Multilayer Polymer Pipeline Composite Structure for Offshore Pressure Resistance
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Solution Overview
Problem
Current pipeline technologies for transporting oil, gas, and CO2 face limitations in diameter and length, particularly offshore, due to mechanical strain, leakage risks, and high maintenance requirements, with steel pipes being rigid and prone to corrosion, and plastic composite pipes having restricted lengths and pressure resistance issues.
Innovation Solution
A continuous multilayer pipeline design featuring an inner fluid-tight ply, inner fibre-reinforced ply, intermediate plies with axially oriented channels or heating elements, and an outer fibre-reinforced ply, manufactured using a combination of extrusion and fibre-wrapping processes, allowing for a smaller bending radius and improved pressure resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel pipes are used for large diameter transport pipelines, then strength and pressure resistance are improved, but corrosion resistance deteriorates and maintenance requirements increase
Solution Approach 1:
The patent employs a composite structure consisting of an inner polymer liner providing corrosion resistance and an outer steel reinforcement layer providing strength and pressure resistance. This composite design allows the pipeline to withstand high pressures while being protected against corrosion by the polymer liner, thereby resolving the contradiction between strength and corrosion resistance.
2Object-affected harmful factors
If plastic composite pipes are used to avoid corrosion, then corrosion resistance is improved, but pressure resistance and strength deteriorate
Solution Approach 1:
The patent creates a composite pipeline structure where an inner polymer liner provides excellent corrosion resistance while an outer steel reinforcement layer supplies the necessary strength and pressure resistance. This combination allows the pipeline to achieve both corrosion resistance and high pressure resistance simultaneously, resolving the contradiction between these two properties.
3Manufacturing precision
If rigid plastic composite pipes are manufactured in fixed lengths, then manufacturing precision is improved, but adaptability and ease of installation deteriorate due to flange joints
Solution Approach 1:
The patent utilizes the flexibility of the polymer liner to enable the pipeline to be bent and adapted to various installation configurations without requiring rigid flange joints. The continuous polymer lining can accommodate bends and curves, providing installation flexibility while maintaining the precision-manufactured segments connected by simpler coupling mechanisms.
4Ease of operation
If flange joints with seals are used to connect pipe segments, then ease of assembly is improved, but reliability deteriorates due to leakage risks under mechanical strain
Solution Approach 1:
The patent merges the sealing function into the continuous polymer liner that extends through the joint areas, eliminating separate flange seals. The polymer liner acts as a continuous barrier against leakage throughout the entire pipeline, including at connection points, thereby maintaining reliability while still allowing for modular assembly of pipe segments.
5Quantity of substance
If large diameter pipes are manufactured, then transport capacity is improved, but manufacturing complexity and storage requirements worsen due to length restrictions
Solution Approach 1:
The patent divides the large diameter pipeline into manageable segments that can be manufactured separately with precise control over length and dimensions. These segments are then connected using coupling mechanisms that maintain the continuous polymer liner, allowing for modular manufacturing and storage while achieving the required large transport capacity when assembled.
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
The solution enables the production of longer, more flexible pipelines with enhanced pressure resistance and reduced mechanical strain, facilitating efficient offshore transportation while minimizing maintenance and storage needs.
Implementation Method 1
a first ply in a first thermoplastic polymer material, said first ply being formed by extrusion
Implementation Method 2
an inner fibre-reinforced ply surrounding said inner fluid-tight ply, said inner fibre-reinforced ply comprising at least one fibre layer and one reinforcement-free layer
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 3A~3B
AI summary
A multilayer pipeline (1) which includes at least: - an inner fluid-tight ply (11) which consists of a first thermoplastic polymer material; - an inner fibre-reinforced thermoplastic polymer ply (14) which includes a wrapped fibre-reinforcement and which surrounds the inner fluid-tight ply; - a first intermediate ply (13) which consists of a second thermoplastic polymer material; - an outer fibre- reinforced thermoplastic polymer ply (12) which includes a wrapped fibre reinforcement, wherein at least one of the inner fibre-reinforced thermoplastic polymer ply (14) and the outer fibre-reinforced thermoplastic polymer ply (12) includes at least one fibre-containing layer (14a-b, 14c-d; 12a-b, 12c-d) and one reinforcement-free layer (14c, 14f; 12c, 12f). A machine assembly (30) for producing the multilayer pipeline (1) and a method of producing the multilayer pipeline (1) are described as well.