Tubular Composite Layer Repair for Real-Time Void Correction
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Solution Overview
Problem
Flexible pipes used for deep and ultra-deep water oil and gas exploration often suffer from defects such as voids and porosity during manufacturing, leading to potential pipe failure and requiring costly remedial actions.
Innovation Solution
A method and apparatus utilizing independently moving abutment elements that can be urged against the outer surface of a tubular composite layer at controlled pressures and temperatures to repair defects in real-time, even as the layer is being manufactured.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional manufacturing processes are used for tubular composite layers, then production speed and efficiency are maintained, but defects such as voids and porosity occur leading to pipe failure
Solution Approach 1:
The patent applies preliminary action by implementing a real-time defect detection and repair system during the manufacturing process. The apparatus detects defects such as voids and porosity in tubular composite layers as they are being produced and immediately applies heat and pressure through abutment elements to repair them before the pipe leaves the production line, thereby maintaining both high reliability and productivity
Solution Approach 2:
The patent implements feedback by using a control system that continuously monitors the manufacturing process, detects defects in real-time, and automatically adjusts the repair parameters (temperature, pressure, duration) of the abutment elements. This closed-loop feedback mechanism ensures defects are corrected immediately without stopping production, maintaining both reliability and productivity
2Reliability
If real-time defect repair is implemented during manufacturing, then pipe reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing the abutment elements to perform multiple functions: they serve as both the heating source and the pressure application mechanism during defect repair. The same apparatus components that form the composite layer also detect and repair defects in real-time, reducing the need for separate specialized equipment and thereby limiting the increase in device complexity
Solution Approach 2:
The patent implements self-service by enabling the manufacturing system to automatically detect and repair its own defects without external intervention. The control system autonomously monitors for voids and porosity and triggers the repair sequence using the integrated abutment elements, allowing the system to maintain high reliability while keeping the added complexity manageable through automation
3Reliability
If defects are repaired after manufacturing, then pipe reliability can be improved, but time-consuming and costly remedial work is required
Solution Approach 1:
The patent applies preliminary action by repairing defects during the manufacturing process itself, before the pipe is completed and shipped. The real-time detection and immediate repair using heat and pressure eliminates the need for post-manufacturing remediation, saving significant time and cost while ensuring pipe reliability
Solution Approach 2:
The patent implements continuity of useful action by maintaining production flow without interruption. The defect repair process is integrated into the continuous manufacturing line, allowing pipes to be produced and repaired in an unbroken sequence, thereby eliminating the time loss associated with stopping production for quality control and post-manufacturing repairs
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 enables continuous and automatic correction of defects in tubular composite layers during production, preventing pipe failure and eliminating the need for costly post-manufacturing analysis and remediation.
Implementation Method 1
urging at least one of said abutment element against an outer surface of the tubular composite layer in order to at least partially repair at least one defective region
Implementation Method 2
at least one heater and/or cooler element, for selectively heating and/or cooling at least one of: the abutment elements, and/or a region of the tubular composite layer, to a desired temperature
Data Source
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AI summary
A method and apparatus are disclosed for at least partially repairing a defect in a tubular composite layer. The apparatus comprises a plurality of independently movable abutment elements (3820) each supported in a spaced apart relationship via a respective one of at least one support member (3810). Each abutment element is associated with a respective drive axis along which the abutment elements are movable and the drive axes of all abutment elements extend outwardly from a common centre point.