METHOD FOR PRODUCING A STEEL UNDERWATER PIPE THAT IS ABLE TO CARRY A CORROSIVE FLUID

Abstract

A method for producing a steel underwater pipe for carrying a corrosive fluid, includes the successive steps: applying a layer of corrosion-resistant steel alloy on a terminal part of the internal wall of each pipe element from its end to be welded; the application of a plastic coating, on the internal wall of each pipe element; covering only a first part of the layer of metal alloy, a terminal part of the layer of metal ally on the side of the end to be welded of each pipe element not being covered by the plastic coating; the coaxial insertion and the crimping of a compression ring against the terminal part of the plastic coating; and the assembly by welding directly together the ends of two pipe elements by a corrosion-resistant steel alloy weld.

Claims

1.-15. (canceled)

16. A method for producing a steel underwater pipe that is able to carry corrosive fluids, particularly water, the internal wall of which is partially lined by a protective coating of plastic material of the liner type wherein the assembly by welding directly together the ends of at least two pipe elements is provided for, comprising the steps wherein are produced successively: a) the application of a layer of corrosion-resistant steel alloy on a terminal part of length L1 of the internal wall of each pipe element from its end to be welded; b) the machining on the pressure side surface of the layer of corrosion-resistant steel alloy, c) the application of a said protective coating of plastic material directly on the internal wall of each pipe element; and covering a first part of length L2 of said layer of corrosion-resistant steel alloy, a second, adjacent part of length L3 of said layer of corrosion-resistant steel alloy on the side of the end to be welded of each pipe element not being covered by said protective coating of plastic material, d) the coaxial insertion of a compression ring of corrosion-resistant steel alloy inside said terminal part of each pipe element and the crimping of a first annular part of length L4 of said compression ring against the pressure side face of the terminal part of said protective coating of plastic material covering a first part of said layer of corrosion-resistant steel alloy, and the welding of the free end of a second annular part of said compression ring against a second part of said layer of corrosion-resistant steel alloy not covered by said protective coating of plastic material, said first annular part of the compression ring comprising an outer side face which is corrugated, over a part at least of its length said second annular part of said compression ring continuing said first annular part, said second annular part being applied against a part of said second part of the layer of corrosion-resistant steel alloy not covered by said coating of plastic material and extending over a length L5 less than L3, from and against the end of said coating of plastic material until said free end of said compression ring closest to the end to be welded of the pipe element, and e) the assembly by welding directly together the ends to be welded of two pipe elements by a corrosion-resistant steel alloy weld.

17. The method according to claim 16, wherein said compression ring comprises a said second annular part the pressure side surface of which is of conical shape, connecting the pressure side surface of the first annular part and the surface of the second part of the layer of corrosion-resistant steel alloy not covered by said coating of plastic material, at the end of said second annular part of the compression ring closest to the end of the pipe element.

18. The method according to claim 17, wherein said second annular part of the compression ring extends against said terminal part of the layer of corrosion-resistant steel alloy over a length L5 of approximately ½ of L3, the length of the terminal part of the layer of corrosion-resistant steel alloy not covered by said coating of plastic material.

19. The method according to claim 16, wherein, in step b), machining is carried out so as to create a corrugation in the form of a plurality of second parallel circular peripheral grooves on the first part of the pressure side face of the layer of corrosion-resistant steel alloy intended to be covered by a terminal part of said protective coating of plastic material.

20. The method according to claim 16, wherein, in step c), the end of said protective coating of plastic material is terminated at a distance L3 from the end to be welded of each pipe element, L3 being at least equal to ⅓ of the length L1 of said layer of corrosion-resistant steel alloy.

21. The method according to claim 16, in step a), the layer of corrosion-resistant steel alloy on the terminal part of the internal wall of each pipe element extends over a length L1 of ½ to 2 times the inner diameter D1 of the pipe element prior to machining and/or of 4 to 20 times the thickness of the pipe element prior to machining.

22. The method according to claim 17, wherein said compression ring comprises at least one first annular part, the outer side face of which is corrugated over a length d3 substantially equal to and facing a length d2 of the corrugated part of the first part of the layer of corrosion-resistant steel alloy, said first and second parallel circular peripheral grooves having a depth of 1 to 1.5 mm, extending over a length of ⅕ to ½ of the length L1 of said layer of corrosion-resistant steel alloy and with a distance of 4 to 6 mm between said first circular grooves and respectively between said second circular grooves.

23. The method according to claim 16, wherein: prior to step a), prior machining is carried out of the bore of said terminal part of length L1 of the internal wall of each pipe element, over a depth intended to receive said layer of corrosion-resistant steel alloy of 1 to 5 mm, and in step b), machining is carried out on the pressure side surface of the layer of corrosion-resistant steel alloy at the inner diameter of the pipe before said prior machining.

24. The method according to claim 16, wherein, before step e), finish machining is also carried out of the end of the pipe to form a chamfer allowing receiving a weld bead during step e) of end-to-end assembly by welding.

25. 1The method according to claim 16, wherein: 1) pipe elements are prepared for welding together by carrying out steps a) to d), and 2) step e) of assembly by welding with a corrosion-resistant steel alloy of the respective ends to be welded of at least 2 pipe elements obtained according to step 1) above is carried out.

26. A pipe element obtained in step 1) and useful in step 2) of claim 24, said pipe element comprising: a layer of corrosion-resistant steel alloy on a terminal part of length L1 of the internal wall of said pipe element from one end to be welded; a protective coating of plastic material applied directly on the internal wall of said pipe element; and covering a first part of length L2 of said layer of corrosion-resistant steel alloy, a second part of length L3 of said layer of corrosion-resistant steel alloy on the side of said end to be welded of said pipe element not being covered by said protective coating of plastic material, a compression ring of corrosion-resistant steel alloy inserted inside the pipe element comprising: (a) a first annular part of length L4 comprising an outer side face which is corrugated, over a part at least of its length L4, said first annular part being crimped against the pressure side face of at least one terminal part of said protective coating of plastic material covering said first part of said layer of corrosion-resistant steel alloy, and (b) a second annular part of length L5 less than L3, continuing said first annular part, applied against a part of said second part of the layer of corrosion-resistant steel alloy not covered by said coating of plastic material, said second annular part of said compression ring extending from and against the end of said coating of plastic material until said free end of said compression ring closest to the end to be welded of the pipe element, welded against said second part of said layer of corrosion-resistant steel alloy not covered by said protective coating of plastic material.

27. The pipe element according to claim 26, wherein, a first part of the pressure side face of the layer of corrosion-resistant steel alloy intended to be covered by a terminal part of said protective coating of plastic material is machined for corrugation, in part at least, and said compression ring comprises at least: (a) one first annular part, the outer side face of which is corrugated in part at least, able to cover said terminal part of said protective coating of plastic material, in line with at least the corrugated part of the first part of the layer of corrosion-resistant steel alloy of which the pressure side face is covered by the terminal part of said protective coating of plastic material, said first annular part extending in line with the second part of the layer of corrosion-resistant steel alloy not covered by said coating of plastic material, and (b) one said second annular part the pressure side surface of which is of conical shape connecting the pressure side surface of the first annular part and the surface of the second part of the layer of corrosion-resistant steel alloy not covered by said coating of plastic material, at the end of said second annular part of the compression ring welded against said second part of said layer of corrosion-resistant steel alloy not covered by said protective coating of plastic material.

28. The hybrid pipe element according to claim 26, wherein the other end of said hybrid pipe element which is not intended to be welded in said step 2) does not comprise said compression ring but comprises a rigid tubular junction sleeve of thermoplastic material, a first longitudinal end of said sleeve being in sealed contact or being formed in a continuous piece with the other end of said coating of plastic material inside said hybrid pipe element, a second end of said sleeve protruding by a length L0 outside the other end of said hybrid pipe element.

29. The hybrid pipe element according to claim 28, wherein said second end of said sleeve protruding outside the other end of said hybrid pipe element is inserted inside another pipe element in sealed contact, with the end of a coating of plastic material set back by a length L0 inside said other pipe element relative to the end of said other pipe element assembled by steel alloy welding with said hybrid pipe element.

30. A steel underwater pipe that is able to carry a corrosive fluid, particularly water, of which the internal wall is partially lined by a protective coating of plastic material of the liner type, in which the assembly by welding directly together said ends to be welded of at least two pipe elements comprising a said compression ring on the side of said end to be welded is provided for according to claim 26.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Other features and advantages of the present invention will be revealed by the description given below, with reference to the appended drawings which illustrate examples of it without any limiting character. In these figures:

[0081] FIGS. 1A to 1F illustrate different steps of an exemplary embodiment of a pipe element 10, 10-1 and 10-2 for use in the method according to the invention;

[0082] FIG. 2 illustrates the assembly by welding of two pipe elements set end to end for implementation of the method according to the invention; and

[0083] FIG. 3 is a variant embodiment of a pipe element lined on the non-machined internal wall of a pipe element 10; and

[0084] FIGS. 4A-4C illustrate a variant embodiment involving the use of a hybrid pipe element equipped with a tubular junction sleeve 5.

DETAILED DESCRIPTION OF THE INVENTION

[0085] In FIG. 1A, a pipe element 10 is shown in which the bore of a terminal part 10a1 of the internal wall 10a has been machined to a depth of 1 to 5 mm, preferably 3 mm, extending from the end to be welded 10b of the pipe element over a length L1 of ½ to 2 times the inner diameter D1 of the pipe element prior to machining, or of 4 to 20 times the thickness e of the pipe element prior to machining, and terminating with an inner chamfer 10a2. Preferably, L1 is equal to the inner diameter D1 of the pipe element prior to machining. In practice, the inner diameter D1 is 150 to 750 mm and the thickness is then respectively 5 to 75 mm.

[0086] In FIG. 1B, the terminal part 10a 1 of the internal wall 10a of the pipe element 10 is coated with a weld overlay 2 of alloy steel resisting the corrosion of the fluid to be transported.

[0087] In FIG. 1C, this weld overlay 2 has then been machined to the nominal inner diameter D1 of the pipe in its current part. Shown in FIG. 1C is the creation on the pressure side of the anti-corrosion weld overlay 2 of a corrugation on the first part 2a of the overlay layer 2 in proximity to the chamfer 10a2, consisting of a plurality of parallel circular peripheral grooves 2d, with a depth of 1 to 1.5 mm extending over a length d2 of ⅕ to ½ of L1, preferably of ¼ to ⅓ of L1, for example approximately 75 mm if L1=D1=210 mm and with a distance between the circular grooves of 4 to 6 mm.

[0088] In FIG. 1C, finish machining has also been carried out of the end 10 of the pipe element 10 and of the corresponding end of the overlay layer 2 so as to form a portion of the chamfer 10c for the deposition of a weld bead intended for the end-to-end assembly of two pipe elements 10-1, 10-2.

[0089] In FIG. 1D, a lining in the form of a coating of flexible plastic material 1 called a “liner” is then carried out, preferably of high-density polyethylene or a polymer material compatible with the fluid to be transported. To accomplish this continuously according to the method called swagelining, an internal tubular shell is then inserted into the pipe 10 then released to be pressed or bonded against the internal wall.

[0090] Then, as shown in FIG. 1E, after the required delay, said tubular shell of the liner 1 is cut at the specified location lb on the overlay layer 2, the end not lined by the liner 1 extends over a length L3 from the end 10b of the pipe element to be welded by approximately at least half of L1. Thus, only a first part 2a of the layer of length L2 comprising the corrugation of the layer 2 of corrosion-resistant alloy is covered by said protective coating of plastic material 1, a second terminal part 2b of length L3 substantially equal to L2 of the layer 2 of corrosion-resistant alloy is not covered by said protective coating of plastic material (1).

[0091] In FIG. 1E, a ring 3 of corrosion-resisting steel alloy, including: [0092] (a) a first annular part 3a, the pressure side face of which is in part corrugated with a plurality of parallel circular peripheral grooves 3d, over a length d3, here substantially identical to d2, the part 3a being able to be inserted and to cover a terminal part la of the lining 1 of high-density polyethylene, over a length L4, in line with the part of the overlay 2 the pressure side face of which is provided with grooves 2a, L4 being less than L3, and [0093] (b) a conical shape 3b continuing the first part 3a, which is able to be inserted, then welded on the internal wall of the pipe element coated with only the overlay 2, extending from and against the end lb of the plastic lining 1 over a length L5 of approximately ½ of L3 until its end 3c closest to the end 10b of the pipe element 10.

[0094] In FIG. 1F, a sleeve or other expandable or deformable tool, inflatable in particular (not shown) inserted in the pipe element, has allowed accomplishing under pressure the crimping of the corrugated part of the first part 3a of the ring 3 and the corrugated part of the first part 2a of the layer 2 of anti-corrosion steel alloy by plastic deformation against the part la of the lining 1 of high-density polyethylene. The crimping of the compression ring 3 combined with the corrugated sectors 2a, 3a, contribute to protect the terminal part 1a of the liner 1 during subsequent welding 11 and the sealing of the steel liner-wall connection 10a. In FIG. 1F, the end 3c of the cone 3b is welded by a weld of anti-corrosion steel alloy 4 so as to enhance the sealing and avoid corrosive liquid being able to penetrate under the ring 3.

[0095] In FIG. 2, the two ends 10b of the two pipe elements 10-1 and 10-2 thus lined are then welded end to end by a peripheral weld 11 accomplished by a method of corrosion-resistant steel alloy welding at the chamfers 10c.

[0096] In FIG. 3, is shown a non-preferred variant in which the internal wall 10a of the pipe element 10, 10-1, 10-2 is not machined prior to the deposition of the overlay 2 forming a coating of anti-corrosion steel alloy 2 which creates a shoulder 2b with a thickness corresponding to the thickness of 3 mm of the overlay 2 relative to the nominal inner diameter of the pipe.

[0097] The method according to the invention applies to the lining of any steel pipe intended for the transport of fluids, particularly to underwater pipes, resting on the bottom of the ocean or providing the bottom-to-surface connection for the transfer of hydrocarbons, for example petroleum or gas, originating in underwater production wells.

[0098] Preferably, the overlay layer of anti-corrosion steel alloy 2 and the compression ring 3 are made of Inconel 625®, i.e. of a Ni 61/Cr 22/Mo 9/Fe 5 alloy. A stainless steel alloy of this type is particularly known for its great strength and its corrosion resistance properties.

[0099] The overlay layer 2 can advantageously be deposited by welding in several layers as described in patent application FR 1752255 in the applicant's name.

[0100] In certain cases, it can happen that it is necessary to carry out a connection to an existing pipe at the bottom of the ocean, including a terminal pipe element 10-3 not equipped with a said compression ring and layer of corrosion-resistant steel alloy and in which it is difficult to directly crimp a compression ring of this type according to the invention in situ in its terminal part or even in the case of cutting into the pipe while it is being laid at an unexpected location. In a case of this type, as shown in FIGS. 4A-4B, it is possible to add, to the pipe element 10-3 at the bottom of the ocean, a hybrid pipe element 10-2 according to the invention equipped (a) with a tubular junction sleeve 5 protruding by L0 outside one end 10d of the hybrid pipe element 10-2 intended to be assembled to said terminal pipe element 10-3 at the bottom of the ocean and (b) a compression ring 3 and layer of corrosion-resistant steel alloy according to the invention at its other end 10c intended to be assembled to a pipe element 10-1 equipped with a compression ring and layer of corrosion resistant steel alloy according to the invention. The other end 5a of the tubular junction sleeve 5 inside the hybrid pipe element 10-2 can be beveled or chamfered and thus assembled in known fashion (for example by electric socket welding as described in FR 2 963 654) to a beveled or chamfered end of complementary shape 1c abutting the plastic lining 1 of the hybrid pipe element 10-2 on the side opposite to the compression ring. For example, the ends 5a and 5b of conical shape of the sleeve 5 are each provided with a spiral wire 8 wound over the conical surface 5a, 5b so that, when supplied with an electrical current at 8a, electric socket welding of said ends 5a, 5b can be carried out against the complementary ends in abutment 1c and 1′a of the plastic linings of the pipe elements 10-2 and 10-3 respectively.

[0101] To accomplish this, the following steps are performed: [0102] stripping the plastic lining 1′ from the terminal end of the pipe element 10-3 of the lined pipe at the bottom of the ocean over the appropriate length L0, preparation of the welding chamfer 1′a of the end of the plastic lining able to be assembled for example by electric socket welding or other with the end of a tubular junction sleeve, [0103] setting the diameter of the steel terminal pipe element 10-3 if necessary, and terminal chamfering 10e, [0104] insertion of the exterior chamfered end 5b of the plastic tubular junction element 5 of the hybrid pipe element 10-2 in the end of the pipe element 10-3 until it comes into abutment on the chamfer 1′a to be welded by electric socket welding of the plastic lining 1′ of the pipe element 10-3, the sleeve 5 protruding by L0 from the end 10d of the hybrid element 10-2 so that the end 10d of the hybrid element 10-2 arrives in abutment or in proximity to the end 10e of the pipe element 10-3 to allow their welding with steel alloy 11′, and [0105] assembly, preferably by electric socket welding, of the chamfer 5b of the plastic sleeve of the hybrid element 10-2 to that 1′a of the plastic lining 1′ of the pipe element 10-3, and [0106] welding in steel alloy 11′ of the end 10d of the hybrid element 10-2 with the end 10e of the pipe element 10-3 equipped with the screen 6 by means of the welding device 7. This screen 6 of ceramics limits the transfer of heat and protects the thermoplastic sleeve through the entire duration of the welding process.

[0107] Shown in FIG. 4C, is a preferred embodiment in which, in the hybrid pipe element 10-2, the sleeve 5 is formed in a continuous piece with the plastic coating 1, hence thete is no welding by electric socket welding to be performed at the junction of the ends 5a /1c inside the hybrid pipe element 10-2 as in FIG. 4A.