Subsea Pipeline Joint Coating with Air-Filled Glass Spheres
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Solution Overview
Problem
Current subsea pipeline laying methods face challenges in accurately determining the touchdown point, leading to potential buckling and overstressing, require excessive ROV usage, are time-consuming for joint formation, and lack efficient insulation at weld sites, especially in deep and remote locations.
Innovation Solution
A method involving the use of air-filled glass spheres in an epoxy coating material applied over the joints of subsea pipelines, combined with a honeycomb wrap and RFID tags, allows for accurate sonar determination of touchdown points and improved insulation, reducing the need for multiple ROVs and speeding up the joint formation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If ROVs are employed to determine the touchdown point, then the touchdown point can be visually identified, but the tether length becomes insufficient when the touchdown point is far from the vessel
Solution Approach 1:
The patent replaces the mechanical tether system with an acoustic/sonar system. Instead of using a physical tether to connect the ROV to the vessel, the system uses acoustic signals transmitted from the vessel to reflect off the pipeline and return to the vessel, enabling touchdown point determination without a long mechanical tether.
Solution Approach 2:
The patent introduces acoustic waves as an intermediary medium to transfer information from the pipeline to the vessel. The acoustic signals serve as a mediator that carries information about the pipeline's position and the touchdown point back to the vessel, eliminating the need for a direct mechanical connection.
2Measurement precision
If a second vessel with a second ROV is used to determine the touchdown point, then the measurement range is extended, but the operational cost increases significantly
Solution Approach 1:
The patent makes the single ROV and single vessel multi-functional by enabling the ROV to perform both pipeline inspection and acoustic signaling functions. The same ROV that inspects the pipeline also serves as the acoustic reflector for range determination, eliminating the need for a second vessel and second ROV.
Solution Approach 2:
The patent combines the inspection function and the ranging function into a single integrated system. The ROV performs both roles: visual inspection of the pipeline and acoustic reflection for distance measurement, merging two previously separate functions into one unified approach.
3Strength
If traditional welding methods are used for joint formation, then the pipes can be joined end-to-end, but the process becomes time-consuming and inefficient
Solution Approach 1:
The patent changes the fundamental parameter of joint formation from mechanical welding to a chemical bonding process using two-part epoxy resin. This chemical bonding method cures faster and can be applied more efficiently than traditional welding procedures, improving productivity while maintaining joint strength.
Solution Approach 2:
The patent uses a composite bonding material consisting of two-part epoxy resin that chemically bonds the pipes together. This composite material approach replaces the thermal and mechanical processes of welding with a chemical bonding process that is both strong and efficient.
4Temperature
If insulating material is applied over the pipe joints, then insulation is provided, but the welding area becomes inaccessible and insulation application becomes time-consuming
Solution Approach 1:
The patent performs the bonding action first by applying the two-part epoxy resin to join the pipes, and only after the joint is formed does the system apply the insulating material. This preliminary bonding action ensures the joint is secure before insulation is applied, and the rapid-curing epoxy minimizes the time the joint remains exposed.
Solution Approach 2:
The patent rushes through the critical exposed joint period by using a rapid-curing two-part epoxy resin that bonds quickly. This minimizes the time window during which the joint is exposed and vulnerable, allowing the insulating material to be applied immediately after bonding without significant exposure time.
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
Enables efficient and accurate determination of touchdown points at a distance, minimizes ROV requirements, accelerates joint formation, and enhances insulation quality, thereby reducing operational costs and risks associated with buckling and hydrate formation.
Implementation Method 1
The joint has coating material extending thereover. This coating material has air-filled glass spheres therein.
Implementation Method 2
sending and receiving sonar signals toward and from the pipeline by the ROV so as to ascertain the touchdown point
Implementation Method 3
applying a coating material over the exterior surface of the first pipe and over the welding and over an exterior surface of the second pipe
Data Source
AI summary
A method of forming a field joint for a subsea pipeline includes the steps of positioning an end of a first pipe adjacent to an end of a second pipe, welding the end of the first pipe to an end of the second pipe, and applying a coating material over an exterior surface of the first pipe, over the welding, and over an exterior surface of second pipe such that the coating material is in sealing relationship therewith. The coating material has air-filled glass spheres therein. A mold is placed over the adjacent pipe sections and the coating material is injected under pressure into the mold.