Spoolable Pipe Solid Hydrocarbon Matrix Corrosion
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Solution Overview
Problem
Current steel pipes used in the oil and gas industry are susceptible to corrosion and require labor-intensive installation, leading to potential leaks and operational disruptions, with existing corrosion-resistant solutions being either expensive or damage-prone.
Innovation Solution
A spoolable pipe design featuring a solid hydrocarbon matrix with a tensile modulus of less than 100,000 psi, incorporating reinforcing fibers and a liquid matrix composition that forms a solid barrier resistant to corrosion and kinking, allowing for efficient spooling and pressure containment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiberglass-reinforced epoxy pipe is used for corrosion resistance, then corrosion protection is improved, but the pipe becomes damage intolerant and requires careful handling
Solution Approach 1:
The patent uses a composite structure combining thermoplastic liner with fiberglass reinforcement embedded in a thermoplastic matrix. This composite approach provides corrosion resistance from the thermoplastic liner while the thermoplastic matrix surrounding the fiberglass fibers provides damage tolerance and flexibility, resolving the contradiction between corrosion protection and damage resistance
Solution Approach 2:
The patent changes the matrix material from rigid epoxy to flexible thermoplastic, altering the mechanical properties of the composite. This parameter change allows the pipe to be corrosion-resistant while also being flexible and damage-tolerant, enabling spooling without kinking or collapsing
2Quantity of substance
If thin-walled pipe is used for low-pressure applications, then material cost is reduced, but the pipe may kink or collapse when spooled
Solution Approach 1:
The patent creates a composite reinforcing layer with fiberglass fibers embedded in thermoplastic matrix that provides structural support for thin-walled pipe during spooling. The composite structure maintains pipe integrity at low wall thickness while enabling flexible installation
Solution Approach 2:
The patent uses flexible thermoplastic materials for both the liner and matrix, creating a flexible pipe system that can be spooled without kinking or collapsing. The flexibility allows thin-walled construction while maintaining spooling capability
3Strength
If high modulus materials such as epoxies are used for reinforcement, then structural strength is improved, but the tendency for thin-walled pipe to kink or collapse increases
Solution Approach 1:
The patent changes the matrix material from high-modulus epoxy to low-modulus thermoplastic, fundamentally altering the mechanical behavior. This parameter change provides structural reinforcement while maintaining flexibility, allowing the pipe to resist collapse during spooling
Solution Approach 2:
The patent uses thermoplastic materials that are easier and cheaper to process than epoxies, allowing for more flexible manufacturing and installation while achieving the required performance through proper material selection and design
4Strength
If bare fiberglass reinforcement is used in thermoplastic liner, then reinforcement is provided, but the fibers are susceptible to corrosion and abrasion
Solution Approach 1:
The patent creates a multi-layer composite structure where the thermoplastic liner provides corrosion protection, the fiberglass fibers provide reinforcement, and the thermoplastic matrix provides abrasion protection and bonds the components together. This composite approach resolves the contradiction by protecting the vulnerable fiberglass fibers
Solution Approach 2:
The thermoplastic matrix acts as an intermediary between the fiberglass fibers and the environment, protecting the fibers from direct exposure to corrosive substances and abrasion while still allowing the fibers to provide their reinforcing function
Data Source
AI summary
A spoolable pipe is disclosed, the spoolable pipe having an internal pressure barrier formed about a longitudinal axis, and a reinforcing layer(s) enclosing the internal pressure barrier that includes a solid hydrocarbon matrix. The pipe can also include an energy conductor(s) integrated with and/or located between the internal pressure barrier and/or the reinforcing layer(s).