Subsea Pipeline Bundle Bulkhead Coupling for Leak-Tight Assembly
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Solution Overview
Problem
Current methods for assembling longer pipeline bundles are hindered by the difficulty in connecting shorter sections end-to-end, requiring extensive welding and inspection, which is costly and time-consuming, and existing solutions are not suitable for subsea environments due to lack of mechanical resistance and leak-tightness.
Innovation Solution
The use of transverse bulkheads with fluid and mechanical coupling formations to connect pipeline bundle sections, allowing for leak-tight and mechanically secure joining of carrier pipes and fluid conduits, facilitated by a method involving complementary fluid coupling formations and a mechanical locking mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding methods are used to connect pipeline bundle sections, then mechanical strength and continuity are improved, but manufacturing complexity and time consumption increase significantly
Solution Approach 1:
The pipeline bundle is divided into multiple pre-assembled sections, each containing a subset of elongate elements (flowlines, power cables, data cables) within a carrier pipe. These modular sections can be manufactured separately and then connected using bulkhead hubs, avoiding the need to weld entire long-distance bundles in one continuous operation.
Solution Approach 2:
Bulkhead hubs serve as intermediary connecting components between pipeline bundle sections. Each bulkhead hub contains fluid coupling formations that interface with complementary formations on adjacent sections, providing both mechanical connection and fluid-tight sealing without requiring direct welding between carrier pipes.
2Reliability
If extensive welding and inspection are performed to ensure leak-tightness, then reliability is improved, but productivity and cost efficiency deteriorate
Solution Approach 1:
The bulkhead hubs are pre-assembled with the pipeline bundle sections, and the fluid coupling formations are pre-positioned and pre-sealed. This preliminary assembly allows for quality control and leak-testing to be performed on individual sections before final installation, rather than requiring extensive inspection of welded joints after complete assembly.
Solution Approach 2:
The invention replaces traditional welding-based mechanical joining with a bulkhead hub connection system that uses fluid coupling formations. These formations create leak-tight seals through mechanical interference fits or gasket-based sealing mechanisms, eliminating the need for complex welding procedures and subsequent non-destructive testing.
3Reliability
If pipeline bundles are manufactured in continuous long sections, then the number of connection interfaces is reduced, but fabrication facility requirements and transportation constraints increase
Solution Approach 1:
The pipeline bundle is segmented into multiple manageable sections that can be manufactured within the constraints of available fabrication facilities. Each section contains a carrier pipe with elongate elements and is terminated by bulkhead hubs, allowing for standardized manufacturing lengths that fit within facility capabilities while maintaining overall system integrity through multiple connection points.
4Adaptability or versatility
If multiple elongate elements are installed separately at subsea location, then installation flexibility is improved, but the number of subsea interfaces and complexity increase
Solution Approach 1:
Multiple elongate elements (flowlines, power cables, data cables) are combined within a single carrier pipe to form an integrated pipeline bundle section. This merging approach reduces the number of separate subsea installation operations required, as all elements are installed together as one unit rather than individually, thereby reducing the total number of subsea interfaces and simplifying the installation process.
Data Source
AI summary
A bundle section of a subsea pipeline bundle has a rigid carrier pipe having an end closed by a transverse bulkhead and one or more fluid conduits in fluid communication with an opening that penetrates the bulkhead. Fluid coupling formations such as a spigot or a recess on an outer face of the bulkhead surround the opening. Leak-tight coupling between successive fluid conduits is effected when the bulkheads of two such bundle sections are brought together. This forces together opposed complementary fluid coupling formations of the bulkheads. The bulkheads connect the adjoining bundle sections fluidly and mechanically.