Pipeline Polymer Sheeting Extrusion for Vertical Adhesion Control
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Solution Overview
Problem
Existing methods for applying protective sheeting to underwater pipelines, particularly those with significant vertical or tilted orientations, face challenges such as varying thickness and adherence issues due to the physical characteristics of polymer materials, which are exacerbated by the J-lay rig setup used in deep water pipeline construction.
Innovation Solution
A method involving a carriage with an end extrusion die and pressure roller system that extrudes and compresses polymer sheeting in close proximity to the pipeline, controlling the timing and temperature to ensure rapid adhesion and minimize deformation, with adjustments for varying pipeline tilts and speeds, and utilizing a computer program to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective sheeting is extruded and wound about the pipeline using known methods, then the pipeline can be protected, but the thickness of the sheeting varies and adhesion fails on vertical or sharply tilted pipelines
Solution Approach 1:
The polymer material is pre-heated in a heating zone before extrusion to ensure it is in the optimal plastic state for consistent extrusion and adhesion, preventing thickness variation and adhesion failure on vertical pipelines
Solution Approach 2:
The temperature of the polymer material is controlled and maintained within a specific range during extrusion by pre-heating, which changes the physical state parameters of the material to ensure uniform flow and consistent thickness application
2Ease of manufacture
If the polymer material is kept soft by heating, then it can be extruded and applied, but it deforms between extrusion and compression on vertical pipelines
Solution Approach 1:
The protective sheeting is extruded and immediately compressed in rapid succession, minimizing the time the material spends in the soft, deformable state. The compression occurs so quickly that the material does not have time to deform under gravity before being secured to the pipeline
Solution Approach 2:
The compression mechanism is positioned immediately after the extrusion die, so that the moment the material is extruded it is already being compressed and secured, preventing deformation before the material can be fixed in place
3Area of stationary object
If the protective sheeting is applied to vertical pipelines using known methods, then coverage is achieved, but the leading end portion fails to adhere to the substrate
Solution Approach 1:
The polymer material is pre-heated before extrusion to ensure it reaches the substrate in the optimal plastic state for adhesion, and the compression mechanism is positioned to immediately press the leading end portion onto the substrate as it is extruded
Solution Approach 2:
The temperature of the polymer material is controlled to maintain it within the optimal plastic state range during extrusion, ensuring consistent adhesion properties as the material contacts the substrate on vertical pipelines
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 method effectively applies uniform protective sheeting to vertically or sharply tilted pipelines, ensuring strong adhesion and preventing deformation, thereby enhancing the durability and corrosion protection of the pipeline coatings.
Implementation Method 1
extruding and simultaneously winding protective sheeting about the pipeline utilizing an end extrusion die fitted to the carriage
Implementation Method 2
compressing the protective sheeting on the pipeline, directly downstream from the end extrusion die, so the protective sheeting adheres to the pipeline
Implementation Method 3
the soft protective sheeting is prevented from deforming between the end extrusion die and the compression area
Data Source
AI summary
A method of applying protective sheeting of polymer material to a pipeline, such as on a J-lay rig, includes the steps of driving a carriage along an annular path about the pipeline; extruding and simultaneously winding the protective sheeting about the pipeline via an end extrusion die fitted to the carriage; compressing the protective sheeting on the pipeline, directly downstream from the end extrusion die, so the protective sheeting adheres to the pipeline; and controlling the drive, extrusion, and compression steps so that the time lapse between expulsion of a cross section of protective sheeting from the end extrusion die and compression of the same cross section of protective sheeting is less than one second.