DK201200462A - A method of and a production facility for winding an elongate armor element - Google Patents

Abstract

The invention relates to a method of winding at least one elongate armor element to form part of a pipe as well as a production facility for the method. The method comprises providing at least one winding station comprising a support structure capable of supporting the elongate armor element wound around said support structure, the support structure has a center axis defined as the axis of the wound elongate armor element supported by the support structure, the support structure comprises a feeding site and a supply site, the supply site has a proximal supply border; wind ing a length section of the elongate armor element onto said support structure; providing an elongate support element having a length and a center axis; arranging said winding station to supply said wound elongate armor element from the supply site of the support structure; supplying said wound elongate element from said supply site and onto said elongate support element.

Description

A METHOD OF AND A PRODUCTION FACILITY FOR WINDING IN ELONGATE

ARMOR ELEMENT

TECHNICAL FIELD

The present invention relates to a method of winding one or more elongate armor elements to form part of a pipe, in particular a pipe which is suitable for conveying fluids under high pressure, such as an unbonded flexible pipe for offshore and subsea transportation of fluids. like hydrocarbons, CO2, water and mixtures hereof. The invention also relates to a production facility for carrying out the method.

BACKGROUND ART

Many types of pipes, in particular high pressure pipes, comprise helically wound armor elements for reinforcement. Such pipes include multi layered flexible pipes for example unbonded flexible pipes comprising at least one polymer layer and at least one armor layer of helically wound armor element (s). For example, unbonded flexible pipes are described in the standard "Recommended Practice for Flexible Pipe", ANSI / API 17 B, Fourth Edition, July 2008, and the standard "Specification for Unbonded Flexible Pipe", ANSI / API 17J, Third Edition, July 2008. Such pipes usually comprise an inner liner also often called an inner sealing sheath or an inner sheath, which is the innermost sealing sheath and which forms a barrier against the outflow of the fluid which is to be conveyed in the bore of the pipe, and one or more armoring layers. Often the pipe further includes an outer protection layer which provides mechanical protection of the armor layers. The outer protection layer may be a sealing layer sealant against ingress of sea water.

In certain unbonded flexible pipes one or more intermediate sealing layers are arranged between armor layers. Examples of unbonded flexible pipes are e.g. disclosed in US 6,978,806; US 7,124,780; US 6,769,454 and US 6,363,974.

The term "unbonded" means in this text that at least two of the layers including the armoring layers and polymer layers are not bonded to each other. In practice the known pipe normally comprises at least two armoring layers located outside the inner sealing sheath and optionally an armor structure located inside the inner sealing sheath normally referred to as a carcass. Usually, the armoring layers comprise or consist of one or more helically wound elongated armoring elements, where the individual armor layers are not bonded to each other directly or indirectly via other layers along the pipe. Thereby the pipe becomes bendable and sufficiently flexible to roll up for transportation.

Other types of pipes including helically wound armor elements for reinforcement include e.g. flexible pipes for exhaust gas systems e.g. as disclosed in EP 2446975.

The term "sealing sheath" is herein used to design a liquid impermeable layer, normally comprising or consisting of polymer. The term "inner sealing sheath" designates the innermost sealing sheath. The term "intermediate sealing sheath" means a sealing sheath which is not the inner sealing sheath and which comprises at least one additional layer on its outer side. The term "outer sealing sheath" means the outermost sealing sheath.

The winding of the one or more elongate armor elements is often cumbersome and difficult, and requires expensive production facilities which are difficult to modify for production of different pipes. US 4,895,011 discloses an apparatus for storing and dispensing elongate flat strip material for use with rotating machinery, such as that used to produce helically wound interlocked flexible pipe. The strip material is fed from an external payoff or supply reel and guided by an inlet guide roller to feed the advancing strip tangentially onto a series of storage guide rollers which are spaced from each other about a circular path concentric with the machine axis. The strip is maintained under tension and wound onto the storage guide rollers to provide a reservoir of strip material arranged in a single row of substantially circular overlapping convolutions concentrically arranged about the machine axis. A roller is used to monitor the amount of strip material that remains stored on the rotating support member, and the rotation of the laughter is terminated when the stored strip material is depleted or is about to be depleted, to allow an operator to attach the trailing end of the depleted stored strip with the leading end of a next successive strip material to be wound onto the storage guide rollers. The arrangement of the storage guide rollers insures a balanced condition of the rotating machine irrespective of the amount of strip material that remains stored. US 4,783,980 discloses an apparatus for making helically wound interlocked flexible pipe from strips by winding the strips onto a mandrel, where the apparatus includes a rotating head mounted for rotation about an axis coincident with the mandrel .. Two supply spools of strip material are mounted on the rear side of the rotating head. US 6,067,829 discloses a wire-spiraling machine continuously producing a tubular structure comprising a spiral winding, particularly a pressure-armor layer, from two non-interlocking wires of large cross section delivered from two reels of wire and two locking wires delivered from two reels of locking wire. A motorized rotating circular cage carries the four reels of wire and locking wire at its rear, while the downstream face of the cage supports, on two adjustable-inclination plates, two on-board twin-track caterpillars for dragging the wire. These caterpillars are arranged just upstream of guide and / or bend rolls leading the wires towards their respective lay point. CA 2678912 discloses winding apparatus and processes for the wrapping or winding of continuous products, such as hose, cable, wire and composite pipe. The methods and apparatus allow for the continuous wrapping or winding of such products without stopping or slowing the production line for re-loading spools or bobbins of winding / wrapping material. The winding apparatus includes a carriage with a multiple of bobbins or spools containing wound up fibers / tapes that are continuously unwound and wrapped in a helical orientation around the inner core or liner of the product as the product passes through the winding machine to an automatic loading system for loading and unloading the spools or bobbins or winding / wrapping material. The apparatus includes a drive system for movement of the carriage. When a bobbin requires replacement, a controlled reduction in winding speed is synchronized with downstream movement of the carriage.

DISCLOSURE OF INVENTION

An object of the present invention is to provide a method of winding one or more elongate armor elements to form part of a pipe, which method can be applied in an in-line process without requiring stopping or slowing the production line for re-loading spools. or bobbins or elongate armor element (s).

Simultaneously it is an object of the invention to provide a method that can be applied in a very cost-effective manner compared to prior art methods.

It is also an object of the invention to provide a production facility suitably for performing the method of the invention and which production facility can further be applied in a flexible manner such that it can be converted relatively quickly and at low cost from one production setup to another production setup.

These and other objects have been solved by the invention as defined in the claims and as described herein below.

It has been found that the invention and embodiments thereof have a number of additional advantages which will be apparent to the skilled person from the following description.

The method of the invention for winding at least one elongate armor element to form part of a pipe comprises • providing at least one winding station comprising a support structure; • winding a length section of the elongate armor element onto the support structure; • providing an elongate support element having a length and a center axis; Arranging the winding station to supply the wound elongate armor element and supplying it to the elongate support element; and • optionally feeding at least one additional length section of the elongate armor element onto the support structure.

According to the invention, the wound elongate armor element can be supplied from the support structure and onto the elongate support element without requiring unwinding or rewinding.

In further details, the invention comprises • providing at least one winding station comprising a support structure capable of supporting the elongate armor element wound around said support structure, the support structure having a center axis defined as the axis of the wound elongate armor element supported by the support structure, the support structure comprises a feeding site and a supply site, the supply site has a proximal supply border; • winding a length section of the elongate armor element onto said support structure; • providing an elongate support element having a length and a center axis; • arranging said winding station to supply said wound elongate armor element from the supply site of the support structure; • supplying said wound elongate element from said supply site and onto said elongate support element,

In a preferred embodiment, the method of the invention comprises • providing at least one winding station comprising a support structure capable of supporting the elongate armor element wound around the support structure, the support structure having a center axis defined as the axis of the wound elongate armor element supported by the support structure, the support structure comprises a feeding site and a supply site, the supply site has a proximal supply border; • winding a length section of the elongate armor element onto the support structure, the at length section of the elongate armor element comprising a proximal end and optionally a distal end, the proximal end being closer to the supply border; • providing an elongate support element having a length and a center axis; • arranging the winding station to supply the wound elongate armor element from the supply site of the support structure; • supplying the wound elongate element from the supply site and onto the elongate support element; • feeding at least one additional length section of the elongate armor element onto the support structure by winding the additional length section of the elongate armor element onto the feeding site of the support structure

By the method of the invention the winding of the elongate armor element onto the support structure of the winding station can be performed independently of the supply of the wound elongate armor element from the support structure and onto the elongate support element. In that way additional length section (s) of the elongate armor element can be wound onto the support structure without stopping or slowing the supply of the wound elongate armor element from the support structure and onto the elongate support element and accordingly without stopping or slowing the production line.

Furthermore, the winding station can easily be arranged for production of the desired armor layer in a very simple and cost effective way. This means that both the preparation and adjustment of the production facility prior to initiating producing the armor layer as well as the production it itself can be performed much faster than when using the prior art methods. This alone is a great advantage both for improved utility of production equipment, low man power requirement and slow pace requirement for production and the economic benefit is therefore quit substantial.

In the following description the term elongate armor element when used in singular should be interpreted to include the plural meaning of the term unless it is specifically stated that it means a single elongate armor element.

In the following description the term elongate armor element section when used in singular should be interpreted to include the plural meaning of the term unless it is specifically stated that it means a single elongate armor element section.

In the following description, the term additional length section of the elongate armor element when used in singular should be interpreted to include the plural meaning of the term unless it is specifically stated that it means a single additional length section of the elongate armor element.

It should be emphasized that the term "comprising / comprising" when used herein is to be interpreted as an open term, i.e. it should be taken to specify the presence of specifically stated feature (s), such as element (s), unit (s), integer (s), step (s) component (s) and combination (s) thereof, but does do not preclude the presence or addition of one or more other stated features.

The term "substantially" should herein be taken to mean that ordinary product variances and tolerances are comprised.

The terms "inside" and "outside" a layer of the pipe are used to designate the relative distance to the axis of the pipe, such that inside a layer means the area encircled by the layer i.e. with a shorter axial distance than the layer and "outside a layer" means the area not encircled by the layer and not contained by the layer, i.e. with a shorter axial distance than the layer.

The term "inner side" of a layer is the side of the layer facing the axis of the pipe. The term "outer side" of a layer is the side of the layer facing away from the axis of the pipe.

The term "innermost layer" means the layer closest to the center axis of the pipe seen in radial direction and the "outermost layer" means accordingly the layer farthest from the center axis of the pipe seen in radial direction.

The winding angle of the elongate armor element is determined relative to the center axis of the element onto which the elongate armor element is wound.

The length direction of the support structure is parallel to its center axis, and accordingly the length of the support structure is determined in its length direction.

The elongate armor element is usually wound to form part of the pipe in form of forming all or part of an armor layer of the pipe. The pipe can comprise several layers as it will be described further below and in principle the armor layer can be an innermost layer, an outermost layer or a layer between other layers.

The elongate armor element can be any type of armor element e.g. of metal or composite material as described in "Recommended Practice for Flexible Pipe", ANSI / API17 B, Fourth Edition, July 2008, and the standard "Specification for Unbonded Flexible Pipe", ANSI / API 17J, Third Edition, July 2008 and / or as described below.

The term "composite armor elements" is herein used to mean any elongate armor element, such as strips or bundles of strips, comprising reinforced polymer, preferably fiber reinforced polymer.

The fibers are advantageously embedded in an at least partially cured polymer matrix. In an embodiment of the invention, the fibers are embedded in a thermoplastic matrix. In principle the polymer matrix can be any kind of polymer matrix. In an embodiment of the invention the polymer matrix is cured at least about 50%. Preferably, the polymer matrix is at least about 70% cured, such as at least about 80% cured, such as at least about 90% cured, such as substantially fully cured.

For example, the composite elongate armor element may be the strips described in DK PA 2011 00334, DK PA 2011 00371, DK PA 2012 00185, US 6,165,586, in WO 01/51839 and / or in US 7,842,149.

The support structure can have any form capable of supporting the elongate armor element wound around the support structure. The feeding site and the supply site can be sites that are specifically separated sections or they can simply be sites that are varying. In an embodiment the feeding site and the supply site are arranged along a direction parallel to the center axis of the support structure. The support structure preferably has a length parallel to its center axis and the feeding site and the supply site are arranged along the length of the support structure. The proximal border of the supply site is preferably also a border of the support structure and accordingly the feeding site will be arranged distal to the supply site.

As will be described further below, the elongate support element is preferably a mandrel or a core part of a pipe under production. In case the elongate armor element is wound to become at least part of an innermost armor layer, the elongate support element will usually be a mandrel. In case the elongate armor element is wound to become at least part of an armor layer which is not an innermost armor layer, the elongate support element will usually be a core part of the pipe during production where the core part of the pipe comprises the layer or layers which is / are to be inside the armor layer during production.

In an embodiment the winding station is arranged such that at least the wound elongate armor element at the supply site of the support structure will be applied to surround the elongate support element when being supplied by passing it beyond the supply border. In other words, simply by passing the wound elongate armor element on the supply site beyond the supply border, the wound elongate armor will be applied to surround the elongate support element. The winding degree at which the elongate armor element will obtain when applied to surround the elongate support element largely depends on the circumference of the stationary structure and the diameter of the elongate support element (mandrel or core pipe). In addition, the winding angle can in an embodiment be adjusted during or after the application onto the elongate support element.

In an embodiment the winding station is arranged such that the center axis of the support structure and the center axis of the support element are substantially parallel. The center axis of the support structure and the center axis of the support element can be displaced. In a preferred embodiment, the center axis of the support structure and the center axis of the support element are substantially coincident.

In an embodiment the winding station is arranged such that the center axis of the support structure is angled with respect to the center axis of the support element. For example, the center axis of the support structure can be angled with respect to the center axis of the support element such that the angle between the center axis of the support structure and the center axis of the support element is up to about 45 degrees. Preferably, the angle between the center axis of the support structure and the center axis of the support element is kept relatively low, such as up to about 35 degrees, preferably from about 5 degrees to about 25 degrees. If the angle becomes too large it may be difficult to arrange the elongate armor element evenly along the length of the elongate support element.

In an embodiment where the wound elongate armor element at the supply site is supplied by passing it beyond the supply border, the method comprises pushing and / or pulling the wound elongate element from the supply site and onto the elongate support element. By supplying the wound elongate armor element from the supply site beyond the supply border and onto the elongate support element by pushing forces alone the obtained winding angle of the elongate armor element on the elongate support element can be relatively steep and close to any winding angle the wound elongate armor element had on the supply site of the support structure. By supplying the wound elongate armor element from the supply site beyond the supply border and onto the elongate support element by pulling forces the obtained winding angle of the elongate armor element on the elongate support element will usually be lower that the winding angle of the wound elongate armor element had on the supply site of the support structure, and the obtained winding angle of the elongate armor element on the elongate support element can be adjusted by adjusting the pulling force.

In one embodiment, while the elongate support element is a mandrel, the elongate armor element is applied to form at least part of an innermost layer of the pipe. Preferably the elongate armor element is applied to form part or all of a carcass of the pipe.

In an embodiment, the elongate support element is a core part of the pipe.

The core part of the pipe can be any part or layer of a pipe onto which an armor layier is to be applied. The core part preferably comprises at least an innermost sealing sheath. The innermost sealing sheath, sometimes also referred to as inner sealing sheath or inner liner, forms a barrier against the outflow of the fluid which is to be conveyed in the bore of the pipe. In other words, the innermost sealing sheath defines the bore of the pipe.

In one embodiment, where the core portion comprises an innermost sealing sheath, the method comprises winding at least one elongate armor element to form a pressure armor layer. The at least one elongate armor element forming the pressure armor layer is preferably applied to have a helically wound structure with a winding angle to the center axis of the core portion of the pipe which is at least about 55 degrees, preferably at least about 70 degrees , such as at least about 80 degrees.

Pressure armor layer of a pipe, for example, is known from "Recommended Practice for Flexible Pipe", ANSI / API 17 B, Fourth Edition, July 2008, and the standard "Specification for Unbonded Flexible Pipe", ANSI / API 17J, Third Edition, July 2008. In a preferred embodiment the pressure armor layer is provided with one single elongate armor element. In another embodiment, the pressure armor layer comprises a plurality of elongate armor elements, such as 2 or 4 elongate armor elements. In an embodiment of the pressure armor an interlocked pressure armor adjacent windings of the elongate armor element are interlocked e.g. by being interlocked with with adjacent windings of the same elongate armoring element, with adjacent windings of another elongate armoring elements while the interlocking can be a direct engagement or an interlocking provided by an interlocking element e.g. an elongate interlocking element or by a plurality of shorter interlocking element. Examples of preferred interlocking structures are described in PCT / DK2012 / 050021. For example, the interlocking of the elongate armor element windings can be provided simultaneously with the passing of the wound elongate armor element from the supply site to the elongate support element.

In an embodiment, the interlocking of the elongate armor element windings is provided after passing the wound elongate armor element from the supply site to the elongate support element, by interlocking adjacent windings using one or more interlocking elements, such as C-shaped clips or strips.

The pressure armor can be provided from elongate armor element with any profiles e.g. with the profiles disclosed in API 17 B / J as referred to above or as described in US 6,065,501, US 6,889,717, US 6,739,355, DK PA 2011 00099 or DK PA 2012 00259.

Examples of profiled metallic elongate armor element (s) comprise one or more of an angular profile, C shaped profile, a U shaped profile, a T shaped profile, an I shaped profile, a K shaped profile, a Z shaped profile, an X shaped profile, a ψ (psi) shaped profile and combinations thereof.

In an embodiment, the elongate armor element for the pressure armor is or comprises a composite pressure armor element, e.g. as described in DK PA 2012 00259.

In an embodiment the pressure armor is not interlocked

In an embodiment the pressure armor is fixed to the liner by fusing, welding, gluing or mechanical interlocking.

In an embodiment, where the core portion comprises an innermost sealing sheath, the method comprises winding at least one elongate armor element to form a tensile armor layer. The at least one elongate armor element forming the tensile armor layer is preferably applied to have a helically wound structure with a winding angle to the center axis of the core portion of the pipe which is up to about 55 degrees, such as from about 5 degrees to about 35 degrees.

The tensile armor layer is preferably provided from a plurality of elongate armor elements such as it is known from the art e.g. as described in the API 17 B / J as referred to above. An embodiment of each elongate armor element is supplied from respective winding stations. In an embodiment two or more elongate armor elements are applied from one winding station.

The elongate armor element for the tensile armor layer is advantageously a composite elongate armor element.

As mentioned above, a particular advantage is that the supply of the wound elongate element from the supply site and onto the elongate support element can be performed without unwinding of the wound elongate element.

In an embodiment the supply of the wound elongate element from the supply site and onto the elongate support element is performed by pushing the wound elongate element beyond the supply border, and a pushing element, such as a cogwheel, a conveyor belt, or similar transmissions means, is arranged to push the wound elongate element onto the elongate support element. The skilled person will immediately understand that the pushing element can be any kind of element capable of taking part in pushing the wound elongate element from the supply site and onto the elongate support element. The wound elongate element can be pushed from the supply site and onto the elongate support element using a plurality of pushing elements.

In an embodiment, the supply of the wound elongate element from the supply site and onto the elongate support element is performed by pulling the wound elongate element beyond the supply border. This can advantageously be performed by providing the elongate armor element is fixed at its proximal end to a movable pulling site which is moving such as to pull the wound elongate element beyond the supply border. The term 'movable' should in this connection be construed as a relative term, namely that the pulling site is movably relative to the supply border. In most situations, it is preferable to keep the winding station and thereby the supply border stationary and move the pulling site.

The pulling site can be any site arranged such that it can assist in pulling the wound elongate element beyond the supply border upon moving it relative to the supply border.

In an embodiment the pulling site which is a part of the elongate support element where the elongate support element is in the form of a core part of the pipe during production or the pulling site is a fitting fixed to the a core part. The core part is moved through the wound elongate element on the support structure of the winding station and thereby pulling the wound elongate element beyond the supply border. As the distance between the supply border and the pulling site increases, the wound elongate element will be pulled beyond the supply border winding after winding. To control how fast the wound elongate element will be pulled beyond the supply border the winding station may comprise a controlling unit at the supply border.

The elongate armor element is preferably applied to the elongate support element to have a helically wound configuration.

In an embodiment, the wound elongate element is supplied from the supply site and onto the elongate support element in a helically wound configuration with windings arranged immediately adjacent to each other and preferably with substantially no distance beyond what is required to ensure flexibility of the pipe. . The adjacent windings are e.g. interlocked e.g. with a lateral play between interlocked windings. The term "lateral play" is well recognized within this technical area and further explanation as to the meaning of the term may e.g. be found in US. 5913439.

In an embodiment, the wound elongate element is supplied from the supply site and onto the elongate support element in a helically wound configuration with windings that are at a distance to each other e.g. with windings of one or more other elongate elements in between.

In an embodiment the winding station is configured such that the pulling of the wound elongate element beyond the supply border provides that the wound elongate element is pulled onto the elongate support element and applied to have a helically wound structure with a desired winding degree.

The support structure of the winding station can have any shape suitably for partially or fully supporting the elongate armor element wound around the support structure. In an embodiment, the support structure of the winding station has a length determined parallel to its center axis. The support structure at least part of its length comprises a support surface facing away from the center axis of the support structure. In an embodiment this support surface is an annular support surface meaning that it extends essentially in a whole ring around the center axis of the support structure. In an embodiment this support surface is at least a semi-annular support surface meaning that it extends at least half way around the center axis of the support structure.

In one embodiment, the support surface is sectioned along a ring shape around the center axis of the support structure. The support surface may e.g. provided by laths, such as laths extending along the length of the support structure, preferably substantially parallel to the center axis of the support structure.

To provide easy supply of the wound elongate element from the support structure supply site and feed onto the elongate support element, the support structure supply site can advantageously comprise a beveled supply immediately adjacent to the supply border. Thereby the circumference at the supply border is smaller than the circumference at a distance from the supply border (closer to the feeding site). This smaller circumference makes it easier to push and / or pull the wound elongate armor element from the supply site to the elongate support element.

In an embodiment of the invention, additional length section of the elongate armor element is in the form of an extension of the elongate armor element section already wound onto the support structure, i.e. these sections are not separated from each other.

In an embodiment of the invention, the feeding of additional length section of the elongate armor element onto the support structure by winding the additional length section of the elongate armor element onto the feeding site of the support structure is provided by first fixing the additional length section of the elongate armor element to the elongate armor element section already wound onto the support structure and thereafter winding the additional length section of the elongate armor element onto the feeding site of the support structure and in another embodiment the feeding of additional length section of the elongate armor element onto the support structure by winding the additional length section of the elongate armor element onto the feeding site of the support structure is provided by first winding the additional length section of the elongate armor element onto the feeding site of the support structure and thereafter fixing the wound additional length section of the elongate armor element to the other elongate armor element section on the support structure.

Whether it is preferred that the additional length section of the elongate armor element is fixed to the previous elongate armor element section on the support structure before or after winding of the additional length section of the elongate armor element depends primarily on the winding method used.

In an embodiment the additional length section of the elongate armor element has a proximal end and a distal end and the method comprises fixing the proximal end of the additional length section of the elongate armor element to the distal end of the length sections of the elongate armor element. on the support structure closer to the supply border prior to winding the additional length section of the elongate armor element onto the feeding site of the support structure.

In an embodiment the additional length section of the elongate armor element has a proximal end and a distal end and the method comprising winding the additional length section of the elongate armor element onto the feeding site of the support structure and thereafter fixing the proximal end of the additional length section of the elongate armor element to the distal end of the length sections of the elongate armor element on the support structure closer to the supply border prior to.

Generally, it is desirable that the supply site of the support structure is essentially not rotating with respect to the elongate support element while supplying the helically wound elongate element. The application of the elongate armor element to the elongate support element is simpler to control.

In an embodiment, the support structure of the winding station has a length determined parallel to its center axis and the feeding side and the supply side are arranged along the length of the support structure such that the supply site is closer to the supply border.

In an embodiment of the invention, the feeding site and the supply site of the support structure are in the form of a feeding section and a supply section, respectively. The feeding section and the supply section are preferably arranged along a length direction parallel to the center axis of the support structure.

The feeding section and the supply section can be arranged with a stiff connection or they may be arranged such that the feeding section can rotate without the supply section being rotating.

In an embodiment, the feeding site of the support structure is essentially not rotating with respect to the elongate support element during the winding of the additional length section of the elongate armor element onto the feeding site of the support structure.

In an embodiment the feeding site, preferably in the form of a feeding section, is rotating with respect to the elongate support element during at least a portion of the winding of the additional length section of the elongate armor element onto the feeding site of the support structure. .

In an embodiment the feeding site, preferably in the form of a feeding section, is rotating with respect to the supply site of the support structure during at least part of the winding of the additional length section of the elongate armor element onto the feeding site of the support structure.

In one embodiment, the winding of the additional length section of the elongate armor element onto the feeding site, preferably in the form of a feeding section, is performed at least in part by rotating the feeding site of the support structure.

In one embodiment, the winding of the additional length section of the elongate armor element onto the feeding site, e.g. in the form of a feeding section, is performed by supplying the additional length section of the elongate armor element from a bobbin which is moved around the center axis of the support structure, whereby there is no need to rotate the feeding site of the support structure.

The phrase that the bobbin is moved around the center axis of the support structure should be taken to mean that the bobbin is moved such that additional length section of the elongate armor element can be supplied from the bobbin and onto the feeding site of the support structure without rotating the support structure. Additional rolls or any other support fittings can be applied between the bobbin and the feeding site to ensure the winding of the additional length section of the elongate armor element.

In one embodiment, the winding of the additional length section of the elongate armor element onto the feeding site, e.g. in the form of a feeding section, is performed by supplying the additional length section of the elongate armor element from a bobbin which is surrounding the stationary structure. This surrounding bobbin (or bobbins) can feed elongate armoring element to the feeding site e.g. by rotating and / or rotating the feeding site of the support structure. Such surrounding bobbin can be relatively large, therefore where the pipe under production is relatively short all the required length - comprising both the first wound length section of armoring element onto the support structure as well as the additional length section supplied of elongate armoring elements - can An embodiment is supplied from one single surrounding bobbin. Thereby no fixing of separate length sections of elongate armoring element is required.

In one embodiment, the winding of the additional length section of the elongate armor element onto the feeding site, e.g. in the form of a feeding section, is performed by supplying the additional length section of the elongate armor element from a bobbin which is surrounding the stationary structure, where this surrounding bobbin (or bobbins) can feed elongate armor element to the feeding site e.g. by pushing it over an edge of the bobbin without unwinding. This method is also best suited for relatively short pipes because longer pipes will require large factory space.

In the embodiment where the feeding site and the supply site of the support structure are in the form of a feeding section and a supply section respectively and where the feeding section can rotate with respect to the supply section, it is an advantage to wind the additional length section of the elongate armor element onto the feeding section of the support structure prior to fixing it to the other elongate armor element section on the support structure. Thereby the whole additional length section of the elongate armor element can be wound onto the feeding section simply by rotating the feeding section of the support structure, where after the additional length section of the elongate armor element is fixed in prolongation to the other elongate armor element section on the support structure which eg is wounded in a previous similar step. The additional length section of the elongate armor element can then be passed to the supply section of the support structure and further additional length section of the elongate armor element can be wound onto the feeding section. In this way it can be ensured that the support structure will continuously have sufficient supply of wound elongate armor element to supply beyond the supply border and onto the elongate support element. In other words, the application of the elongate armor element can be provided in an in-line process without undesired stopping or slowing of the production line.

In the embodiment where the winding of the additional length section of the elongate armor element onto the feeding site is performed by supplying the additional length section of the elongate armor element from a bobbin which is moved around the center axis of the support structure, the additional length section of the elongate armor element may be fixed to the previous elongate armor element section on the support structure before, after or simultaneously with winding of the additional length section of the elongate armor element.

The simplest way which provides both a simple fix and a smooth transition is to fix the additional length section of the elongate armor element to the previous elongate armor element section on the support structure before winding the additional length section of the elongate armor element. Therefore, in a preferred embodiment, the winding of the additional length section of the elongate armor element onto the feeding site is performed by supplying the additional length section of the elongate armor element from a bobbin which is moved around the center axis of the support structure and the feeding of additional length section of the elongate armor element onto the support structure by winding the additional length section of the elongate armor element onto the feeding site of the support structure is provided by first fixing the additional length section of the elongate armor element to the elongate armor element section already wound onto the support structure and thereafter winding the additional length section of the elongate armor element onto the support site feeding site.

The additional length section of the elongate armor element can then be passed to the supply section of the support structure and further additional length section of the elongate armor element can be wound onto the feeding section. In that way, it can be ensured that the support structure will continuously have sufficient supply of wound elongate armor element to supply across the supply border and onto the elongate support element. In other words, the application of the elongate armor element can be provided in an in-line process without undesired stopping or slowing of the production line.

The length section of the elongate armor element and / or the additional length section of the elongate armor element may be wound with full or preferably partial overlap onto the support structure or part of the support structure such as the feeding site e.g. a form of a feeding section. Thereby a longer section of the elongate armor element can be wound around the support structure simultaneously.

In an embodiment, the length section of the elongate armor element and / or the additional length section of the elongate armor element is wound with full or partial overlap onto a portion of the support structure longer from the supply border and the elongate armor element is wound with no overlap or only interlocking overlap with another part of the support structure closer to the supply border. For example, the turns of the elongate armor element may be passed from the part of the support structure longer from the supply border to the part of the support structure closer to the supply border using a transmission means such as one or more cogwheels or one or more conveyer belts which simultaneously diminish or remove overlap of windings. In addition, the turns of the elongate armor element can be applied to the elongate support element in a desired helical configuration with or without interlocking.

Where the elongate armor element is in the form of a tensile armor layer, the elongate armor element is preferably wound with full or partial overlap onto the support structure part further from the supply border and the elongate armor element is wound with no overlap onto another part of the support structure closer to the supply border. The turns of the elongate armor element are passed from the part of the support structure further from the supply border to the part of the support structure closer to the supply border using a transmission means.

The part of the support structure longer from the supply border can advantageously be in the form of the feeding section and the part of the support structure closer to the supply border can advantageously be the supply section.

In an embodiment the length section of the elongate armor element and / or the additional length section of the elongate armor element is / are helically wound onto the feeding site. This may require a relatively long feeding site or a relatively frequent or continuous winding of additional length section (s) in particular where the winding degree of the elongate armor element as applied to the elongate support element is relatively high. This embodiment is therefore mainly suitable where the winding degree of the elongate armor element as applied to the elongate support element is relatively low.

As mentioned the turns of elongate armor element carried on the support structure can be passed along the length of the support structure e.g. while changing the configuration of optional overlap. In practice, this matching of the elongate armor element windings along the length of the support structure can be performed in any way. This matching can advantageously be performed using any type of transmission means.

In an embodiment the additional length section of the elongate armor element after being wound onto the feeding site of the support structure is passed from the feeding site to the supply site, e.g. using one or more cogwheels, conveyer belts, or similar transmissions means.

The transmission means applied in passing the elongate armor element windings along the length of the support structure can advantageously be operatively connected to the push / pull element applied for supplying the elongate armor element from the supply site to the elongate support element. For example, the operative connection can be a mechanical connection or a connection via the operating / control system.

The method can advantageously comprise winding a plurality of elongate elements onto the support structure and supplying the plurality of wound elongate element from the supply site and onto the elongate support element.

The plurality of elongate armor element can be applied from the same winding station or from separate winding stations.

The plurality of elongate armor element can advantageously be applied to the elongate support element in a side by side relationship, such that it will have a configuration when applied which is generally known from tensile armor layers of unbonded flexible pipes e.g. as described in "Recommended Practice for Flexible Pipe", ANSI / API 17 B, Fourth Edition, July 2008, and the standard "Specification for Unbonded Flexible Pipe", ANSI / API 17J, Third Edition, July 2008.

In an embodiment of the method the method comprises • providing a plurality of winding stations, each comprising a support structure capable of supporting the elongate armor element wound around the support structure, each support structure has a center axis defined as the axis of the wound elongate armor element supported by the support structure, each support structure comprises a feeding site and a supply site arranged along the length of the respective support structure, each supply site has a proximal supply border; • winding a length section of the elongate armor element onto each support structure, the at length section of the elongate armor element comprising a proximal end and an optionally a distal end, the proximal end being closer to the supply border of the respective support structure; • arranging the plurality of winding stations along the length of the elongate support element to supply the wound elongate armor elements from the supply sites of the support structures; • supplying the wound elongate elements from the supply site and onto the elongate support elements.

The plurality of winding stations are preferably arranged to perform their operation in an in-line process. In an embodiment the plurality of winding stations are arranged along a length of the production line, such as in series one after the other optionally partially overlapping e.g. with the supply section or a part thereof surrounded by the feeding section of a longitudinal previous support structure.

In an embodiment the plurality of winding station are arranged along the length of the elongate support element partly overlapping configuration.

In an embodiment plurality of winding station are arranged along the length of the elongate support element with a distance in length direction to each other, such as from about 1 cm to 3 m. In principle the distance could be longer, but generally this will result an unnecessary use of space.

The plurality of winding stations are preferably provided in individual stations which are operatively connected e.g. by an operating and / or control system.

The method comprising applying a plurality of elongate armor elements can advantageously further comprise • feeding at least one additional length of some or each of the elongate armor elements onto the respective support structures preferably by fixing a proximal end of the respective additional length sections to the respective distal ends of the length sections of the elongate armor elements which have already been wound onto the respective support structures; and • winding the additional length sections of the elongate armor elements onto the feeding sites of the respective support structures.

As mentioned above, the embodiment where the fixing of additional length section of the elongate armor element to the elongate armor element closer to the supply border is required it can advantageously be performed prior to winding, the winding is advantageously performed by supplying the additional length section of the elongate armor element from a bobbin which is moved around the center axis of the support structure, whereby there is no need to rotate the feeding site of the support structure.

Alternatively or additionally, the method comprising applying a plurality of elongate armor elements can advantageously further comprise • feeding at least one additional length of some or each of the elongate armor elements onto the respective support structures by winding the additional length sections of the elongate armor elements onto the feeding sites of the respective support structures; and • fixing a proximal end of the respective additional length sections to the respective distal ends of the length sections of the elongate armor elements which are closer to the respective supply border of the respective support structures.

The winding, passing and further processing can be performed as described above.

The method of the invention is advantageously applied in the production of one or more armor layer of an unbonded flexible pipe.

The invention also relates to a production facility suitably for winding at least one elongate armor element to form part of a pipe the production equipment as described above.

For example, the elements of the production facility may be described above with the description of the method of the invention.

The production facility of the invention comprises • at least one winding station comprising a support structure capable of supporting the elongate armor element wound around the support structure, the support structure having a center axis defined as the axis of the wound elongate armor element when supported by the support structure, • a pre-winding arrangement for winding a length section of the elongate armor element onto the support structure; • an arrangement for pushing and / or pulling the wound elongate element from the support structure and onto an elongate support element; and • an in-line winding arrangement for helically winding additional length section (s) of the elongate armor element onto the support structure.

In an embodiment the support structure comprises a feeding site and a supply site arranged along the length of the support structure and the supply site has a proximal supply border.

The arrangement for pushing and / or pulling the wound elongate element onto the elongate support element is advantageously arranged for pushing and / or pulling the wound elongate element over the supply edge and onto the elongate support element.

In a preferred embodiment the in-line winding arrangement comprises an arrangement for fixing the additional length section of the elongate armor element to the length section of the elongate armor element closer to the supply border prior to, simultaneously with or after winding of the additional length section of the elongate armor element.

In an embodiment the production facility of the invention comprises • at least one winding station comprising a support structure capable of supporting the elongate armor element wound around the support structure, the support structure having a center axis defined as the axis of the wound elongate armor element when supported by the support structure, the support structure comprises a feeding site and a supply site arranged along the length of the support structure, the supply site has a proximal supply border; • a pre-winding arrangement for winding a length section of the elongate armor element onto the support structure; • an arrangement for pushing and / or pulling the wound elongate element over the supply edge and onto an elongate support element; and • an in-line winding arrangement for helically winding the additional length section of the elongate armor element onto the feeding site of the support structure while the additional length section of the elongate armor element has been or is adapted to be fixed to the length section of the elongate armor element closer to the supply border or the additional length section of the elongate armor element is in the form of a not separate extension of the length section of the elongate armor element closer to the supply border.

Advantageously the pre-winding arrangement and the in-line winding arrangement are provided by the same winding arrangement.

Alternatively, the pre-winding arrangement and the in-line winding arrangement are provided by different winding arrangements. For example, the prewinding arrangement may be provided prior to starting the in-line production of the armor layer of the pipe.

In an embodiment the production facility comprises the elongate support element in the form of a mandrel as described with the description of the method above.

In another embodiment the production facility comprises the elongate support element in the form of a pipe core as described with the description of the method above.

In an embodiment the production facility comprises a pipe core conveying line for conveying the elongate support element in the form of a pipe core, preferably the winding station is arranged relative to the pipe core conveying line, such that at least the wound elongate armor element at the supply site of the support structure will be applied to surround a pipe core conveyed on the pipe core conveying line.

In an embodiment of the production facility of the invention the winding station is arranged such that the center axis of the support structure and a center axis of the mandrel or a center axis of a pipe core conveyed on the pipe core conveying line are substantially parallel. For example, the center axis of the support structure and the center axis of the mandrel or the center axis of a pipe core conveyed on the pipe core conveying line are substantially identical. By keeping the center axis of the support structure and the center axis of the mandrel or center axis of a pipe core conveyed on the pipe core conveying line substantially identical to a very regular and simple application of the elongate armor element from the supply site to the elongate support element can be obtained.

In an embodiment of the production facility of the invention, the winding station is arranged such that the center axis of the support structure is angled with respect to a center axis of the mandrel or a center axis of a pipe core conveyed on the pipe core conveying line. Advantageously, the angle between the center axis of the support structure and the center axis of the mandrel or the center axis of a pipe core conveyed on the pipe core conveying line is not too high, since this may make an even application of the elongate armor element from the supply site to the elongate support element rather difficult. Generally, it is desired that the angle between the center axis of the support structure and the center axis of the mandrel or center axis of a pipe core conveyed on the pipe core conveying line is about 45 degrees or less, preferably up to about 35 degrees. , such as from about 5 degrees to about 25 degrees.

In an embodiment the winding station comprises a supply arrangement arranged to push and / or pull the wound elongate element from the supply site and onto the elongate support element by passing it beyond the supply border without unwinding the wound elongate element. The supplying arrangement can advantageously comprise one or more transmissions means e.g. as described above in the description of the method of the invention.

In an embodiment the winding station comprises a pushing element for pushing the wound elongate element beyond the supply border.

Advantageously, the pushing element is or comprises a transmission means, such as a cogwheel or a conveyor belt.

In an embodiment the supplying arrangement is arranged to pull the wound elongate element from the supply site and onto the elongate support element. The winding station can thereby be configured such that the pulling of the wound elongate element beyond the supply border provides that the wound elongate element is pulled onto the elongate support element and applied to have a helically wound structure with a pre-selected winding degree.

In an embodiment, the support structure of the winding station at least part of its length along its center axis comprises a support surface facing away from the center axis of the support structure. Advantageously, the support surface is an annular or at least semi-annular support surface.

The support surface is advantageously described in the above description of the method of the invention.

In an embodiment the supply site of the support structure comprises a beveled supply end immediately adjacent to the supply border, such that the circumference at the supply border is smaller than the circumference at a distance from the supply border.

In an embodiment, the support structure is configured not to rotate with respect to the elongate support element while supplying the helically wound elongate element.

In an embodiment the feeding site and the supply site of the support structure are in the form of a feeding section and a supply section, respectively, arranged along the length of the support structure.

In an embodiment the feeding site of the support structure is configured not to rotate with respect to the elongate support element during winding of additional length section of elongate armor element onto the feeding site of the support structure.

In an embodiment the feeding site of the support surface is configured to rotate with respect to the elongate support element during at least part of the winding of additional length section of elongate armor element onto the feeding site of the support structure, the rotation of the support structure. feeding site preferably is part of the in-line winding arrangement.

In an embodiment the feeding site of the support structure is configured to rotate with respect to the supply site of the support structure during at least part of the winding of additional length section of elongate armor element onto the feeding site of the support structure, the Rotating the feeding site preferably is part of the in-line winding arrangement.

In an embodiment the winding station comprises a passing element for passing additional length section of the elongate armor element wound onto the feeding site of the support structure to the feeding site to the supply site. The passing element is optionally provided by transmission means, e.g. comprising one or more cogwheels and / or conveyer belts.

Advantages of the various embodiments of the support structure are as described in the above description of the method of the invention.

As described above in the description of the method, the production facility advantageously comprises a plurality of winding stations.

In an embodiment the plurality of winding stations can be moved with respect to each other, preferably such that the plurality of winding stations is a variable number of winding stations. Thereby the production facility can be adjusted in a simple way for winding elongate armor elements for production of armor layers with different structure, sizes, winding angles and / or number of elongate armor elements.

All features of the inventions including ranges and preferred ranges can be combined in various ways within the scope of the invention, unless there are specific reasons for not combining such features.

LETTER DESCRIPTION OF DRAWINGS

The invention will be explained more fully below in connection with a preferred embodiment and with reference to the drawings in which: FIG. 1 is a schematic side view of a part of a production facility of the invention suitable for performing the method of the invention and comprising a winding station and an elongate support element where the elongate armor element is wound to form part of an inner armor layer normally called a carcass of a pipe. FIG. 2 is a schematic side view of a production facility of the invention suitable for performing the method of the invention and comprising a winding station and an elongate support element where the elongate armor element is wound to form part of a tensile armor layer of a pipe. FIG. 3 is a schematic side view of a production facility of the invention suitable for performing the method of the invention and comprising a winding station and an elongate support element where the elongate armor element is applied to the elongate support element in the form of a pipe core, where the center axis of the support structure and the center axis of the pipe core are not coincident or parallel. FIG. 4 is a schematic side view of a production facility of the invention suitable for performing the method of the invention and comprising a winding station and an elongate support element and transmission means for pushing / passing the wound elongate armor element closer to the supply border. FIG. 5 is a schematic side view of a production facility of the invention suitable for performing the method of the invention and comprising a winding station and an elongate support element where the winding station comprises a support structure with a feeding section and a supply section. FIG. 6 is a schematic side view of a winding station of a production facility of the invention suitably for performing the method of the invention wherein the winding station comprises a support structure with a feeding section and a supply section and an annular support surface and an annular support surface provided by lengthwise laths. FIG. 7 is a schematic side view of two arranged with a partially overlapping configuration. FIG. 8 is a schematic side view of a winding station of a production facility of the invention suitably for performing the method of the invention wherein the winding station comprises a support structure with a feeding section and an asymmetrical supply section FIG. 9 is a schematic top view of a set of production facilities. Each production facility of the invention is arranged to produce an armor layer of the pipe. FIG. 10 is a schematic side view of a production facility of the invention arranged to produce an armor layer of a pipe. FIG. 11 is a schematic side view of a typical unbonded flexible pipe comprising at least one armor layer comprising a helically wound elongate armor element which can be applied using the method of the invention. FIG. 12 is a schematic side view of another typical unbonded flexible pipe comprising at least one armor layer comprising a helically wound elongate armor element which can be applied using the method of the invention.

The figures are schematic and may be simplified for clarity. Throughout, the same reference numerals are used for identical or corresponding parts.

The production facility shown in FIG. 1 comprises a winding station 5 and an elongate support element 6 in the form of a mandrel 6. The winding station 5 comprises a support structure 1 with a length L and a proximal supply border S. The support structure comprises a feeding site 2a and a supply. site 2b where the supply site 2b is closer to the supply border S than the feeding site 2a. The support structure comprises a beveled supply end 4 immediately adjacent to the supply border S. The winding station 5 is fixed to a bearing element such as a wall, a floor or a sealing by a mounting structure 7. Optionally also the mandrel 6 is mounted via the mounting structure 7. The production facility further comprises a pushing arrangement in the form of a cogwheel 8. The support structure 1 of the winding station 5 and the mandrel 6 are arranged such that their respective center axis' 9 are coincident with each other .

As shown an elongate armor element 3a, 3b is wound to form part of an inner armor layer of a pipe. A length section of the elongate armor element 3a (which is the first section of the elongate armor element applied) has been applied from the support structure 1 of the winding station 5 and onto the mandrel 6 by pushing it beyond the proximal supply border S using the cogwheel 8. The pushing arrangement could advantageously comprise several cogwheels eg arranged in the circumference of the proximal supply border S. The proximal end of the length section of the elongate armor element 3a is fixed to a movable site M, which ensures that the wound elongate armor element 3a does not unwind. The movable site M is advantageously moved by being arranged on a transport belt or similar e.g. a conveyor belt that simultaneously supports the wound elongate armor element after it leaves the mandrel 6.

Additional length section of elongate armor element 3b is simultaneously wound onto feeding site 2a of support structure 1, e.g. from a bobbin not shown that is moved around the center axis 9 of the support structure 1.

When the bobbin not shown runs out of the additional length section of the elongate armor element 3b, the bobbin is replaced and the distal end of the wound additional length section of the elongate armor element 3b is fixed to the additional length section of the elongate armor element on the replacement bobbin and the winding of additional length section of the elongate armor element is continued. This replacement of the bobbin can be performed while continuing the application of elongate armor element windings by pushing it beyond the proximal supply border S and onto the mandrel 6 using the cogwheel 8.

The production facility shown in FIG. 2 comprises a winding station 15 comprising a support structure 11 with a length L and a proximal supply border S. The support structure comprises a feeding site 12a and a supply site 12b where the supply site 12b is closer to the supply border S than the feeding site 12a. The support structure comprises a commanded supply end 14 immediately adjacent to the supply border S. The commanded supply end 14 is longer than the commanded supply end 4 of the support structure of FIG. 1, because the elongate armor element to be applied using the production facility in FIG. 2 is a tensile armor with a lower winding degree than the winding degree used in the production of a carcass as in FIG. First

The winding station 15 is fixed to a bearing element, such as a wall, a floor or a sealing by a mounting structure 17. A core part of a pipe 16 onto which the tensile armor should be applied is arranged to pass through the support structure 11. The support structure 11 of the winding station 15 and the core part of a pipe 16 are arranged such that their respective center axis' 19 are coincident with each other.

As shown, an elongate armor element 13a, 13b is wound to form part of a tensile armor layer. A length section of the elongate armor element 13a (which is the first section of the elongate armor element applied) has been applied from the support structure 11 of the winding station 15 and onto the core part of a pipe 16 by pulling and optionally additional pushing using a not shown pushing element, such that the elongate armor element windings are passed beyond the proximal supply border S. The core portion of the pipe 16 is advantageously arranged on a movable conveyor belt such that upon passing the core portion of a pipe 16 through the support structure 11 and forward, the turns of the elongate armor element 13a, 13b is passed from the supply site 12b beyond the supply border S and onto the core part of the pipe 16. The winding degree of the elongate armor element 13a, 13b as it will have on the core part of the pipe 16 can be adjusted by the structure of the support structure, optional pushing elements and the pulling provided by passing the core part of the pipe 16 forwa rd.

The not shown proximal end of the length section of the elongate armor element 13a applied to the core portion of the pipe 16 can advantageously be fixed to a movable pulling site which provides the initial pulling and ensures that the wound elongate armor element 13a does not unwind.

Additional length section of elongate armor element 13b is simultaneously wound onto feeding site 12a of support structure 1, e.g. from a bobbin not shown that is moved around the center axis 19 of the support structure 11.

When the bobbin not shown runs out of the additional length section of the elongate armor element 13b, the bobbin is replaced and the distal end of the wound additional length section of the elongate armor element 13b is fixed to the additional length section of the elongate armor element on the replacement bobbin and the winding of additional length section of the elongate armor element is continued.

The production facility shown in FIG. 3 comprises a winding station 25 comprising a support structure 21 with a proximal supply border S. The winding station 25 is fixed to a bearing element by a mounting structure 27. A core portion of a pipe 26 onto which an elongate armor element is provided wound is arranged to pass through the support structure 21. The support structure 21 of the winding station 25 and the core part of a pipe 26 are arranged such that their respective center axis' 29a, 29b are angled with respect to each other with an angle a. A length section of an elongate armor element 23 is being wound onto the support structure 21.

The production facility shown in FIG. 4 comprises a winding station comprising a support structure 31 with a proximal supply border S. The support structure 31 comprises a feeding site 32a and a supply site 32b where the supply site 32b is closer to the supply border S than the feeding site 32a. The winding station is fixed to a bearing element by a mounting structure 37. A core portion of a pipe 36 onto which an elongate armor element is wound is arranged to pass through the support structure 31. A length section of an elongate armor element 33 is being wound onto the support structure 31. The production facility comprises transmission means in the form of an arrangement 38 for pushing the wound elongate armor element from the feeding site 32a, towards the supply site 32b and optionally beyond the supply boarder S. The arrangement 38 for pushing is illustrated by a number of cogwheels. Naturally other pushing arrangements could be applied e.g. as described above.

The production facility shown in FIG. 5 comprises a winding station comprising a support structure 41 with a proximal supply border S. The support structure 41 comprises a feeding section 42a and a supply section 42b where the supply section 42b is closer to the supply border S than the feeding section 42a. The winding station is fixed to a bearing element by a mounting structure 47. A core part of a pipe 46 onto which an elongate armor element is wound is arranged to pass through the support structure 41.

The feeding section 42a is configured to rotate without rotation of the supply section 42b. A length section of an elongate armor element 43a has been wound and is arranged on the supply section 42b. This wound section of elongate armor element 43a can be applied to the core portion of pipe 46 as described above. Simultaneously, additional length section of elongate armor element 43b can be wound onto feeding section 42a as shown, rotating the feeding section as indicated by arrow b. When the additional length section of elongate armor element 43b has been applied to the feeding section 42a, rotation of feeding section 42a is stopped and the end of the additional length section of elongate armor element 43b is fixed to the distal end of elongate armor element 43a. Thereafter a transmission means is forwarding the wound additional length section of the elongate armor element 43b to the supply section as indicated by the arrow a. This can advantageously be provided by providing the support surface of the feeding station 42a or comprising one or more conveyor belts moving in the length direction of the support structure 41. In that way the feeding of additional length section of the elongate armor element can be provided without stopping the supply of elongate armor element beyond the supply border S and onto the elongate armor element 46 .

The winding station of a production facility shown in FIG. 6 comprises a support structure 51 with a proximal supply border S. The support structure 51 comprises a feeding section 52a and a supply section 52b where the supply section 52b is closer to the supply border S than the feeding section 52a. The winding station is fixed to a bearing element by a mounting structure 57.

The support structure has an annular support surface 51a, 51b, 54 provided by an annular feeding section surface 51a, an annular supply section surface 51b and a surface of a beveled supply end 54 immediately adjacent to the supply boarder S. The annular feeding section surface 51a and the annular supply section surface 51b are sectioned along their ring shape around the center axis of the support structure by being provided by lengthwise laths. FIG. 7 shows an embodiment of two winding stations 65a, 65b arranged with a partially overlapping configuration. The two winding stations 65a, 65b are each similar to the winding station of FIG. 6th

The production facility shown in FIG. 8 comprises a winding station comprising a support structure 71 with a proximal supply border S. The support structure 71 comprises a feeding section 72a and a supply section 72b where the supply section 72b is closer to the supply border S than the feeding section 72a. The winding station is fixed to a bearing element by a mounting structure 77. A core part of a pipe 76 onto which an elongate armor element is wound is arranged to pass through the support structure 71. The feeding section 72a has an annular feeding section surface 71a which is sectioned along its ring shape around the center axis of the support structure 71 by being provided by lengthwise laths. The supply section has an asymmetrical outer surface forming an asymmetrical beveled supply end 74 immediately adjacent to the supply boarder S. FIG. 9 shows a production line for production of an unbonded flexible pipe P. The production line starts with the production of a carcass by a production facility comprising at least one winding station 85a e.g. as described above. The unfinished pipe Pa is transported to an extruding station 81, where an inner liner is applied onto the carcass. The unfinished pipe Pa is there after being transported to an anti wear tape winding station 82a where an anti wear layer is applied. The unfinished pipe Pa is then transported to a production facility comprising at least one winding station 85b, where a pressure armor layer is applied e.g. as described above. The unfinished pipe Pa is then transported to a further anti wear tape winding station 82b where a further anti wear layer is applied. The unfinished pipe Pa is then transported to a production facility comprising a plurality of winding stations 85c, where a first tensile armor layer is applied e.g. as described above. The unfinished pipe Pa is there after being transported to a further anti wear tape winding station 82c where a further anti wear layer is applied. The unfinished pipe Pa is then transported to a production facility comprising a plurality of winding stations 85d, where a second tensile armor layer is applied e.g. as described above. Finally, the unfinished pipe Pa is transported to an extruding station 83, where a protection layer is applied.

Each of the production facilities comprising winding station (s) 85a, 85b, 85c, 85d can independently of each other be a production facility according to the invention. FIG. 10 shows a section of production line for production of an unbonded flexible pipe. The section of the production line includes a production facility for applying a plurality of elongate armor elements to form a tensile armor layer. The production facility comprises a plurality of winding stations 95 as described above. The winding stations 95 are arranged in a series where they partly overlap each other to save production space. A core pipe 96a is fed to the series of winding stations 95, each winding station applying 1-10 elongate armor elements, such as 1 or 2 elongate armor element (s), preferably 1 elongate armor element. After passing the series of winding stations 95 the core pipe 96b has been provided with a tensile armor layer. FIG. 11 and FIG. 12 show examples of a structure of a typically unbonded flexible pipe.

The unbonded flexible pipe shown in FIG. 11 comprises an innermost liquid impervious inner sealing sheath 105 (inner liner) defining a bore where fluid is to be transported as indicated by the bold arrow. The liquid impervious inner sealing sheath 105 can be of any polymer material suitable for forming such liquid impervious barrier. Inside the liquid impervious inner sealing sheath 105 the pipe comprises an inner armor layer 106 (a carcass), which is normally of metal. The carcass 106 is not liquid tight.

On the outer side of the liquid impervious inner sealing sheath 105, the pipe comprises a pressure armor layer 103 which is often of helically wound armor element (s) of metal or composite material e.g. wound with the method described above. The pressure armor layer 103 is not liquid tight.

Outside the pressure armor layer 103, the shown pipe comprises an intermediate liquid impervious sheath 104. Such intermediate liquid impervious sheath 104 will often be omitted.

Outside the intermediate liquid impervious sheath 104 (or outside the pressure armor layer 103 if the intermediate liquid impervious sheath is omitted) the pipe comprises two cross wound tensile armor layers 102a, 102b wound from elongate armor elements preferably by the method of the invention.

The pipe further comprises a liquid impervious sheath 109 for mechanical protection and protection against ingress of sea water.

The unbonded flexible pipe shown in FIG. 12 is the unbonded flexible pipe of FIG. 11 with the difference that the liquid impervious sheathl09 is replaced with a liquid permeable outer protecting sheath 109a protecting the armor layers mechanically but allowing ingress of sea water. The liquid permeable outer protecting sheath 109a is perforated with orifices 107 to allow the ingress of sea water.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. Flowever, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are provided by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art. the art from this detailed description.

The invention is defined by the features of the independent claim (s).

Preferred embodiments are defined in the dependent claims. Any reference numerals in the claims are intended to be non-limiting for their scope.

Some preferred embodiments have been shown in the foregoing, but it should be stressed that the invention is not limited to these, but may be embodied in other ways within the subject matter defined in the following claims.

Claims (59)

1. A method of winding at least one elongate armor element to form part of a pipe, the method comprising • providing at least one winding station comprising a support structure capable of supporting the elongate armor element wound around said support structure, the support structure has a center axis defined as the axis of the wound elongate armor element supported by the support structure, the support structure comprises a feeding site and a supply site, the supply site has a proximal supply border; • winding a length section of the elongate armor element onto said support structure; • providing an elongate support element having a length and a center axis; • arranging said winding station to supply said wound elongate armor element from the supply site of the support structure; • supplying said wound elongate element from said supply site and onto said elongate support element, preferably the length section of the elongate armor element wound onto said support structure comprises a proximal end and optionally a distal end, the proximal end being closer to the supply border and the method comprises feeding at least one additional length section of said elongate armor element onto said support structure by winding said additional length section of said elongate armor element onto the feeding site of said support structure.

2. The method of claim 1, wherein said winding station is arranged such that at least the wound elongate armor element at the supply site of the support structure will be applied to surround said elongate support element when being supplied by passing it beyond said supply border.

3. The method of claim 1 or claim 2, wherein said winding station is arranged such that the center axis of the support structure and the center axis of the support element are substantially parallel, optionally the center axis of the support structure and the center axis of the support element are substantially coincident.

4. The method of claim 1 or claim 2, wherein said winding station is arranged such that the center axis of the support structure is angled with respect to the center axis of the support element, preferably the angle between the center axis of the support structure and the center axis of the support element is up to about 45 degrees, such as up to about 35 degrees, such as from about 5 degrees to about 25 degrees.

5. The method of the preceding claims, wherein said method comprises pushing and/or pulling the wound elongate element from said supply site and onto said elongate support element, by passing it beyond said supply border.

6. The method any one of the preceding claims, wherein said elongate support element is a mandrel, the elongate armor element is applied to form at least part of an innermost layer of the pipe, preferably the elongate armor element is applied to form a part of or the whole of a carcass of the pipe.

7. The method of any one of the preceding claims, wherein said elongate support element is a core part of the pipe, the core part preferably comprises at least an innermost sealing sheath.

8. The method of claim 7, wherein the core part comprises an innermost sealing sheath, the method comprises winding at least one elongate armor element to form a pressure armor layer, the at least one elongate armor element forming the pressure armor layer is preferably applied to have a helically wound structure with a winding angle to the center axis of the core part of the pipe which is at least about 55 degrees, preferably at least about 70 degrees, such as at least about 80 degrees.

9. The method of claim 7, wherein the core part comprises an innermost sealing sheath, the method comprises winding at least one elongate armor element to form a tensile armor layer, the at least one elongate armor element forming the tensile armor layer is preferably applied to have a helically wound structure with a winding angle to the center axis of the core part of the pipe which is up to about 55 degrees, such as from about 35 degrees to about 50 degrees.

10. The method of any one of the preceding claims, wherein said supplying of said wound elongate element from said supply site and onto said elongate support element, is performed without unwinding of the wound elongate element.

11. The method of any one of the preceding claims, wherein said supplying of said wound elongate element from said supply site and onto said elongate support element, is performed by pushing and/or pulling said wound elongate element beyond the supply border.

12. The method of claim 11, wherein said supplying of said wound elongate element from said supply site and onto said elongate support element is performed by pushing said wound elongate element beyond the supply border, wherein a pushing element such as a cogwheel, a conveyer belt, or similar transmissions means, is arranged to push the wound elongate element onto said elongate support element.

13. The method of claim 11, wherein said supplying of said wound elongate element from said supply site and onto said elongate support element is performed by pulling said wound elongate element beyond the supply border, said elongate armor element is preferably fixed at its proximal end to a movably pulling site which is moving such as to pull said wound elongate element beyond the supply border.

14. The method of claim 13, wherein said pulling site which is a part of the elongate support element in form of a core part of the pipe or a fitting fixed to the a core part of the pipe, the core part is moved through the wound elongate element on the support structure of the winding station and thereby pulling said wound elongate element beyond the supply border.

15. The method of claim 14, wherein said winding station is configures such that the pulling of said wound elongate element beyond the supply border provides that the wound elongate element is pulled onto said elongate support element and applied to have a helically wound structure with a desired winding degree.

16. The method of any one of the preceding claims, wherein said wound elongate element is supplied from said supply site and onto said elongate support element in a helically wound configuration.

17. The method of any one of the preceding claims, wherein said support structure of said winding station has a length parallel to its center axis, the support structure in at least a part of its length comprises a support surface facing away from the centre axis of the support structure, preferably said support surface is an annular or an at least semi-annular support surface.

18. The method of claim 17, wherein said support surface is sectioned along a ring shape surrounding the center axis of the support structure.

19. The method of any one of the preceding claims, wherein said supply site of said support structure comprises a beveled supply end immediately adjacent to the supply border, preferably such that the circumference at the supply border is smaller than the circumference at a distance from the supply border.

20. The method of any one of the preceding claims, wherein said additional length section of the elongate armor element has a proximal end and a distal end and the method comprising fixing said proximal end said additional length section of the elongate armor element to the distal end of the length sections of said elongate armor element on the support structure closer to the supply border prior to winding said additional length section of the elongate armor element onto the feeding site of said support structure.

21. The method of any one of the preceding claims 1-19, wherein said additional length section of the elongate armor element has a proximal end and a distal end and the method comprises winding said additional length section of the elongate armor element onto the feeding site of said support structure and thereafter fixing said proximal end said additional length section of the elongate armor element to the distal end of the length sections of said elongate armor element on the support structure closer to the supply border.

22. The method of any one of the preceding claims, wherein said feeding site and said supply site of said support structure are in form of respectively a feeding section and a supply section, preferably arranged along a length direction parallel to the centre axis of the support structure.

23. The method of any one of the preceding claims, wherein said feeding site of said support structure is essentially not rotating with respect to the elongate support element during the winding of said additional length section of said elongate armor element onto the feeding site of said support structure.

24. The method of any one of the preceding claims 1-22, wherein the feeding site of said support surface is rotating with respect to the elongate support element during at least a part of the winding of said additional length section of said elongate armor element onto the feeding site of said support structure.

25. The method of any one of the preceding claims 1-22 and 24, wherein the feeding site of said support structure is rotating with respect to the supply site of the support structure during at least a part of the winding of said additional length section of said elongate armor element onto the feeding site of said support structure.

26. The method of any one of claim 24 and 25, wherein the winding of said additional length section of said elongate armor element onto the feeding site of said support structure is performed at least partly by rotating said feeding site of said support structure.

27. The method of any one of the preceding claims, wherein said length section of the elongate armor element and/or said additional length section of said elongate armor element is wound with partial overlap onto said feeding site.

28. The method of any one of the preceding claims, wherein said length section of the elongate armor element and/or said additional length section of said elongate armor element is helically wound onto said feeding site.

29. The method of any one of the preceding claims, wherein said additional length section of said elongate armor element after having been wound onto said feeding site of said support structure is passed from the feeding site to the supply site, e.g. using one or more cogwheels, conveyer belts, or similar transmissions means.

30. The method of any one of the preceding claims, wherein the method comprising winding a plurality of elongate elements onto said support structure and supplying said plurality of wound elongate element from said supply site and onto said elongate support element.

31. The method of any one of the preceding claims, wherein the method comprising • providing a plurality of winding stations, each comprising a support structure capable of supporting the elongate armor element wound around said support structure, each support structure has a center axis defined as the axis of the wound elongate armor element supported by the support structure, each support structure comprises a feeding site and a supply site arranged along the length of the respective support structures, each supply site has a proximal supply border; • winding a length section of the elongate armor element onto each of said support structure, the at length section of the elongate armor element comprises a proximal end and optionally a distal end, the proximal end being closer to the supply border of the respective support structure; • arranging said plurality of winding stations along the length of the elongate support element to supply said wound elongate armor elements from the supply sites of the support structures; • supplying said wound elongate elements from said supply site and onto said elongate support elements.

32. The method of claim 31 further comprising • feeding at least one additional length of each of said elongate armor elements onto said respective support structures, preferably by fixing a proximal end of said respective additional length sections to the respective distal ends of the length sections of said elongate armor elements which has already been wound onto the respective support structures; and • winding said additional length sections of said elongate armor elements onto the feeding sites of said respective support structures.

33. The method of claim 31 or 32 further comprising • feeding at least one additional length of each of said elongate armor elements onto said respective support structures by winding said additional length sections of said elongate armor elements onto the feeding sites of said respective support structures; and • fixing a proximal end of said respective additional length sections to the respective distal ends of the length sections of said elongate armor elements which are closer to the respective supply border of the respective support structures.

34. The method of any one of claims 31-33, wherein said plurality of winding station are arranged along the length of the elongate support element with a distance to each other determined along the center axis of the elongate support element.

35. The method of any one of claims 31-33, wherein said plurality of winding station are arranged along the length of the elongate support element partly overlapping configuration.

36. A production facility suitably for winding at least one elongate armor element to form part of a pipe the production equipment comprising • at least one winding station comprising an support structure capable of supporting the elongate armor element wound around said support structure, the support structure has a center axis defined as the axis of the wound elongate armor element when supported by the support structure, • a pre-winding arrangement for winding a length section of the elongate armor element onto said support structure; • an arrangement for pushing and/or pulling said wound elongate element from the support structure and onto an elongate support element; and • an in-line winding arrangement for helically winding additional length section(s) of said elongate armor element onto the support structure.

37. The production facility of claim 36, wherein the support structure comprises a feeding site and a supply site arranged along the centre axis of the support structure, the supply site has a proximal supply border, preferably the arrangement for pushing and/or pulling said wound elongate element onto the elongate support element comprises pushing and/or pulling said wound elongate element over the supply edge and onto the elongate support element.

38. The production facility of claim 36, wherein the in-line winding arrangement comprises an arrangement for fixing said additional length section of the elongate armor element to the length section of said elongate armor element closer to the supply border prior to, simultaneous with of after winding of said additional length section of the elongate armor element.

39. The production facility of claim 36 wherein the pre-winding arrangement and the in-line winding arrangement are provided by the same winding arrangement.

40. The production facility of claim 39 wherein the pre-winding arrangement and the in-line winding arrangement are provided by different winding arrangements.

41. The production facility of any one of the preceding claims 36-40, wherein the production facility comprises the elongate support element in form of a mandrel, the winding station is arranged relative to the mandrel such that at least the wound elongate armor element at the supply site of the support structure will be applied to surround said mandrel when being supplied by passing it beyond said supply border.

42. The production facility of any one of the preceding claims 36-40, wherein the production facility comprises a pipe core conveying line for conveying the elongate support element in form of a pipe core, the winding station is arranged relative to the pipe core conveying line, such that at least the wound elongate armor element at the supply site of the support structure can be applied to surround a pipe core conveyed on the pipe core conveying line.

43. The production facility of any one of the preceding claims 36-42, wherein said winding station is arranged such that the center axis of the support structure and a center axis of the mandrel or a center axis of a pipe core conveyed on the pipe core conveying line are substantially parallel, optionally the center axis of the support structure and the center axis of the mandrel or the center axis of a pipe core conveyed on the pipe core conveying line are substantially identical.

44. The production facility of any one of the preceding claims 36-42, wherein said winding station is arranged such that the center axis of the support structure is angled with respect to a center axis of the mandrel or a center axis of a pipe core conveyed on the pipe core conveying line, preferably the angle between the center axis of the support structure and the center axis of the mandrel or the center axis of a pipe core conveyed on the pipe core conveying line is up to about 45 degrees, such as up to about 35 degrees, such as from about 5 degrees to about 25 degrees.

45. The production facility of any one of the preceding claims 36-44, wherein said winding station comprises a supplying arrangement arranged to pushing and/or pulling the wound elongate element from said supply site and onto the elongate support element by passing it beyond said supply border without unwinding of the wound elongate element.

46. The production facility of claim 45, wherein said winding station comprises a pushing element for pushing said wound elongate element beyond the supply border, preferably the pushing element is or comprises a cogwheel, a conveyer belt, or similar transmissions means.

47. The production facility of claim 45, wherein said supplying arrangement is arranged to pulling the wound elongate element from said supply site and onto the elongate support element, said winding station is configures such that the pulling of said wound elongate element beyond the supply border provides that the wound elongate element is pulled onto said elongate support element and applied to have a helically wound structure with a preselected winding degree.

48. The production facility of any one of the preceding claims 36-47, wherein said support structure of said winding station in at least a part of its length along its center axis comprises a support surface facing away from centre axis of the support structure, preferably said support surface is an annular or an at least semi-annular support surface.

49. The production facility of claim 48, wherein said support surface is sectioned along a ring shape surrounding the center axis of the support structure.

50. The production facility of any one of the preceding claims 36-49, wherein said supply site of said support structure comprises a beveled supply end immediately adjacent to the supply border, preferably such that the circumference at the supply border is smaller than the circumference at a distance from the supply border.

51. The production facility of any one of the preceding claims 36-50, wherein said support structure is configured to not rotate with respect to the elongate support.'

52. The production facility of any one of the preceding claims 36-50, wherein said feeding site and said supply site of said support structure are in form of respectively a feeding section and a supply section arranged along the length of the support structure.

53. The production facility of any one of the preceding claims 36-52, wherein said feeding site of said support structure is configured to not rotate with respect to the elongate support element during winding of additional length section of elongate armor element onto the feeding site of said support structure.

54. The production facility of any one of the preceding claims 36-50 and 52-53, wherein the feeding site of said support surface is configured to rotate with respect to the elongate support element during at least a part of the winding of additional length section of elongate armor element onto the feeding site of said support structure, said rotation of the feeding site preferably is a part of the in-line winding arrangement.

55. The production facility of any one of the preceding claims 36-50 and 52-54, wherein the feeding site of said support structure is configured to rotate with respect to the supply site of the support structure during at least a part of the winding of additional length section of elongate armor element onto the feeding site of said support structure, said rotation of the feeding site preferably is a part of the in-line winding arrangement.

56. The production facility of any one of the preceding claims 36-55 wherein said winding station comprises a passing element for passing additional length section of said elongate armor element wound onto said feeding site of said support structure from the feeding site to the supply site, the passing element is optionally provided by one or more cogwheels, conveyer belts, or similar transmissions means.

57. The production facility of any one of the preceding claims 36-56 wherein said production facility comprises a plurality of winding stations.

58. The production facility of claim 57 wherein said plurality of winding stations can be moved with respect to each other.

59. The production facility of claim 57 or claim 58, wherein said plurality of winding stations is a variable number of winding stations.