WO99/13257 PCT/CA97/00657 PIPE COUPLING The present invention relates to a connection for a tubular composite structure. 5 In USP 5,261,462, there is described a tubular composite structure which may be used as a flexible pipe. The structure shown in USP 5,261,462 is made up of a number of layers of helically wound composite with elastomeric strip interposed between the successive 10 passes of the composite. A pair of layers are provided with radial projections that are located between a pair of elastomeric strips of an adjacent layer so that relative movement between the adjacent layers is controlled during bending. 15 The tubular structure shown in the above-noted U.S. patent has met with acceptance in the field and provides an effective alternative to conventional steel welded pipe. It is, however, necessary to connect the composite structure to conventional fittings to 20 facilitate its installation in a practical environment. In the above-noted U.S. patent, there is shown a method of connecting a pair of tubular structures in end-to-end relationship by utilizing the helically wound nature of the composite layers. The elastomeric strips 25 between the composite layers are removed and replaced with further composite layers so that a strong connection could be obtained. It was also proposed in the prior patent that a similar process might be utilized with a coupling by providing helical recesses in the flange of 30 the coupling and laminating the tubular structure to the coupling. Such an arrangement has not been found satisfactory due to the high end loads that are imposed upon the flexible couplings and the tendency of the 35 composite structure to unwind from the coupling when subjected to pressure fluctuations. In general, it is found that the interface between the flexible tubular structure and the end fitting should have at least the same structural integrity as the flexible pipe itself and WO99/13257 PCT/CA97/00657 2 that such a connection should be designed and tested to ensure that it equals or exceeds the maximum axial load in the pipe due to transportation and service loading. This axial load can result from external axial tension or 5 can be generated by internal pressure. A common technique to connect an end fitting to a flexible pipe involves swaging an outer wall of the fitting to trap the pipe wall between concentric walls of the fitting. The mechanical interference provided 10 resists axial loads and radial projections on the walls of fitting increase the grip on the pipe wall. This technique relies upon the resilience of the pipe wall and so is not practical where relatively rigid elements are use to fabricate the pipe wall. 15 An alternative technique is used with flexible pipe distributed by Wellstream Corporation. Such pipe utilizes an interlocked steel carcass that has limited axial movement between adjacent passes to allow limited bending. Helically wound wire layers support the 20 carcass. The wire layers are wound in opposite hand and are laid over a reverse taper on the fitting to secure the fitting. A cavity within the fitting is filled with epoxy to hold the layers in situ and resist axial loads. The use of the reverse taper introduces a 25 spreading force on the overlapping wires as an axial load is applied which tends to allow the wires to extrude from the fitting. Moreover, the initial increase in diameter necessary to provide the reverse taper introduces potential slackness in the fitting that may permit an 30 initial axial movement of the pipe relative to the fitting. It is an object of the present invention to provide a connector that obviates or mitigates the above disadvantages. 35 According to the present invention, there is provided in general terms a connector for a multi-layered composite tubular structure in which a cone member is WO99/13257 PCT/CA97/00657 3 inserted between adjacent layers of the tubular structure. The radially outer layers of the structure are helically wound in opposite directions over the conical outer surface of the cone. A female cone member 5 is positioned over the radially outer surface of the outer layers and an axial force applied between the two cone members to clamp the composite layers between their conical surfaces. Preferably the layers are braided to one 10 another at their distal end to maintain structural integrity and as a further preference a wire is braided into the strips to provide a circumferential band. A filler is applied to the voids between the strips and conical surfaces. The surfaces are arranged so that 15 axial forces applied to the pipe tend to reduce the volume of the voids and the filler thereby opposes such reduction. An embodiment of the invention will now be described by way of example only with reference to the 20 accompanying drawings, in which Figure 1 is a general side view of a tubular structure with the layers thereof progressively removed; Figure 2 is a section on the line 2-2 of the structure shown in Figure 1; 25 Figure 3 is a sectional view of the tubular structure of Figures 1-3 incorporating a connector; Figure 4 is a side view showing a portion of the connector; Figure 5 is a view similar to Figure 4 showing 30 a subsequent stage in the formation of a connector; Figure 6 is a view portion of Figure 4 on an enlarged scale; and Figure 7 is a view of the line 7-7 of Figure 5. Figures 1-2 show a tubular structure as 35 exemplified in the above-noted U.S. patent and which will be described briefly to assist in the understanding of the present invention.
WO99/13257 PCT/CA97/00657 4 Referring therefore to Figure 1, a tubular structure 10 has a circumferential wall 12 that is formed from a pair of juxtaposed wall elements 14,16. An outer sheath 18 completes the wall 12 and provides protection 5 from the environment for the elements 14,16. As can best be seen in Figure 2, the radially inner wall element 14 comprises three separate layers, namely 20, 22 and 24. The inner layer 20 consists of a continuous flexible plastic cylinder 26 having a spirally 10 wound protrusion 28 projecting radially outwardly therefrom. The layer 20 can typically be formed from a thermoplastic polymer or elastomeric material and is preferably impermeable to the fluids to which it may be exposed. Layer 20 may also act as an inner liner 15 although a separate liner of impermeable material may be provided so that the cylinder 26 may be formed from a material having different properties. The outer layer 24 of the inner wall element consists of a spirally wound composite strip 30 having a 20 radially inward projection 32 directed towards the inner layer 20. The composite strip 30 has the same pitch and hand as the spiral projections 28. However, the projections 32 and 28 are staggered axially and overlap in the radial direction. 25 A second spirally wound composite strip 34 is located between the successive passes of the strip 30 and located axially so as to be aligned with the projection 28. Composite strips 30,34 each consist of a bundle of fibres or roving, for example E-glass, generally 30 orientated in the direction of the winding with a matrix disbursed between the fibres. The strips may contain transverse fibres to resist secondary stresses such as transverse shear, interlaminar shear, longitudinal shear, and cross fibre shear in the strip that are induced by 35 internal pressure and in bending of the structure. The matrix may, for example, be polyester. Typically, the composite strips will have 75% by weight of fibre and 25% WO99/13257 PCT/CA97/00657 5 by weight of matrix although, as will be discussed more fully below, alternative materials and ratios may be used. 5 Located between the composite strips 30,34 are a pair of spirally wound elastomeric strips 36,38. These strips may be any suitable elastomer such as neoprene. Strips 36 and 38 are located on opposite flanks of the composite strip 30 and act to maintain the composite 10 strips 30 and 34 in spaced relationship. An intermediate layer 22 is located between the layers 20,24 and consists of a pair of composite spirally wound strips 40,42. Each of these strips 40,42 is of the same hand and same pitch as the strips 30 and 34 and is 15 axially located so as to overlap in the axial direction each of the adjacent strips 30,34 in the outer layer 24. Each of the strips 40 and 42 is located between adjacent ones of the projections 32,28. A pair of elastomeric strips 44,46 and 48,50 is associated with the composite 20 strips 40 and 42 respectively and located on opposite sides thereof. Strip 44 is thus interposed between the composite strip 40 and the projection 28 and elastomeric strip 46 is interposed between the strip 40 and projection 32. Similarly, the elastomeric strips 48 and 25 50 are interposed between the composite strip 42 and the projections 32 and 28 respectively. A layer of friction-reducing material such as polyethylene film 52 is located between the inner layer 20 and intermediate layer 22. Similarly, a layer of 30 friction-reducing material 54 is applied between the outer layer 24 and intermediate layer 22 so as to minimize the resistance to relative movement between the layers 22 and 24. Outer wall element 16 is separated from the 35 inner wall element 14 by a friction-reducing film 56. The outer wall element 16 consists of inner and outer layers 58,60 which in turn are separated by a friction reducing film 62. Each of the layers 58 and 60 consists WO99/13257 PCT/CA97/00657 6 of alternating composite strips 64 and elastomeric strips 66 that are spirally wound. The pitch between successive passes of each strip 64 is greater than that of the 5 composite strips of the inner wall element 14 so that in general there will be a greater number of individual strips 64 than there are strips 30,34. For added clarity, each separate strip 64 has been denoted with a suffix a,b in Figure 3 with the corresponding elastomeric 10 strip 66 also denoted with suffixes a, b and c. The pitch of the strips 64,66 in outer layer 60 of the outer wall element 16 is the same as that of the inner layers 58. However the strips 64,66 in the layer 60 are wound in an opposite hand to those in the layer 58 as can be seen in 15 Figure 1. A friction-reducing film 68 is located between the outer sheath 18 and the layer 60 to minimize resistance to relative movement between the sheath and outer layer 60. 20 In operation, the principal bending stiffness of the structure 10 is determined by the flexible layer 20. The composite strips of the outer layer 24 and intermediate layer 22 of wall element 14 essentially constitute helical springs formed from composite material 25 and do not contribute significantly to the bending stiffness of the overall structure. The overlapping of the composite strips of the intermediate layer 22 and outer layer 24 provides a continuous barrier of composite material in a radial direction in the wall element 14 and 30 thereby supports the layer 20 against internal pressure to inhibit extrusion of the layer 20 through the wall element 14. The elastomeric strips act to maintain the composite strips uniformly distributed along the axial length of the tubular structure and interact with the 35 projections 28 and 32 to maintain the composite strips 40,42 of the intermediate layer centred between the composite strips 30,34 of the outer layer 24.
WO99/13257 PCT/CA97/00657 7 As the tubular structure is flexed transverse to its longitudinal axis, the composite strips on one side of the neutral axis move apart and the composite 5 strips on the other side of the neutral axis move together. This is accommodated by a bodily displacement of the elastomeric strips which, however, maintain a uniform loading across the composite strip to maintain them uniformly distributed and maintain the continuous 10 composite barrier in the radial direction. Further detail of the manufacture and performance of the tubular structure may be found from prior U.S. patent and need not be described further at this time. 15 In order to connect the pipe 10 to a conventional fitting it is necessary to provide a connector that terminates the pipe and permits a fitting to be attached to the pipe. Referring therefore to Figure 3, a connector 20 generally indicated 100 includes a male conical member 102 that has a radially outer conical surface 104 and an internal bore 106. The bore 106 has a thread 108 that receives a boss 110 of a flange 112. The conical member 102 is secured to the flange 112 by the thread 108 and 25 boss 110. It may be welded if preferred. Connector 100 also includes a cup 114 having a conical inner surface 116 of similar included angle to the surface 104. The cup 114 terminates one end in a flange 118 of similar diameter to the flange 112. 30 Each of the flanges 112,118 include holes 120,122 respectively to receive studs 124. The holes 120 in flange 112 are threaded to engage the studs 124 whereas the holes 122 in flange 118 provide a clearance for the studs 124. Studs 124 project to the opposite 35 side of flange 112 to the cup 114 and so provide suitable attachment to a conventional fitting 126 shown in ghosted outline.
WO99/13257 PCT/CA97/00657 8 An injection port 128 is provided in the male member 102 to allow a filler to be injected into the bore 106. Similarly, a port 130 is provided in the cup 114 to allow a filler to be injected between the conical 5 surfaces 104,116 of the male member and cup respectively. A shoulder 132 is formed on the surface 104 to provide a circumferentially extending recess and a similar undercut 134 is formed on the inner surface 116. The shoulders 132,134 define an annular recess indicated 10 at 136 extending about the connector 100. As shown in Figure 3, the male member 102 is dimensioned to be inserted between two of the layers that collectively make up the wall elements 14,16. The bore 106 is dimensioned to receive the 15 layers that make up the inner wall element 14. The inner layer 20 is welded to a stub end 142 at the seam 144. A radial web 146 on the stub end 142 extends across the face of the flange 112 to provide a sealing face with the fitting 126. A compression ring 148 inhibits extrusion 20 of the web 146 as the fitting 126 is tightened against flange 112. The assembly of the connector 100 to the pipe 10 proceeds as follows with the dimensions recited being typical for a 2 inch internal diameter pipe: 25 1. The cup 114 is placed over the pipe (pipe end of the cup first) at a distance from the pipe end so that there is enough space for the subsequent steps. 2. A hose clamp is tightened onto the pipe 30 approximately 20 inches from the end for a pipe of 2 inch diameter. 3. The outer cover 18 is removed from the pipe end to the hose clamp. 4. The elastomer strips 66 of layer 60 are removed 35 from the pipe end to the hose clamp. 5. The composite strips 64 of layer 60 are peeled back from the pipe end to the hose clamp.
WO99/13257 PCT/CA97/00657 9 6. The exposed layer of polyethylene film 62 is removed from the pipe end to the hose clamp. 7. The elastomer strips 66 of layer 58 are removed from the pipe end to the hose clamp. 5 8. The composite strips 64 of layer 58 are peeled back from the pipe end to the hose clamp. 9. The exposed layer of polyethylene film 56 is removed from the pipe end to the hose clamp. 10. Two inches is removed from the end of the inner 10 wall element 14. 11. A half inch of layers 24 and 22 are removed to expose the inner liner 20. 12. The elastomer strips 36,38 of layer 24 are removed back to 15 inches from the end of the 15 pipe. 13. A minimum of 3 inches, and preferably up to 15 inches, of polyethylene film 54 is removed from the end of the pipe between layers 24 and 22. 14. A minimum of 3 inches, and preferably up to 15 20 inches, of elastomer strips 44,46,48,50 are removed from the end of the pipe in layer 22. 15. The cone 102 is slid over the inner wall element 14 as close as possible to the hose clamp so that at least 2 1/2 inches of the 25 inner wall element 14 is exposed behind the cone 102. 16. The stub end 142 is inserted through the threaded flange 112 and trimmed so that it extends 3 inches beyond the threaded flange 112 30 which is then positioned at the end of the pipe 10. 17. Both the stub end 142 and the pipe 10 are supported (at the exposed inner wall element 14 and the stub end 142 is fused to the exposed 35 inner liner 20. 18. The flashing is removed from the seam 144.
WO99/13257 PCT/CA97/00657 10 19. The cone 102 is moved to the threaded flange 112 and screwed onto the boss 110. 20. The hose clamp is removed and the composite strips 5 64 of layers 58 and 60 of the outer wall element 16 are then wrapped onto the cone. The strips overlap to provide a diamond pattern, as shown in Figures 4,5, and 6, and define voids between the adjacent layers. 10 21. The last 6 inches of the composite strips 64 at the flange end of the cone 102 are braided with one another such that each of the composite strips 64 of layer 58 passes repeatedly over, and then under, the composite strips 64 of layer 60. 15 22. A one sixteenth inch diameter steel wire 154 is braided together with the composite strips 64 of layers 58 and 60 for a length of 1/2 inch immediately behind the cone shoulder 132. 23. A one eighth inch diameter steel wire 152 is braided 20 together with the composite strips 64 for a length of 1/2 inch immediately behind the previous braided steel wire. 24. The cup 114 is moved over onto the braided cone 102, and rotated so that the cup vent hole 130 is 1800 25 from the cone injection hole 128. 25. The cup 114 is tightened to the threaded flange 112 by studs 124. 26. The pipe is pretensioned to 1,000 pounds axial load. 27. A liquid thermosetting polymer resin such as epoxy 30 or vinyl ester is injected through the cone injection hole 128 into the void between the cup and the cons and the void between the cone and the line simultaneously and allowed to cure.
WO99/13257 PCT/CA97/00657 11 The application of the composite strips to the conical surface 104 of the member 102 results in the strips overlapping and forming rhombic voids 150. The 5 bottom of each void is closed by the conical surface of the member 102 and the top closed by the surface 116 of the cup 114. The progressively increasing diameter of the surface 104 causes the volume of the voids 150 to increase progressively toward the end of the pipe 10. 10 Accordingly, any relative movement between the pipe and the connector results in a reduction of the volume of the voids which is resisted by the injected thermosetting polymer. The spaced conical surfaces 104,116 prevent the composite strips from expanding radially as an axial load 15 is applied. The polymer used may typically be a vinyl ester such as that available from Dow Chemical under the trade name DOW Derakane 411 Vinyl Ester. Other thermosetting polymers including epoxies or polyesters could be used or alternatively thermoplastic polymers 20 such as polyamide or polyethylene with a suitable melt temperature can be used. The composite strips 64 of layers 58 and 60 are braided to one another for their last six inches as shown in Figure 4. 25 The braiding applied to the composite strips is best seen in Figures 5 and 7, and includes a pair of circumferential bands 152,154 of braiding wire that is interwoven with the braided layers of composite strips. The bands 152,154 provide a mechanical abutment against 30 the recess 136 and with the braiding of the strips 58,60 binds the ends to one another to prevent the strips from unravelling or extruding from between the surfaces. The anchoring of the strips to one another and to the recess 136 also facilitates the frictional 35 engagement of the composites against the conical surface as axial loads are applied to enhance further the retention of the pipe with the connector. With the anchoring of the strips, an axial load tends to cause the WO99/13257 PCT/CA97/00657 12 strips to engage the conical surfaces as a band brake so that the greater the load, the greater the frictional retention. It is contemplated that under certain conditions a cylindrical surface could be used for the 5 insert with sufficient frictional engagement of the strips being provided from their mechanical interconnection and braiding. In tests with a sample pipe, axial loads in the order of 60,000 lbs. have been accommodated. 10