Flexible Pipe Smoothing Insert for Helical Gap Bridging
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Solution Overview
Problem
Conventional flexible pipe designs face issues such as fluid flow rate reduction and fluid-induced pulsation due to helical gaps between carcass tape windings, which can lead to pipe blockage and catastrophic failures, especially in extreme deep-water environments, and existing inserts are difficult to manufacture and may become displaced during use.
Innovation Solution
A windable insert with a specific cross-section is used to bridge the helical gaps between carcass tape windings, allowing for smooth fluid flow while maintaining the flexibility of the pipe, and is manufactured using a carcass winding machine to ensure proper positioning and interlocking with the carcass tape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If folded tape inserts or multi component inserts are used to cover the gap between carcass windings, then fluid flow rate is improved, but the insert becomes difficult to manufacture and may become displaced during use
Solution Approach 1:
The insert is divided into distinct functional segments: a header portion that engages with the carcass winding, a body portion that spans the helical gap, and an intermediate region that provides transition. This segmentation allows each portion to be optimized for its specific function while simplifying the overall manufacturing process through standardized components.
Solution Approach 2:
Instead of trying to clamp or fix the insert to the carcass winding as in conventional designs, the invention inverts the approach by designing the insert to self-locate and self-retain through its geometric configuration. The curved header portion naturally engages with the carcass winding geometry, eliminating the need for additional clamping mechanisms and simplifying manufacturing.
2Reliability
If the width of the folded tape is increased to better cover the gap, then gap coverage is improved, but the insert cannot be wound with desired overlap during conventional manufacturing
Solution Approach 1:
The insert design changes the geometric parameters of the tape cross-section, specifically incorporating curved portions with controlled radii and angles. This allows the insert to maintain adequate width for gap coverage while enabling proper overlap during conventional winding operations through its modified cross-sectional geometry.
Solution Approach 2:
The solution moves from considering only the width parameter in the radial direction to incorporating the cross-sectional geometry in multiple dimensions. The curved header and intermediate regions provide dimensional control that enables both adequate gap coverage and proper winding overlap through three-dimensional geometric configuration rather than simple width adjustment.
3Productivity
If conventional inserts are used to smooth the bore, then fluid flow is improved, but the inserts require clamping or fixing mechanisms that increase device complexity
Solution Approach 1:
The insert is designed to be self-sufficient without requiring external clamping or fixing mechanisms. The curved header portion self-locates against the carcass winding geometry, and the body portion self-retains through its configuration, eliminating the need for additional clamping devices and reducing overall system complexity.
Solution Approach 2:
The curved intermediate region acts as a mediator between the header portion and the body portion, providing a transition that enables the insert to naturally engage with the carcass winding and maintain position without additional fixing mechanisms. This intermediate geometry facilitates self-location and self-retention.
Data Source
AI summary
An elongate tape element, flexible pipe body and methods of manufacturing flexible pipe body-, the elongate tape element having a cross-section comprising a first portion, extending from a first free edge of the elongate tape element corresponding to a first end of a cross section of the elongate tape element, wherein the first portion is curved for locating in a first gap region that extends between two adjacent windings of a carcass tape of flexible pipe body; and a body portion, extending between the first portion and a remaining end of the cross section corresponding to a remaining free edge of the elongate tape element, having a length for bridging a further gap region extending between a one of the two adjacent windings and a further adjacent winding of the carcass tape that is adjacent to said a one of the two adjacent windings of the carcass tape.