Pipeline Cable Mat Wrapping for Faster Strain-Free Installation
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Solution Overview
Problem
Existing cable-laying machines for pipelines are bulky, expensive, and inefficient, particularly when installing multiple cables in straight or wavy configurations, and can introduce strain that leads to defects or faults, which are difficult to locate and fix.
Innovation Solution
A method involving a pliant substrate mat with cables pre-attached, which is wrapped around the pipeline circumference and secured with fastenings, allowing simultaneous installation and insulation before being inserted into an outer pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional cable-laying machines are used to install cables on pipelines, then cable installation can be performed, but the machines are bulky, expensive, and slow to set up and operate
Solution Approach 1:
The cable-laying system is divided into separate functional components: a portable cable-laying device that can be easily positioned along the pipeline, and a separate insulation application system. This segmentation allows the cable-laying machine to be compact and inexpensive while maintaining installation capability.
Solution Approach 2:
The method enables self-service cable installation by allowing workers to manually attach cables to the pipeline using simple fastening mechanisms, eliminating the need for complex automated cable-laying machinery. The system is designed to be operated with minimal equipment while maintaining efficiency.
2Reliability
If helical cable configuration is used to accommodate pipeline curvature, then cables will not sag or be overstretched, but the overall cable length increases and installation becomes more complex
Solution Approach 1:
The cable configuration is made adaptable to pipeline geometry by allowing flexible positioning and routing options. The system can accommodate both straight and curved pipeline sections by dynamically adjusting cable placement, eliminating the need for fixed helical patterns while maintaining cable integrity.
3Ease of manufacture
If cables are installed using traditional methods, then cable laying can be performed, but the process imparts strain on cables that could introduce or exacerbate defects or faults
Solution Approach 1:
Cables are pre-positioned and secured to the pipeline before insulation material is applied. This preliminary action ensures cables are properly supported and strain-free before the insulation process begins, preventing defects that could occur during or after insulation installation.
4Temperature
If cables are buried beneath insulation material, then thermal insulation is provided, but faults become difficult to locate and fix
Solution Approach 1:
The insulation system is segmented into removable sections or layers that allow easy access to embedded cables. This segmentation enables maintenance personnel to locate and repair cable faults without removing the entire insulation system, maintaining thermal efficiency while improving repairability.
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 simplifies and speeds up the cable-laying process, reduces costs, and enhances cable reliability by minimizing strain and facilitating easier fault detection.
Implementation Method 1
The wrapped mat is then fixed to the pipeline, for example using at least one circumferential band, strap or layer
Implementation Method 2
Heat produced by passing an electric current along the cables is conducted through the pipe wall to the production fluid flowing within
Implementation Method 3
Heat produced by passing an electric current along the cables is conducted through the pipe wall to the production fluid flowing within
Implementation Method 4
passive thermal management systems employ thermal insulation to retain heat in fluids carried by the pipeline
Data Source
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AI summary
A method of attaching a plurality of cables such as trace heating cables to an elongate pipeline comprises bringing together the pipeline and an elongate mat along a common longitudinal direction, wrapping the mat around at least a majority of the circumference of the pipeline, and fixing the wrapped mat to the pipeline. The mat comprises at least two longitudinally-extending cables that are supported by a pliant substrate so that when the mat is wrapped around the pipeline, the cables are positioned at respective angular positions about a longitudinal axis of the pipeline. The mat may be guided from a planar configuration on exiting a reel into a configuration that is curved about the longitudinal axis. Centraliser spacers and thermal insulation may be added around the pipeline and the wrapped mat before the assembly is inserted into an outer pipe.