A flexible pipe 机翻标题: 暂无翻译,请尝试点击翻译按钮。

公开号/公开日
WO2015139708 A1 2015-09-24 [WO2015139708] / 2015-09-24
申请号/申请日
2015WO-DK50055 / 2015-03-18
发明人
GLEJBØL KRISTIAN;
申请人
NATIONAL OILWELL VARCO;
主分类号
IPC分类号
F16L-011/08
摘要
(WO2015139708) The invention concerns a flexible pipe for offshore applications, such as for use as a riser in oil production.  The flexible pipe has a longitudinal axis and comprises a pressure resilient core pipe structure with an inner surface defining a bore, and at least a pair of cross wound and non-bonded tensile armor layers surrounding said core pipe structure.  The pressure resilient core pipe structure comprises an embedded pressure armor structure, wherein the embedded pressure armor structure comprises a plurality of layers of helically wound continuous fibers, wound with a winding angle of about 60 degrees or more relative to the longitudinal axis of the pipe and embedded in a cured polymer matrix.  The fibers are individually bonded to the cured polymer matrix.  Preferably each of said layers of helically wound continuous fibers have a fiber density of at least about 40 %.
机翻摘要
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地址
代理人
代理机构
;
优先权号
2014DK-0070139 2014-03-21
主权利要求
(WO2015139708) PATENT CLAIMS   1. A flexible pipe having a longitudinal axis and comprising a pressure resilient core pipe structure with an inner surface defining a bore, and at least a pair of cross wound and non-bonded tensile armor layers surrounding said core pipe structure, said pressure resilient core pipe structure comprising an embedded pressure armor structure, wherein the embedded pressure armor structure comprises a plurality of layers of helically wound continuous fibers, wound with a winding angle of about 60 degrees or more relative to the longitudinal axis of the pipe and embedded in a cured polymer matrix, wherein said fibers are individually bonded to the cured polymer matrix, preferably each of said layers of helically wound continuous fibers have a fiber density of at least about 40 %.   2. The flexible pipe of claim 1, wherein each of said layers of helically wound continuous fibers comprise a plurality of fibers, where each continuous fiber is wound adjacent to neighboring continuous fibers, preferably adjacent continuous fibers are touching or have a distance to each other of up to about 2 mm, such as up to about 1 mm.   3. The flexible pipe of claim 1 and claim 2, wherein each of said layers of helically wound continuous fibers comprise a plurality of substantially identical fibers.   4. The flexible pipe of any one of the preceding claims, at least two of said pluralities of layers of helically wound continuous fibers are embedded in a common layer of cured polymer matrix, said common layer of cured polymer matrix preferably comprises all of said pluralities of layers of helically wound continuous fibers.   5. The flexible pipe of any one of the preceding claims, at least two of said pluralities of layers of helically wound continuous fibers are embedded in distinct layer of cured polymer matrix.    6. The flexible pipe of any one of the preceding claims, wherein each of said layers of helically wound continuous fibers have a layer thickness corresponding to up to 2 times the average thickness of the continuous fibers.   7. The flexible pipe of any one of the preceding claims, wherein each of said layers of helically wound continuous fibers have a layer thickness corresponding to the thickness of the continuous fibers.   8. The flexible pipe of any one of the preceding claims, wherein the continuous fibers in each respective layer of helically wound continuous fibers have equal thickness, preferably the continuous fibers in each respective layer of helically wound continuous fibers are substantially identical.   9. The flexible pipe of any one of the preceding claims, wherein the embedded pressure armor structure comprises an even number of layers of helically wound continuous fibers, preferably the embedded pressure armor structure comprises up to 50 layers, such as from about 4 to about 30 layers, such as from about 12 to about 24 layers of layers of helically wound continuous fibers.   10. The flexible pipe of any one of the preceding claims, wherein about half of the plurality of layers of helically wound continuous fibers are helically wound in a first direction and the remaining of the layers of helically wound continuous fibers are helically wound in the opposite direction of the first direction.   11. The flexible pipe of any one of the preceding claims, wherein at least a number of the plurality of layers of helically wound continuous fibers are helically wound one above the other, preferably such that the continuous fibers of one layer of helically wound continuous fibers are in contact with continuous fibers of helically wound continuous fibers of a radial inside and/or a radial outside layer of helically wound continuous fibers.   12. The flexible pipe of any one of the preceding claims, wherein the plurality of layers of helically wound continuous fibers are arranged in one or    more stacks of contacting layers, preferably the plurality of layers of helically wound continuous fibers are arranged in up to four stacks of contacting layers.   13. The flexible pipe of any one of the preceding claims, wherein each of said layers of helically wound continuous fibers have a fiber density of at least about 50 %, preferably at least about 60%, such as at least about 70 %, such as at least about 75 %.   14. The flexible pipe of any one of the preceding claims, wherein at least 50 %, such as at least 90 % of said continuous fibers have lengths of at least about 100 m, preferably at least about 500 m. 15.  The flexible pipe of any one of the preceding claims, wherein said continuous fibers are spun from cut fibers.   16. The flexible pipe of any one of the preceding claims, wherein said continuous fibers comprise filaments, preferably a major part, such as all of the continuous fibers are filaments. 17.  The flexible pipe of any one of the preceding claims, wherein said continuous fibers comprise yarns, preferably yarns comprising filaments, said yarns are preferably primary yarns.   18. The flexible pipe of any one of the preceding claims, wherein said continuous fibers comprise braided filaments. 19.  The flexible pipe of any one of the preceding claims, wherein said continuous fibers comprise carbon fibers, glass fibers, basalt fibers, polymer fibers and combinations thereof.   20. The flexible pipe of claim 16, wherein the polymer fibers are selected from thermoset polymer fibers, such as epoxy fibers, polyester fibers, vinylester fibers, polyurethane fibers, phenolic fibers and thermoplastic polymer fibers, such as aramide fibers, polypropylene fibers, polyethylene fibers, polycarbonate fibers, thermoplastic polyester fibers and mixtures    thereof, preferably the thermoplastic polymer fiber(s) preferably has/have a melting temperature of at least about 150 deg.C, such of at least about 200 deg.C.   21.  The flexible pipe of any one of the preceding claims, wherein the continuous fibers of the embedded pressure armor structure are impregnated with a polymer which is different from the cured polymer matrix in which the elongate armor elements are embedded, preferably the fibers are   impregnated with resin which has been cured, such as an epoxy resin.   22. The flexible pipe of any one of the preceding claims, wherein the continuous fibers are helically wound with a winding angle of at least about 70 degrees, such as at least about 80 degrees relative to the longitudinal axis of the pipe.   23. The flexible pipe of any one of the preceding claims, wherein said pressure resilient core pipe structure has an outer surface and a thickness between the inner surface and the outer surface determined in radial direction, the thickness of the pressure resilient core pipe structure is preferably at least about 0.2 cm, preferably from about 0.4 cm to about 5 cm.   24. The flexible pipe of claim 23, wherein the plurality of layers of helically wound continuous fibers of the pressure resilient core pipe structure are concentrated in at least one thickness region of the pressure resilient core pipe structure, preferably the elongate armor elements are concentrated in a thickness region of the pressure resilient core pipe structure at a distance from the inner surface of the pressure resilient core pipe structure.   25. The flexible pipe of any one of the preceding claims, wherein the pressure resilient core pipe structure is a layered structure comprising an inner polymer layer and at least one outer layer surrounding the inner polymer layer, preferably the continuous fibers are concentrated in at least one of said at least one outer layer of the pressure resilient core pipe structure.    26. The flexible pipe of claim 25, wherein the inner polymer layer is substantially free of said continuous fibers.   27.  The flexible pipe of claim 25 or claim 26, wherein the inner polymer layer is of a substantially homogeneous polymer, preferably selected among polyolefins, cross-linked or not, for example polyethylene (PE) or   polypropylene (PP); polyamides, for example polyamide 11 (PA-11) or polyamide 12 (PA-12); fluorinated polymers, for example polyvinylidene fluoride (PVDF); polysulfides, for example polyphenylene sulfide (PPS);   polyurethanes (PU); polyesters; polyacetals; polyethers, for example polyethersulfone (PES), polyetheretherketone (PEEK) and rubbers such as butyl rubber, most preferred the inner polymer layer is of PA-12, high density PE (HDPE), cross-linked polyethylene (XLPE), PVDF or combinations thereof.   28. The flexible pipe of any one of claims 25 - 27, wherein the inner polymer layer is the innermost layer of the pressure resilient core pipe structure.   29. The flexible pipe of any one of claims 25 - 28, wherein the pressure resilient core pipe structure comprises an innermost film layer on the inner side of said inner polymer layer, said innermost film layer is preferably a metal layer. 30.  The flexible pipe of any one of the preceding claims 25-29, wherein at least one outer layer of said pressure resilient core is an intermediate layer in the form of an intermediate film layer, said intermediate film layer is preferably a metal layer.   31. The flexible pipe of claim 30, wherein an outer layer comprising said cured polymer matrix comprises at least a part of said layers of helically wound continuous fibers arranged outside said intermediate film layer, preferably said cured polymer matrix is arranged directly outside said intermediate film layer and interfacially bonded thereto.    32.  The flexible pipe of any one of claims 25 - 31, wherein an outer layer comprising said cured polymer matrix comprises at least a part of said layers of helically wound continuous fibers, preferably said outer layer comprising said cured polymer matrix comprises all of said layer of helically wound continuous fibers   33.  The flexible pipe of claims 31 or 32, wherein said outer layer   comprising said cured polymer matrix is interfacially bonded to an underlying layer, such as the intermediate film layer, optionally via a bonding layer preferably comprising maleic anhydride. 34.  The flexible pipe of any one of claims 31-33, wherein said outer layer comprising said cured polymer matrix is an outermost layer of said pressure resilient core pipe structure.35.  The flexible pipe of any one of claims 31-33, wherein said pressure resilient core pipe structure comprises an outermost polymer layer free of said layers of helically wound continuous fibers, said outermost polymer layer is preferably of a substantially homogeneous polymer, preferably selected among polyolefins, cross-linked or not, for example polyethylene (PE) or polypropylene (PP); polyamides, for example polyamide 11 (PA-11) or polyamide 12 (PA-12); fluorinated polymers, for example polyvinylidene fluoride (PVDF); polysulfides, for example   polyphenylene sulfide (PPS); polyurethanes (PU); polyesters; polyacetals; polyethers, for example polyethersulfone (PES), polyetheretherketone (PEEK) and rubbers such as butyl rubber, most preferred the inner polymer layer is of PA-12, high density PE (HDPE), cross-linked polyethylene (XLPE), PVDF or combinations thereof. 35.  The flexible pipe of any one of claims 33 or 34, wherein said flexible pipe comprises an anti-friction layer wound around said pressure resilient core pipe structure between the resilient core pipe structure and said pair of cross wound and non-bonded tensile armor layers, preferably said anti-friction layer is in direct contact with, but non-bonded to said pressure resilient core pipe structure.    36. The flexible pipe of any one of claims 31-33, wherein said pressure resilient core pipe structure comprises an outermost polymer layer in form of an anti-friction layer, such as a wound anti-friction layer, preferably said anti- friction layer of said pressure resilient core pipe structure is directly below said pair of cross wound and non-bonded tensile armor layers.   37. The flexible pipe of any one of claims 35 or 36, wherein said antifriction layer is of a wound material, preferably wound edge-to-edge or with an edge-to-edge overlap of up to 50 %, such as from about edge-to-edge to an overlap of about 30 %.   38. The flexible pipe of any one of claims 35-37, wherein said anti-friction layer is a of a tape having a thickness of up to about 3 mm, such as from about 0.1 to about 2 mm, such as from about 0.5 to about 1.5 mm.   39. The flexible pipe of any one of claims 35-38, wherein said anti-friction layer is of or comprises a polymer tape, preferably selected from a fluoride containing polymer.   40. The flexible pipe of any one of claims 35-39, wherein said anti-friction layer is of a fibrous tape, preferably comprising a woven or braided fibrous material optionally impregnated with a polymer, such as a resin, preferably a cured resin, such as a cured thermosetting resin, preferably selected from epoxy resins, vinylepoxyester resins polyester resins, polyimide resins, bis- maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, polyolefins or mixtures comprising at least one of the foregoing thermosetting resins. 41.  The flexible pipe of any one of the preceding claims, wherein said cured polymer matrix comprising said embedded elongate armor elements comprises a cured thermosetting resin, preferably selected from epoxy resins, vinylepoxyester resins polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins,    polyolefins or mixtures comprising at least one of the foregoing thermosetting resins.   42. The flexible pipe of any one of the preceding claims, wherein said cured polymer matrix comprises cross-linked polyolefins, such as cross-linked polyethylene.   43. The flexible pipe of any one of the preceding claims, wherein said cured polymer matrix comprises a cured elastomer.   44. The flexible pipe of any one of the preceding claims, wherein said cured polymer matrix comprises cured epoxy resin. 45.  The flexible pipe of any one of the preceding claims, wherein the pressure resilient core pipe structure comprises at least one acidic neutralizing chemically active compound, preferably in the form of a chemically active compound which can neutralize at least one of C02 and H2S, preferably the chemically active compound is selected from ZnO, PbO, CuO, CdO, NiO, Sn02 and Mo03, and combinations thereof.   46. The flexible pipe of any one of the preceding claims, wherein the pressure resilient core pipe structure comprises at least one cationic clay silicate, such as kaolinite; smectite; lllite; chlorite; and synthetic cationic clays.   47. The flexible pipe of any one of the preceding claims, wherein said pair of cross wound and non-bonded tensile armor layers are wound with a winding angle of about 55 degrees or less, such as with a winding angle of from about 30 degrees to about 45 degrees.   48. The flexible pipe of any one of the preceding claims, wherein said plurality of armor layers surrounding said core pipe structure are not bonded to each other or to the bonded pressure armor layer.   49. The flexible pipe of any one of the preceding claims, wherein each of said pluralities of armor layers surrounding said core pipe structure comprise    a plurality of helically wound elongate armor elements, which elongate armor elements are not bonded to each other.   50. The flexible pipe of any one of the preceding claims, wherein at least one of said pluralities of armor layers surrounding said core pipe structure comprises a plurality of elongate armor elements made from metal, e.g. in form of metal wires.   51. The flexible pipe of any one of the preceding claims, wherein at least one of said pluralities of armor layers surrounding said core pipe structure comprises a plurality of elongate armor elements made from fiber reinforced polymer.   52. The flexible pipe of any one of the preceding claims, wherein said flexible pipe comprises a thermal insulating layer.   53. The flexible pipe of any one of the preceding claims, wherein said flexible pipe comprises a holding layer outside the outermost of the armor layers surrounding said core pipe structure.   54. The flexible pipe of any one of the preceding claims, wherein said flexible pipe comprises an outermost protection sheath.   55. A method of producing a flexible pipe of any one of the preceding claims, the method comprising providing a pressure resilient core pipe structure with an inner surface defining a bore and a longitudinal axis of the pipe, and winding at least a pair of cross wound and non-bonded tensile armor layers to surround said core pipe structure, wherein the production of said pressure resilient core pipe structure comprises providing at least one layer of a curable polymer matrix and winding a plurality of layers of continuous fibers with a winding angle of about 60 degrees or more relative to the longitudinal axis of the pipe such that the individual continuous fibers are embedded in the curable polymer matrix and curing said curable polymer matrix, said curable polymer matrix optionally being partly cured prior to winding of said continuous fibers.    56. The method of claim 55, wherein the method comprises winding each of said layers of continuous fibers from a plurality of continuous fibers, such that each continuous fiber is wound adjacent to neighboring continuous fibers, preferably adjacent continuous fibers are arranged to touch or have a distance to each other of up to about 2 mm, such as up to about 1 mm.   57. The method of claim 55 or claim 56, wherein the method comprises winding a plurality of layers of continuous fibers to be embedded in a common layer of the curable polymer matrix.   58. The method of any one of the preceding claims 55-57, wherein the method comprises providing two or more layers of curable polymer matrix.   59. The method of any one of the preceding claims 55-58, wherein the method comprises winding said plurality of layers of continuous fibers one above the other, preferably such that the continuous fibers of one layer of helically wound continuous fibers are in contact with continuous fibers of helically wound continuous fibers of a radial inside and/or a radial outside layer of helically wound continuous fibers.   60. The method of any one of the preceding claims 55-59, wherein the method comprises winding said plurality of layers of continuous fibers to be embedded in said curable polymer matrix to ensure that each of said layers of helically wound continuous fibers have a fiber density of at least about 40 %, preferably at least about 50%, such as at least about 60 %, such as at least about 70 %, such as at least about 75 %.   61. The method of any one of the preceding claims 55-60, wherein the method comprises impregnating said continuous fibers with a curable resin prior to winding, preferably the resin differs from the curable polymer matrix into which the wound continuous fibers are embedded.   62. The method of any one of the preceding claims 55-61, wherein the method comprises extruding an inner polymer layer wherein said at least one layer of a curable polymer matrix is provided outside said inner polymer layer,    said inner polymer layer is preferably the innermost layer of the pressure resilient core pipe structure or said pressure resilient core pipe structure comprises an innermost layer in the form of an innermost film layer.   63.  The method of claim 62, wherein the inner polymer layer is of a substantially homogeneous polymer, preferably selected among polyolefins, cross-linked or not, for example polyethylene (PE) or polypropylene (PP); polyamides, for example polyamide 11 (PA-11) or polyamide 12 (PA-12);   fluorinated polymers, for example polyvinylidene fluoride (PVDF); polysulfides, for example polyphenylene sulfide (PPS); polyurethanes (PU); polyesters; polyacetals; polyethers, for example polyethersulfone (PES),   polyetheretherketone (PEEK) and rubbers such as butyl rubber, most preferred the inner polymer layer is of PA-12, high density PE (HDPE), cross- linked polyethylene (XLPE), PVDF or combinations thereof.   64.  The method of any one of the preceding claims 62-63, wherein the method comprises applying an intermediate layer in the form of an   intermediate film layer between said inner polymer layer and said curable polymer layer, said intermediate film layer is preferably a metal layer.   65. The method of any one of the preceding claims 62-64, wherein the method comprises applying a layer of bonding material prior to applying said curable polymer layer for increasing interfacial bonding between the cured polymer layer and an underlying layer, said bonding layer preferably comprising maleic anhydride.   66. The method of any one of the preceding claims 55-65, wherein said curable polymer matrix comprises a thermosetting resin precursor for a thermoset polymer, preferably selected from epoxy resins, vinyl-epoxy-ester resins, polyester resins, polyimide resins, bis-maleimide resins, cyanate ester resins, vinyl resins, benzoxazine resins, benzocyclobutene resins, or mixtures comprising at least one of the thermosetting resin precursors, the moldable, curable impregnation substance preferably additionally comprises a hardener for the thermosetting resin precursor(s).    67. The method of any one of the preceding claims 55-66, wherein said curable polymer matrix comprises a thermoplastic polymer, the thermoplastic polymer preferable being cross-linkable, e.g. by peroxide, electromagnetic radiation, hydrolyse and optionally grafted silane and combinations thereof. 68.  The method of any one of the preceding claims 55-67, wherein said curable polymer matrix comprises a curing agent, the curing agent for example being selected from sulphur, phenolic curing agents , aliphatic hardeners, amine and polyamine curing agents, peroxides at least, silanes and mixtures comprising at least one of the foregoing. 69.  A hybrid riser pipe for transporting fluid between an upper facility and a subsea facility, the riser has a center axis and a length along the center axis and comprises at least one unbonded flexible metal armored riser section and a composite pipe section, wherein the composite pipe section is a flexible pipe of any one of claims 1- 55. 70.  The hybrid riser pipe of claim 69, wherein said riser pipe comprises two unbonded flexible metal armored riser sections, one of the unbonded flexible metal armored riser sections is connected to a first end of the composite pipe section and the other one of the unbonded flexible metal armored riser sections is connected to a second end of the composite pipe section, preferably the composite pipe section is longer than each of the unbonded flexible metal armored riser sections, more preferably the composite pipe section has a length of at least about 100 m, such as at least about 500 m, such as at least about 1000 m, and each of the unbonded flexible metal armored riser sections has a length of up to about 50 % of the length of the composite pipe section, such as of about 25 %, such as of about 10 % of the length of the composite pipe section.   71. The hybrid riser pipe of claim 69 or claim 70, wherein said unbonded flexible metal armored riser section(s) comprises at least two cross-wound tensile armor layers each comprising a plurality of helically wound elongate metal armor elements wound with a winding angle of about 60 degree or less    relative to the center axis, preferably said unbonded flexible metal armored riser section comprises a liquid impervious inner sealing sheath defining a bore and sealing against outflow from said bore and a liquid impervious outer sealing sheath sealing against ingress of water and optionally one or more intermediate liquid impervious sheath(s), said liquid impervious sheaths form at least one annulus, at least one of said cross-wound tensile armor layers being arranged in said annulus.
法律状态
(WO2015139708) LEGAL DETAILS FOR WO2015139708  Actual or expected expiration date=2017-09-21    Legal state=ALIVE    Status=PENDING     Event publication date=2015-03-18  Event code=WO/APP  Event indicator=Pos  Event type=Examination events  Application details  Application country=WO WODK2015050055  Application date=2015-03-18  Standardized application number=2015WO-DK50055     Event publication date=2015-09-24  Event code=WO/A1  Event type=Examination events  Published application with search report  Publication country=WO  Publication number=WO2015139708  Publication stage Code=A1  Publication date=2015-09-24  Standardized publication number=WO2015139708  LEGAL DETAILS FOR DESIGNATED STATE BR112016021521  Actual or expected expiration date=2035-03-18    Legal state=ALIVE    Status=PENDING   Corresponding cc:  Designated or member state=BR Corresponding appl: BR112016021521  Application date in the designated or member state=2015-03-18   Application number in the designated or member state=2016BR-0021521 Corresponding cc:  Designated or member state=BR Corresponding pat: BR112016021521  Publication stage code in the designated or member state=A1  Publication date in the designated or member state=2016-11-01   Publication number in the designated or member state=BR112016021521    Event publication date=2016-11-01  Event code=WO/REG  Event code=BR/B01A  Event type=Examination events  Reference to a national code Pct publication - request for entry into the national phase Comunicacao da publicacao internacional pct. apresentacao de peticao de requerimento de entrada na fase nacional Corresponding cc:  Designated or member state=BR  LEGAL DETAILS FOR DESIGNATED STATE EP3120063  Actual or expected expiration date=2035-03-18    Legal state=ALIVE    Status=PENDING   Corresponding cc:  Designated or member state=EP Corresponding appl: EP15765725  Application date in the designated or member state=2015-03-18   Application number in the designated or member state=2015EP-0765725 Corresponding cc:  Designated or member state=EP Corresponding pat: EP3120063  Publication stage code in the designated or member state=A1  Publication date in the designated or member state=2017-01-25   Publication number in the designated or member state=EP3120063    Event publication date=2015-11-04  Event code=WO/121  Event type=Designated states  EP: The EPO has been informed by wipo that ep was designated in this application Corresponding cc:  Designated or member state=EP
专利类型码
A1
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