Thermoset Composite Flexible Pipe Armour Production
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Solution Overview
Problem
Existing flexible pipe designs for deep and ultra-deep water environments face challenges with residual strain in thermoset composite armour layers, leading to increased weight, material costs, and potential failure under high tension and pressure, while also being susceptible to adhesion, abrasion, and environmental factors.
Innovation Solution
A method of producing flexible pipes using thermosetting composite material by helically wrapping it under predetermined tension around a fluid-retaining layer and then heating to cure, eliminating residual strain and reducing weight while maintaining high strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker and stronger materials are used for armour layers, then strength and stiffness are improved, but weight increases
Solution Approach 1:
The patent applies composite materials consisting of high-strength fibres embedded in a thermoset matrix to create armour layers that provide high strength and stiffness while maintaining low weight. The composite structure allows optimal fibre orientation to bear tensile loads efficiently, achieving superior strength-to-weight ratio compared to traditional metallic materials.
2Strength
If thermoset composite material is wound to create armour layers, then high specific strength is achieved, but residual strain is introduced
Solution Approach 1:
The patent applies preliminary action by pre-curing the thermoset composite material to form rigid rods before winding them into the armour layer configuration. This ensures the material achieves its full strength properties before being formed into the final pipe structure, eliminating residual strain that would otherwise be introduced during winding of uncured material.
3Reliability
If deeper water exploration is pursued, then oil demand is met, but environmental factors increase risk of pipe failure
Solution Approach 1:
The patent employs composite armour layers with thermoset matrix and high-strength fibres to achieve the mechanical properties required for deepwater applications. The composite structure provides superior strength-to-weight ratio, chemical resistance, and environmental durability needed to withstand high pressure, temperature variations, and corrosive seawater conditions at great depths.
4Stability of the object's composition
If traditional metallic materials are used for armour layers, then ductility is maintained, but chemical resistance and specific strength are reduced
Solution Approach 1:
The patent uses composite materials where high-strength fibres provide the structural framework for maintaining dimensional stability and resistance to deformation, while the thermoset matrix provides chemical resistance and environmental durability. This composite approach achieves both ductility-like flexibility and superior chemical resistance that metallic materials cannot provide alone.
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 solution results in flexible pipes with reduced weight and improved performance, specifically designed for deep and ultra-deep water applications, with armour layers that are substantially free of residual strain, providing enhanced resistance to adhesion, abrasion, and environmental factors.
Implementation Method 1
heating the length to cure the thermosetting composite material
Data Source
AI summary
To produce a flexible pipe body, a length of tensile armour element (300) of pre-preg composite material is fed towards a fluid-retaining layer (602). The tensile armour element (300) passes through a guide (604) an a pre-heater (606). The tensile armour element (300) is then applied to the fluid-retaining layer (602), being wrapped around the fluid-etaining layer (602) by virtue of the rotation of the layer (602), the linear translation of the layer (602), and the fixed position of the tensile armour element feed (601). The element (300) is fed to the fluid-retaining layer under a constant, predetermined controlled tension. Positioning head (608) helps to position the element (300) on the fluid-retaining layer (602). As tensile armour element is wound onto the pipe body, the pipe body continues to move in a, linear direction and the pipe body moves through an oven (610).