct layers provide visual and structural indicators for quality verification during field installation.
Solution Approach 2:
The composite multi-layered structure creates distinct interfaces and material transitions that facilitate quality inspection. The different materials and their interfaces provide visual cues and structural characteristics that make it easier to verify proper assembly and joint quality in the field compared to homogeneous metal welds.
Data Source
AI summary
Multi-layered pipes, machines for forming multi-layered pipes, and methods of forming multi-layered pipes, such as for use in the hydrocarbon industry as may form high-pressure pipelines including forming an inner metal tube from a first metal stock, and while forming the inner metal tube, forming at least a second metal tube around the inner tube from at least a second metal stock. In some methods, sheet metal is bent to form tubes having seams, which are welded while the tubes are being formed. Some methods are performed proximate to an installation site for the multi-layered pipe, such as a hydrocarbon extraction or transportation site. Some methods are performed on a vehicle and proximate to an installation site.