Flexible pipe and coupling therefor
11300231 · 2022-04-12
Assignee
Inventors
Cpc classification
F16L47/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L33/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29K2023/0691
PERFORMING OPERATIONS; TRANSPORTING
B29K2033/08
PERFORMING OPERATIONS; TRANSPORTING
B29C65/4815
PERFORMING OPERATIONS; TRANSPORTING
B29K2027/18
PERFORMING OPERATIONS; TRANSPORTING
B29K2077/10
PERFORMING OPERATIONS; TRANSPORTING
B29K2071/12
PERFORMING OPERATIONS; TRANSPORTING
B29K2067/003
PERFORMING OPERATIONS; TRANSPORTING
B29C66/72141
PERFORMING OPERATIONS; TRANSPORTING
B29K2059/00
PERFORMING OPERATIONS; TRANSPORTING
B29C66/7392
PERFORMING OPERATIONS; TRANSPORTING
B29C65/3616
PERFORMING OPERATIONS; TRANSPORTING
B29K2071/00
PERFORMING OPERATIONS; TRANSPORTING
F16L39/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L33/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29K2277/10
PERFORMING OPERATIONS; TRANSPORTING
B29K2077/00
PERFORMING OPERATIONS; TRANSPORTING
B29C66/7212
PERFORMING OPERATIONS; TRANSPORTING
B29K2081/04
PERFORMING OPERATIONS; TRANSPORTING
B29C66/71
PERFORMING OPERATIONS; TRANSPORTING
F16L13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29K2075/00
PERFORMING OPERATIONS; TRANSPORTING
B29C66/73941
PERFORMING OPERATIONS; TRANSPORTING
B29K2081/06
PERFORMING OPERATIONS; TRANSPORTING
F16L47/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C66/73921
PERFORMING OPERATIONS; TRANSPORTING
B29K2033/08
PERFORMING OPERATIONS; TRANSPORTING
B29C66/12822
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B29K2027/16
PERFORMING OPERATIONS; TRANSPORTING
B29K2027/18
PERFORMING OPERATIONS; TRANSPORTING
B29K2059/00
PERFORMING OPERATIONS; TRANSPORTING
F16L33/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B29K2071/12
PERFORMING OPERATIONS; TRANSPORTING
B29K2277/10
PERFORMING OPERATIONS; TRANSPORTING
B29K2081/04
PERFORMING OPERATIONS; TRANSPORTING
B29C66/12842
PERFORMING OPERATIONS; TRANSPORTING
B29K2077/10
PERFORMING OPERATIONS; TRANSPORTING
B29K2067/00
PERFORMING OPERATIONS; TRANSPORTING
F16L13/007
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29K2023/0683
PERFORMING OPERATIONS; TRANSPORTING
B29K2023/0691
PERFORMING OPERATIONS; TRANSPORTING
B29K2027/16
PERFORMING OPERATIONS; TRANSPORTING
B29C66/7394
PERFORMING OPERATIONS; TRANSPORTING
B29C66/73774
PERFORMING OPERATIONS; TRANSPORTING
F16L11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L53/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29K2077/00
PERFORMING OPERATIONS; TRANSPORTING
B29K2067/003
PERFORMING OPERATIONS; TRANSPORTING
B29K2081/06
PERFORMING OPERATIONS; TRANSPORTING
B29K2075/00
PERFORMING OPERATIONS; TRANSPORTING
B29C65/425
PERFORMING OPERATIONS; TRANSPORTING
B29C66/71
PERFORMING OPERATIONS; TRANSPORTING
F16L11/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C66/8266
PERFORMING OPERATIONS; TRANSPORTING
B29C66/5344
PERFORMING OPERATIONS; TRANSPORTING
B29K2067/00
PERFORMING OPERATIONS; TRANSPORTING
B29C66/7212
PERFORMING OPERATIONS; TRANSPORTING
B29K2023/0683
PERFORMING OPERATIONS; TRANSPORTING
B29C66/72321
PERFORMING OPERATIONS; TRANSPORTING
B29K2071/00
PERFORMING OPERATIONS; TRANSPORTING
B29C66/612
PERFORMING OPERATIONS; TRANSPORTING
B29C66/73755
PERFORMING OPERATIONS; TRANSPORTING
B32B15/14
PERFORMING OPERATIONS; TRANSPORTING
B32B25/10
PERFORMING OPERATIONS; TRANSPORTING
International classification
F16L11/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L33/01
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B29C65/48
PERFORMING OPERATIONS; TRANSPORTING
B29C65/00
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B32B25/10
PERFORMING OPERATIONS; TRANSPORTING
B32B15/14
PERFORMING OPERATIONS; TRANSPORTING
F16L53/30
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L33/34
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L47/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L33/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L39/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L47/24
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16L11/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Construction of a sealed connection between an elastomeric or synthetic polymer flexible pipe or hose and a metallic coupling member. The coupling member surrounds an armor layer at a free end of the flexible pipe or hose. A sealing area is defined by a recessed portion of the pipe coupling into which a sealing material is introduced. An inner liner layer of the flexible pipe or hose may extend into the sealing area where it is bonded to the sealing material. The sealing material and the inner liner layer may each be comprised of a semi-crystalline thermoplastic material. Furthermore, a reinforcement material may be provided in the inner liner layer.
Claims
1. A synthetic polymer flexible pipe for the transportation of high pressure and/or temperature hydrocarbon liquids or gases, the synthetic polymer flexible pipe having an axis and comprising: (i) an inner liner layer; (ii) an armour layer surrounding an end of the flexible pipe; (iii) a pipe coupling disposed at the end of the pipe and surrounding the armour layer; (iv) a sealing area defined by a recessed portion of the pipe coupling; and (v) a sealing material disposed in the sealing area; wherein the inner liner layer of said pipe end extends into the sealing area and is bonded to the sealing material; and wherein the sealing material is non-elastomeric and both the sealing material and the inner liner layer of the flexible pipe comprise the same class of synthetic polymer selected from the group consisting of thermoplastics and thermosets; and wherein the pipe coupling has at least one sealing material port passing through a wall of the pipe coupling and having a first opening into the sealing area and at least one bonding material port passing through the wall of the pipe coupling and having a second opening into an annular bonding area between an outer surface of the pipe and an inner surface of the pipe coupling, wherein the pipe comprises a sealing ring forming a seal between the outer surface of the pipe and the inner surface of the pipe coupling, and wherein first and second openings are spaced apart along the axis of the pipe on opposite axial sides of the sealing ring.
2. The flexible pipe according to claim 1, wherein the flexible pipe and the sealing material each comprise a semi-crystalline thermoplastic material.
3. The flexible pipe according to claim 1, wherein the sealing material is provided as an injectable fluid or molten synthetic polymer.
4. The flexible pipe according to claim 1, wherein the sealing material is provided as a solid meltable seal.
5. The flexible pipe according to claim 1, wherein the portion of the inner liner layer of the flexible pipe which extends into the sealing area is exposed to the sealing material within the sealing area.
6. The flexible pipe according to claim 1, wherein the semi-crystalline thermoplastic material of the sealing material is indirectly bonded to at least one of the inner liner layer and the pipe coupling via an intermediate adhesive tie layer.
7. The flexible pipe according to claim 6, wherein the adhesive tie layer comprises a semi-crystalline thermoplastic material.
8. The flexible pipe according to claim 2, wherein the semi-crystalline thermoplastic material of the inner liner layer and/or sealing material is a polyvinylidene fluoride (PVDF) material.
9. The flexible pipe according to claim 1, wherein the pipe coupling is formed from a metal or a metal alloy.
10. The flexible pipe according to claim 1, wherein a cylindrical sleeve member is disposed beneath the inner liner at the end of the flexible pipe and cooperates with the pipe coupling proximate the sealing area to support a portion of the inner liner layer extending into the sealing area.
11. The flexible pipe according to claim 10, wherein an outer surface of the cylindrical sleeve member is inclined at an acute angle relative to the central longitudinal axis of the pipe.
12. The flexible pipe according to claim 1, wherein the inner liner layer is coupled to the pipe coupling by a crimped or swaged connection.
Description
(1) Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
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(21) The inner liner 1 may be formed from any suitable type of semi crystalline thermoplastic, e.g. polymers derived from polyolefins. Possible options include, but are not necessarily limited to: polypropylene; fully or partially cross-linked polyethylene; polyamides such as polyamide-polyimide; polyimide (PI) (PA6, PA11 or PA12); polyurethanes (PU); polyureas; polyesters; polyacetals; polyethers such as polyethersulphone (PES); polyoxides; polysulfides such as polyphenylene sulphide (PPS); polysulphones such as polyarylsulphone (PAS); polyacrylates; polyethylene terephtalate (PET); polyether-ether-ketones (PEEK); polyvinyls; polyacrylonitrils; polyeterketoneketone (PEKK). Further options include co-polymers of the foregoing such as fluorous polymers; homo-polymers or copolymers of, for example, trifluorethylene (VF3) or tetrafluoroethylene; coplolymers or terpolymers comprising two or more different members selected from VF2, VF3, chlorotrifluorethylene, tetrafluoroethylene, hexafluoropropene or hexafluoroethylene; polymer blends comprising one or more of the above mentioned polymers and composite materials, such as an abovementioned polymer compounded with reinforcement fibres such as glassfibers and/or carbon fibers and/or aramid fibers. The choice of semi crystalline thermoplastic for a given application will depend on the specific expected service conditions of the flexible pipe and perhaps other considerations such as ease of manufacture and cost.
(22) The inner liner 1 is surrounded by a consolidating fabric layer 8. The fabric layer 8—which may include rubber—is surrounded by a steel sleeve 7 which increases in thickness towards the end of the flexible hose. The steel sleeve 7 is surrounded by one or more armour layers 9 comprising of, for example, one or more helically wound layers of steel cord, steel wires or glass/carbon/aramid fibre strands or rovings embedded within a rubber cushioning layer 10. The armour layers 9 and cushioning layers 10 may be provided in the form of tape which is wound around the inner liner 1 in one or more plies. Different plies may be wound at different winding angles.
(23) If present, the reinforcement material 2 within the inner liner 1 may take the form of helically wound steel cord, steel wires or fibre strands or rovings with a winding angle of between 25 degrees and 85 degrees relative to the longitudinal axis 100 of the flexible hose (see
(24) The steel cord and/or steel wires may be wound such that adjacent windings are interlocked. The reinforcement material 2 may also comprise fibre strands and/or rovings selected from the list comprising glass fibres, carbon fibres, UHmwPE (ultra high molecular weight polyethylene) fibres (Dyneema) and aramid fibres. It will be understood that this list is non-exclusive. The reinforcement material may be a textile weave or fabric made up of one or more of the aforementioned materials. The reinforcement material 2 may be provided in the form of a tape containing one or more of the abovementioned materials. The reinforcement material 2 may be over-extruded with the same semi-crystalline thermoplastic material from which the inner liner 1 is made. It is preferable that the reinforcement material 2 may accommodate shear deformation caused by the application of loads, e.g. during bending. Accordingly, the reinforcement material 2 is optionally not bonded to the thermoplastic material of the inner liner 1 within which it is embedded.
(25) A source of heat may be incorporated into the inner liner 1, for example by adding an electric heat tracing layer above and/or below and/or amongst the reinforcement material 2 (also shown in
(26) The internal diameter of the annular hose coupling 13 increases in a generally stepwise fashion from left to right as viewed in
(27) The end portion of the flexible hose is prepared to receive the hose coupling in a conventional manner, for example by curing and stripping back to progressively expose its underlying layers. A cylindrical inner sleeve 6 is disposed within the end portion of the flexible hose. The internal diameter defined by the inner sleeve 6 is selected so as to be substantially equal to the internal diameter of the flexible hose defined by its inner liner 1. The outer surface of the inner sleeve 6 tapers towards the longitudinal axis 100. As the inner sleeve 6 is inserted into the end of the flexible hose its tapered portion(s) engage the innermost surface of the inner liner 1. Progressive insertion of the inner sleeve 6 into the flexible hose causes the internal diameter of the inner liner 1 to expand as it is forced up the tapered surface(s) of the inner sleeve 6.
(28) The recessed portion 3 of the hose coupling 13 is partially closed by the inner sleeve 6 when the hose coupling is fitted over the expanded end of the flexible hose. Once positioned over its end, the hose coupling may optionally be crimped onto the flexible hose from the outside. An epoxy resin 11 is introduced—via end caps 12—into the area between the inner surface of the hose coupling body 13 and the stripped back layers of the flexible hose.
(29) Once the hose coupling is in place, the inner sleeve 6 therefore supports the expanded end portion of the inner liner 1 within the recessed portion 3 of the hose coupling body 13 together with an end of the surrounding fabric layer 8 and steel sleeve 7. All three layers are compressed—for example by crimping or swaging from the inside—between the outer surface of the inner sleeve 6 and an opposing surface of the hose coupling body 13 in a manner which closes off the path between the recessed portion 3 and the internal cylindrical volumes of the flexible hose and the coupling body 13.
(30) The internal volume of the recessed portion 3—hereinafter “the sealing area”—is bounded by the inner wall of the coupling body 13 and—in a preferred embodiment—the radial outer surface of the inner sleeve 6. One surface portion of the inner wall of the coupling body 13 is inclined at an acute angle relative to the longitudinal axis 100 of the flexible hose. The acute angle may be approximately 45 degrees. An end portion of the flexible hose—i.e. its inner liner 1 and fabric layer 8—extends into the sealing area 3 as shown in greater detail in
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(32) A passage is provided through an exterior surface of the hose coupling body 13 to provide access to the sealing area 3 via a removable end cap 5. In one embodiment, a non-elastomeric sealing material can be introduced into the sealing area 3 through the passage using a built-in nipple connector 4. As shown in
(33) For some types of sealing material 15, complete bonding between the respective surfaces within the sealing area 3 necessitates coating them with a tie layer 14 before introducing the sealing material 15. The tie layer may be applied using conventional electrostatic coating techniques. Application of a tie layer may also add thermal insulation and mechanical strength to the connection within the sealing area 3.
(34) In one embodiment, the sealing material 15 comprises a non-elastomeric semi-crystalline thermoplastic material such as an injection grade polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA) or a cross-linked polyethylene (PEX). In one embodiment, the sealing material 15, the inner liner 1 and the tie layer 14 each comprise a non-elastomeric semi-crystalline thermoplastic material. Ideally, the inner liner 1, the tie layer 14, and the sealing material 15 are formed from the same non-elastomeric semi-crystalline thermoplastic material so as to create a single homogeneous polymer structure providing the best possible chemical bond between the hose coupling body 13 and the inner liner 1 within the sealing area 15.
(35) The homogeneous polymer structure, e.g. based on the PVDF, PFA or PEX materials discussed above, will be substantially liquid impervious at a pressure difference of the order of 5-10 bar. Consequently, any reinforcement material 2 embedded within the inner liner 1 is protected from corrosion. If the selected polymer structure is formed from a more liquid permeable thermoplastic material then a fibre-based reinforcement material 2 (as described above) may be utilised as an alternative to steel. Where fibre-based material is undesirable, galvanised steel wire or cable may be employed as a means of protecting against corrosion.
(36) All adjacent layers of the flexible hose are permanently chemically bonded to each other in a manner known in the art. However, in a preferred embodiment it is important that the bonding process employed does not affect the non-bonded character of the reinforcement material 2 within the flexible hose's inner liner 1. For example, the thermoplastic material, e.g. PEX, may become cross-linked upon adding the reinforcement material 2.
(37) The thermoplastic material of the inner liner 1 is permanently and fully chemically bonded to the surrounding rubber encased armour layers 9, 10. Consequently, shear deformation of the thermoplastic material of the inner liner 1 during bending and the application of combined loads may be minimised. The PVDF, PFA or PEX materials discussed above have sufficient bonding and mechanical properties for high pressure applications. If more inert and temperature resistant materials like partially or fully fluorinated thermoplastics are employed, additional production steps may be required to obtain full bonding. The term full bonding is to be understood as meaning that either the mechanical strength limit of the elastomer rubber or that of the thermoplastic layer is exceeded before the bond is broken. Since deformation and compound loadings on a fully bonded pipe are taken up by both the inner liner 1 and the surrounding rubber encased armour layers 9, 10, this helps to avoid known failure mechanisms and provides a significant performance improvement in flexible hoses.
(38) The external layers of the flexible hose surrounding the rubber encased armour layers 9, 10 comprise an anti-wear layer 17 and an outer cover 18. These layers may be applied in the form of tapes and may comprise uni-directional, bi-directional or multi-directional reinforcement material selected from one or more of the types already described above. The external layers may be over-extruded with a final thermoplastic layer. For example, an impact resistant layer 19 in the form of a UHmwPE (ultra high molecular weight polyethylene) tape may be applied to provide extra impact resistance and anti-wear characteristics. An alternative arrangement (shown in
(39) An alternative arrangement for the external layer of the flexible hose is shown in
(40) An alternative manner of effecting a sealed connection between a hose and a metallic coupling member will now be described with reference to
(41) The innermost layer of the flexible hose is a semi-crystalline polymer inner liner 1′ within which is embedded a reinforcement material 2′. The inner liner 1′ is exposed at the free end of the hose and formed with an angled chamfer at its distal end which is complimentary in shape to an annular seat formed in the hose coupling 13′ (see the left hand side of the recess in
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(44) The term “recessed portion” is to be Understood in this context as defining the inner enlarged diameter space bounded by the hose coupling body and the inner liner 1′ of the flexible hose, i.e. including the volume within which the solid meltable sealing ring 23 is seated. The radial passage closed by the end cap 5′ is initially empty as shown more clearly in
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(47) A tie layer 14′ may be applied to the inner surface of the hose coupling 13′ to provide a more reliable cohesive bond between the sealing material and the metallic (e.g. steel) hose coupling. The choice of tie layer 14′ will vary depending upon the chemical make-up of the thermoplastic material used in the sealing material. The cohesive bond, between the sealing material and the surface of the hose coupling 13′ within the sealing area, must be able to withstand the tendency for the inner liner 1′ to creep under high temperatures and/or pressures.
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(49) It will be appreciated that the various embodiments of the present invention provide a number of advantages over existing arrangements for connecting a flexible hose to a hose coupling. Most significantly, by providing a non-elastomeric semi crystalline sealing material within the sealing area which is the same (or chemically similar) as that of the inner liner of the flexible hose, a homogeneous polymer structure extends from the flexible hose all the way into the hose coupling, i.e. the liner becomes the seal and the seal is the liner. This structure provides a moisture-proof and gas-tight barrier more capable of withstanding harsh production environments than known prior art products.
(50) Also, by embedding reinforcement material within the inner liner layer of the flexible hose, its connection with a hose coupling can be further strengthened and improved. The integration of a reinforcement material into the inner liner layer closer to the core of the flexible hose makes the bonded hose stronger and thus enables downscaling, if desired, of the outer armour layers. For example, the number of rubber outer reinforcement plies or the size thereof may be reduced. Consequently, it becomes possible to achieve a more lightweight and/or flexible hose system. A properly designed reinforced inner layer can also replace the need for an inner carcass because the supporting function is now incorporated within the inner liner layer itself.
(51) The embodiment of
(52) The various embodiments of the present invention provide a sealing arrangement that overcomes, or at least ameliorates, one or more of the following problems associated with elastomeric seals. Firstly, high temperatures cause softening of elastomers which results in an increased rate of liquid/gas diffusion, thus accelerating chemical degradation. This temperature-related issue can arise independently of high pressure considerations, although of course high pressures will further exacerbate the problem.
(53) Modifications and improvements may be made to the foregoing without departing from the scope of the invention as defined by the accompanying claims. For example, a possible alternative to the aforementioned meltable seal is a susceptor tape which could be wound around the outer surface of the flexible hose and its liner prior to fitting of the hose coupling.