Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L11/00—Hoses, i.e. flexible pipes
  • F16L11/04—Hoses, i.e. flexible pipes made of rubber or flexible plastics
  • F16L11/08—Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements embedded in the wall
  • F16L11/081—Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements embedded in the wall comprising one or more layers of a helically wound cord or wire
  • F16L11/083—Hoses, i.e. flexible pipes made of rubber or flexible plastics with reinforcements embedded in the wall comprising one or more layers of a helically wound cord or wire three or more layers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
  • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
  • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
  • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
  • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
  • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
  • B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
  • B29C63/08—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like by winding helically
  • B29C63/10—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like by winding helically around tubular articles
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B1/00—Layered products having a non-planar shape
  • B32B1/08—Tubular products
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/02—Layer formed of wires, e.g. mesh
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
  • B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
  • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B15/00—Layered products comprising a layer of metal
  • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
  • B32B15/088—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyamides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
  • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
  • B32B27/286—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polysulphones; polysulfides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
  • B32B27/288—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42 comprising polyketones
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
  • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/10—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material
  • B32B3/18—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. formed of separate pieces of material characterised by an internal layer formed of separate pieces of material which are juxtaposed side-by-side
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
  • B32B7/04—Interconnection of layers
  • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2271/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as reinforcement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2307/00—Use of elements other than metals as reinforcement
  • B29K2307/04—Carbon
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2009/00—Layered products
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2023/00—Tubular articles
  • B29L2023/005—Hoses, i.e. flexible
  • B29L2023/006—Flexible liners
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
  • B32B2262/10—Inorganic fibres
  • B32B2262/106—Carbon fibres, e.g. graphite fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2274/00—Thermoplastic elastomer material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/54—Yield strength; Tensile strength
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/724—Permeability to gases, adsorption
  • B32B2307/7242—Non-permeable
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/726—Permeability to liquids, absorption
  • B32B2307/7265—Non-permeable
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2597/00—Tubular articles, e.g. hoses, pipes
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L11/00—Hoses, i.e. flexible pipes
  • F16L11/04—Hoses, i.e. flexible pipes made of rubber or flexible plastics
  • F16L2011/047—Hoses, i.e. flexible pipes made of rubber or flexible plastics with a diffusion barrier layer

Definitions

• the present invention relates to a subsea flexible pipe intended for the transport of fluids comprising, from the inside to the outside:
• At least one tensile armor ply not linked to the sealing layer, the at least one tensile armor ply comprising at least one armor element wound around the sealing layer;
• the tubular structure is for example a layer of composite material of a flexible pipe for transporting fluid through a body of water.
• Flexible pipes of the aforementioned type are used in particular in deep water in the oil and gas industry as well as in the renewable energy industry. Typically, they are used for the transport of hydrocarbon fluids, the reinjection of carbon dioxide into an underwater reservoir or for the transport and distribution of hydrogen produced at sea. through a stretch of water between a surface assembly and a bottom assembly. These pipes can also extend between two sets of surfaces.
• the bottom assembly is intended to collect the fluid exploited at the bottom of the body of water.
• the surface assembly is generally floating. It is intended to collect, potentially process, and distribute fluid.
• the surface assembly can be a semi-submersible platform, an FPSO or another floating assembly.
• the flexible pipe has a length greater than 800 m, even greater than 1000 m or 2000 m for ultra-deep water applications.
• the flexible pipe is sized to withstand a very high hydrostatic pressure, for example 200 bar for a submerged pipe at a depth of 2000 m.
• the flexible pipe is generally dimensioned to resist an axial tension greater than the total weight of the flexible pipe suspended from a surface assembly and extending underwater from the surface to the seabed. This is particularly the case when the flexible pipe is used as a riser (“riser” in English) intended to ensure, in service, a vertical connection between the seabed and the surface assembly.
• riser riseriser
• the capacity of the flexible pipe to support its own weight when it is suspended in water makes it possible in particular to facilitate its installation at sea from a laying vessel.
• flexible pipes which are both light and very resistant to external hydrostatic pressure. It is also preferable that the flexible lines be resistant to the internal pressures encountered in production. It is also advantageous that the flexible pipes have excellent resistance to fatigue, in particular to endure the multiple cycles of displacement of the pipe under the effect of the movements of the body of water and of the entire surface.
• tubular reinforcing structure consists of a composite material with a thermoplastic matrix, for example a composite material comprising a PEEK (polyetheretherketone) matrix reinforced with carbon fibers.
• PEEK polyetheretherketone
• Such pipes are known as "Thermoplastic Composite Pipe” (TCP) and are described in particular in the normative document DNVGL- ST-F1 19, “Standard Practice - Thermoplastic composites pipes”, published in September 2019 by DNV GL (Det Norske Veritas GL).
• TCP flexible pipes generally comprise, from the inside out, a tubular internal sealing sheath made of polymer material (“polymer liner”, in English language), a tubular reinforcing structure made of composite material and an external sheath (“cover”). in English language) protection in polymeric material.
• the tubular reinforcement structure being theoretically sealed, the tubular internal sheath is optional.
• most of these flexible pipes include a tubular internal sheath in order to guarantee the tightness of the pipe in the event that the tubular reinforcing structure presents a manufacturing defect affecting its tightness.
• the presence of the tubular inner sheath facilitates the manufacture of the flexible pipe TCP. Indeed, this first layer then forms a central core on which one comes to bear to roll up the plurality of composite laminates forming the tubular reinforcing structure.
• the tubular reinforcing structure is typically glued or welded to the tubular inner sheath in order to prevent the tubular inner sheath from collapsing during rapid decompression of the pipe transporting hydrocarbons in the gas phase.
• the outer protective sheath is optional but when it is present, it is advantageously glued or welded to the tubular reinforcement structure, the assembly thus forming a flexible pipe TCP with a totally completely bonded structure.
• TCP pipes are marketed in particular by the companies Magma Global Ltd (TCP registered trademark m-pipe®) and Airborne Oil & Gas B.V. .
• tubular reinforcing structure consists of a composite material with a thermosetting matrix, for example a composite comprising an epoxy resin matrix reinforced with glass fibers.
• thermosetting matrix for example a composite comprising an epoxy resin matrix reinforced with glass fibers.
• hybrid flexible pipes which have an intermediate structure between that of TCP flexible pipes and that of flexible pipes of the unbonded type.
• These pipes comprise, from the inside outwards, an internal tubular sealing sheath, a tubular reinforcing structure made of composite material, at least one ply of tensile armor and an external sheath.
• the tubular reinforcing structure is advantageously made of a composite material with a thermoplastic matrix, but it is also possible to use a thermosetting matrix.
• the reinforcing tubular structure is advantageously welded or glued to the tubular inner sheath.
• the tensile armor plies or plies are similar to those of unbonded type flexible pipes, that is to say they consist of helically wound wires.
• these pipes may comprise an internal carcass located inside the internal sealing sheath, said internal carcass having the function of increasing the resistance to crushing (“collapse” in English) of the pipe.
• the internal carcass is formed for example of a profiled metal strip, wound in a spiral.
• the coils of the strip are advantageously stapled to each other, which makes it possible to take up the crushing forces.
• the tubular reinforcement structure comprises a tube made of composite material and has both the function of a pressure vault arranged outside a tubular internal sheath and of a carcass arranged inside the tubular internal sheath , that is to say that it generally takes up most of the radial forces applied to the pipe.
• the tubular reinforcing structure linked to the internal tubular sealing sheath, also has a gas barrier function, such as the acid gases of the H 2 S and CO 2 type contained in the hydrocarbon fluids transported to the inside the internal tubular sealing sheath. It thus makes it possible to protect the metallic reinforcing elements of the flexible pipe against corrosion phenomena.
• the critical pressure from which water is likely to infiltrate into the hybrid flexible pipe, as well as the quantity of water which can infiltrate therein, depend on the quality of the bonding on the one hand between the different layers of the flexible pipe and on the other hand between the thermoplastic matrix and the reinforcing material, within the tubular reinforcing structure.
• An object of the invention is therefore to obtain a hybrid flexible pipe having a composite structure that is intact over time, in particular at high hydrostatic pressure.
• the subject of the invention is a flexible pipe of the aforementioned type, in which the thickness of the sealing layer is less than 15 mm.
• the flexible pipe according to the invention may comprise one or more of the following characteristics, taken separately or in any technically possible combination:
• the sealing layer has a water permeability coefficient of less than 2.10-4 cm 3 (STP).cm -2 .s' 1 .bar 1 ;
• the composite reinforcement structure comprises a winding of at least two laminated reinforcing layers, each reinforcing layer being made from a thermoplastic matrix reinforced with reinforcing fibers;
• the reinforcement layer is made from a thermoplastic polyetheretherketone (PEEK) matrix reinforced with carbon fibers;
• PEEK thermoplastic polyetheretherketone
• the sealing layer is devoid of reinforcing materials
• the sealing layer is formed by rolling up at least two strips of a thermoplastic material and by welding the at least two strips together;
• the thickness of the sealing layer is less than 3 mm, advantageously less than 2 mm, even more advantageously less than 1 mm;
• the sealing layer is formed from a tubular sheath of extruded thermoplastic material; - when the sealing layer is formed from a tubular sheath of extruded thermoplastic material, the thickness of the sealing layer is from 3 to 15 mm, preferably from 3 mm to 10 mm;
• the sealing layer is bonded to the composite reinforcement structure
• the waterproofing layer is not linked to the composite reinforcement structure
• the sealing layer is made from a thermoplastic material selected from polyolefins, polyamides, fluoropolymers, thermoplastic elastomers, polyaryletherketones, copolymers thereof, any of their mixtures and mixtures comprising them, preferably from polyaryletherketones;
• the sealing layer is made from the same thermoplastic material as that used for the thermoplastic matrix of each reinforcing layer of the composite reinforcing structure, advantageously from polyetheretherketone (PEEK).
• PEEK polyetheretherketone
• the invention also relates to a process for manufacturing a flexible pipe comprising the following steps:
• the at least one ply of tensile armor comprising at least one armor element wrapped around the sealing layer;
• an external sealing sheath arranged around the at least one ply of tensile armor; in which the thickness of the sealing layer is less than 15 mm.
• the method according to the invention may comprise one or more of the following characteristics, taken in isolation:
• the sealing layer is formed by winding around the composite reinforcement structure at least two strips of a thermoplastic material, and welding the at least two strips together;
• the formation of the sealing layer is carried out by extruding a thermoplastic material on the composite reinforcement structure.
• Figure 1 is a partially cutaway perspective view of a flexible pipe according to the invention.
• a flexible pipe 10 according to the invention is schematically illustrated in Figure 1.
• the flexible pipe 10 comprises a central section 12 partly illustrated in FIG. 1. It comprises, at each of the axial ends of the central section 12, an end fitting (not shown).
• the flexible pipe 10 according to the invention is not limited to a certain category of end fittings. Examples of end fittings that can be used with the flexible pipes 10 of the invention are described in WO 2019/068757.
• the pipe 10 delimits an internal passage 13 for the circulation of a fluid, advantageously a petroleum fluid.
• the internal passage 13 extends along an axis A-A', between the upstream end and the downstream end of the pipe 10. It opens through the end pieces (not shown).
• the flexible pipe 10 is intended to be laid across a body of water 14 in a fluid exploitation installation, in particular hydrocarbons.
• the expanse of water 14 is, for example, a sea, a lake or an ocean.
• the depth of the expanse of water 14 to the right of the fluid exploitation installation is for example between 500 m and 4000 m.
• the installation comprises a surface assembly and a bottom assembly (not shown) or two surface assemblies which are advantageously connected together by the flexible pipe 10.
• the surface assembly is, for example, floating. It is advantageously formed by a floating production, storage and offloading unit called FPSO (“Floating Production, Storage and Offloading” in English), a floating unit dedicated to liquefied natural gas called FLNG (“Floating Liquified Natural Gas” in English). English language), a semi-submersible platform or an offloading buoy.
• FPSO floating Production, Storage and Offloading
• FLNG floating Liquified Natural Gas
• the surface assembly is a fixed rigid structure of the “jacket” type or an oscillating structure fixed to the bottom of the sea, which can for example be a TLP (“Tension Leg Platform”).
• the flexible pipe 10 connects the bottom assembly to the surface assembly.
• the flexible pipe 10 is therefore partially submerged in the expanse of water 14 and has an upper end placed in a volume of air.
• the flexible pipe 10 is completely submerged in the body of water 14 and connects, for example, two bottom assemblies (not shown) to each other.
• Another variant consists of a flexible pipe 10 partially submerged in the body of water 14 and connecting for example two surface assemblies (typically an unloading buoy and an FPSO). This is particularly the case for flexible lines of the OOL (Oil Offloading Line) type.
• OOL Olet Offloading Line
• the pipe 10 delimits a plurality of concentric layers around the axis A-A′, which extend continuously along the central section 12 up to the end pieces located at the ends of the pipe.
• the pipe 10 comprises at least one internal tubular sheath 20 based on polymer material advantageously constituting an internal sealing sheath, a composite structure of tubular reinforcement 21, applied around the tubular sheath 20 in being bonded thereto, and a sealing layer 22, applied around the composite reinforcing structure 21.
• the pipe 10 has no internal tubular sheath 20, the composite reinforcing structure 21 then being sealed and ensuring the sealing function.
• the pipe 10 further comprises in this example a plurality of tensile armor plies 24, 25 arranged externally with respect to the sealing layer 22, being unrelated to the sealing layer 22.
• the pipe 10 further comprises anti-wear layers 26, interposed between the sealing layer 22 and the tensile armor plies 24, 25, as well as between the plies of tensile armor 24, 25.
• the anti-wear layers 26 consist of one or more strips of thermoplastic material wound along the axis (A-A') but which are not welded together , unlike the sealing layer 22. These anti-wear layers 26 are therefore not sealed.
• the pipe 10 also advantageously comprises a reinforcing tape 28, wrapped around the tensile armor plies 24, 25 and an outer sheath 30, intended for the mechanical protection and sealing of the pipe 10.
• the tubular sheath 20 is intended to seal the fluid transported in the passage 13 in a sealed manner.
• the tubular sheath 20 also has the function of protecting the composite reinforcing structure 21 against abrasion linked to the presence of abrasive particles. , for example sand, within the fluid transported in the passage 13.
• the tubular sheath 20 is formed from a polymer material, preferably thermoplastic.
• the polymer forming the tubular sheath 20 is chosen from a polyolefin such as polyethylene, a polyamide such as PA11 or PA12, or a fluorinated polymer such as polyvinylidene fluoride (PVDF) or copolymers of polyvinylidene fluoride and polyhexafluoropropylene (PVDF-HFP).
• a polyolefin such as polyethylene
• a polyamide such as PA11 or PA12
• a fluorinated polymer such as polyvinylidene fluoride (PVDF) or copolymers of polyvinylidene fluoride and polyhexafluoropropylene (PVDF-HFP).
• the tubular sheath 20 comprises a polymer chosen from PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamide-imide), PEI (polyether-imide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenyleneether), PPS (polyphenylene sulfide), LCPs (polymers liquid crystals), PPA (polyphthalamide), copolymers thereof, and/or mixtures thereof or a mixture of one or more of these with a polysiloxane, PTFE (polytetrafluoroethylene) or PFPE ( perfluoropolyether).
• PEK polyetherketone
• the tubular sheath 20 may for example comprise a mixture of polyaryletherketone and a polysiloxane, such as those described in application WO 2019/150060.
• the tubular sheath 20 comprises at least 50% by mass of the polymer defined above (or of the mixture thereof when it is a mixture), more preferably at least 75% by mass, even more preferably at least 80% by mass, typically at least 90% by mass, relative to the total mass of the tubular sheath 20.
• the tubular sheath 20 consists of one of the polymers defined above or of one of the mixtures defined above and fillers and/or additives.
• the thickness of the tubular sheath 20 is for example between 1 mm and 20 mm.
• the tubular sheath 20 is formed of a tube of polymer material, of a strip of assembled polymer material, or of an impregnated polymer mat.
• tubular sheath 20 is formed of a tube, it is advantageously obtained by extrusion of a thermoplastic tube chosen in particular from the polymers mentioned above.
• the tubular sheath 20 is formed from a strip of assembled polymer material, it is advantageously produced by extrusion and winding of thermoplastic strips of a polymer as described above.
• the turns of a first layer are contiguous (edge to edge without overlap) and the turns of an upper layer are arranged so as to have an overlap of two lower adjacent bands ensuring the sealing of the tubular sheath 20.
• the flexible pipe 10 has no internal carcass, it is designated by the English term “smooth bore”.
• the internal surface of the tubular sheath 20 directly delimits the internal passage 13.
• the composite reinforcement structure 21 is applied directly to the tubular sheath 20. It is assembled on the tubular sheath 20 to form a bonded assembly with the tubular sheath 20.
• the composite reinforcement structure 21 comprises at least one, preferably a plurality of laminated composite reinforcement layers, and optionally, an anti-delamination layer interposed between at least two reinforcement layers.
• Each laminated reinforcement layer comprises a superposition of composite reinforcement layers.
• each composite reinforcement layer comprises a polymer matrix 40 and reinforcing fibers 42 embedded in the matrix 40.
• the matrix 40 is formed from a polymer, in particular from a thermoplastic polymer.
• the polymer of the tubular sheath 20 is advantageously of the same nature as that of the matrix 40.
• the polymer of the tubular sheath 20 and the polymer of the matrix 40 are capable of melting and forming an intimate mixture, without phase separation, after cooling.
• the polymer forming the matrix 40 is chosen from a polyolefin such as polyethylene, a polyamide such as PA11 or PA12, or a fluorinated polymer such as polyvinylidene fluoride (PVDF) or polyvinylidene fluoride copolymers and polyhexafluoropropylene (PVDF-HFP).
• a polyolefin such as polyethylene
• a polyamide such as PA11 or PA12
• a fluorinated polymer such as polyvinylidene fluoride (PVDF) or polyvinylidene fluoride copolymers and polyhexafluoropropylene (PVDF-HFP).
• the matrix 40 comprises a polymer chosen from PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamide-imide), PEI (polyether-imide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenyleneether), PPS (polyphenylene sulfide) LCPs (polymer crystals liquids), PPA (polyphthalamide), copolymers of these and/or mixtures thereof or else a mixture of one or more of these with a polysiloxane, PTFE (polytetrafluoroethylene) or PFPE (perfluoropolyether).
• PEK polyetherketone
• PEEK poly
• the matrix 40 can for example comprise a mixture of polyaryletherketone and a polysiloxane, for example such as those described in application WO2019/150060.
• the matrix 40 comprises at least 50% by weight of the polymer defined above (or of the mixture thereof when it is a mixture), more preferably at least 75% by mass, even more preferably at least 80% by mass, typically at least 90% by mass, relative to the total mass of the matrix 40.
• the matrix 40 consists of one of the polymers defined above or of one of the mixtures defined above and fillers and/or additives.
• the reinforcing fibers 42 are for example carbon fibers, glass fibers, aramid fibers, and/or basalt fibers.
• the reinforcing fibers 42 generally have a maximum tensile strength greater than 2 GPa, advantageously greater than 3 GPa and comprised for example between 3 GPa and 6 GPa, as measured at 23° C. according to Standard ASTM D885M - 10A (2014 )e1.
• maximum tensile strength and “tensile strength” have the same meaning and designate the ultimate tensile strength measured during a test. of traction.
• the reinforcing fibers 42 advantageously have a tensile modulus greater than 50 GPa, for example between 70 GPa and 500 GPa, in particular between 50 GPa and 100 GPa for glass fibers, between 100 GPa and 500 GPa for carbon fibers and between 50 GPa and 200 GPa for aramid fibers, as measured at 23°C according to Standard ASTM D885M - 10A(2014)e1.
• tensile modulus In the present application, the terms "tensile modulus”, “Young's modulus” and “tensile modulus of elasticity” have the same meaning and designate the modulus of elasticity measured during a tensile test.
• the density of the reinforcing fibers 42 is generally between 1.4 g/cm3 and 3.0 g/cm3.
• the reinforcing fibers 42 are for example arranged, for each of the composite reinforcing layers, unidirectionally in the matrix 40. They are then parallel to each other. As a variant, the reinforcing fibers 42 are crossed in two orthogonal directions, or else are arranged randomly in the matrix (not shown).
• the length of the reinforcing fibers 42 in each composite layer is greater than 100 m, and is in particular between 100 m and 4500 m.
• the diameter of the composite fibers is for example less than 100 microns, and is in particular between 4 microns and 10 microns.
• each composite reinforcement layer is formed from a winding of at least one composite strip 44 having several layers of fibers 42 embedded in an elongated matrix 40, of length greater than at least 10 times its width and at least 10 times its thickness.
• each composite strip 44 is greater than 100 m and is between 100 m and 4500 m.
• the width of each composite band 44 is between 6 mm and 50 mm.
• the thickness of each composite band 44 is between 0.1 mm and 1 mm.
• Each composite strip 44 thus has, at 23° C., a tensile modulus greater than 10 GPa, in particular between 30 GPa and 170 GPa, as measured by Standard NF EN 2561, January 1996, an elongation at break greater than 1 %, in particular between 1% and 5%, as measured by Standard NF EN 2561, January 1996, and a maximum tensile strength greater than 100 MPa, and in particular between 350 MPa and 3500 MPa as measured by the Standard NF EN 2561, January 1996.
• each reinforcement layer the or each composite strip 44 is wound helically around the axis A-A' of the tubular sheath 20, and is heated to cause the partial melting of the matrix 40, and the connection with the successive turns of the composite strip 44, and/or with the adjacent layers which may be other reinforcing layers, anti-delamination layers or the tubular sheath 20.
• the absolute value of the winding helix angle p of each composite strip 44 with respect to the axis A-A' of the pipe 10 is for example between 55° and 85°. This ensures elongation of the composite under the effect of internal pressure, and adequate cooperation with the armor layers 24, 25.
• each composite layer is generally between 0.10 mm and 10 mm, for example between 0.12 mm and 7 mm, or between 0.22 mm and 5 mm.
• the sealing layer 22 is intended to confine the composite reinforcing structure 21 in leaktight manner. sealing 22, the layer 22 has the function of limiting, preferably of preventing, the contact between the infiltrated water and the composite reinforcement structure 21 .
• the sealing layer 22 can be bonded or unbonded to the composite reinforcement structure 21 .
• the permeability of the sealing layer depends on the material chosen for its production as well as the temperature to which the layer is subsequently exposed.
• the water permeability of the polymer materials that may be suitable for producing the sealing layer 22 is between 1x10 -7 cm 3 (STP).cm -1 .s' 1 .bar 1 and 2x10 -5 cm 3 ( STP).cm -1 .s -1 .bar 1 . Therefore, for a thickness of sealing layer 22 of between 1 mm and 20 mm, the water permeability of the layer is 5 ⁇ 10 -8 cm 3 (STP).cm -2 .s' 1 .bar 1 at 2x10 -4 cm 3 (STP).cm -2 .s' 1 .bar 1 .
• permeability of the sealing layer 22 is meant in the sense of the invention the ability of said sealing layer 22 as a whole to allow water to pass through.
• the permeability of the sealing layer may be different from the permeability of the material constituting the layer, in particular due to the presence of any discontinuities or faults in the sealing layer which would facilitate the passage of water or because the layer sealing is made on the basis of a discontinuous structure like a wound strip.
• the permeability of the sealing layer is clearly understood here as that of the layer as a whole, including the material and any interstices or interfaces between the discontinuous regions forming the layer.
• the permeability measurement refers to the permeability of the sealing layer as a whole, as it is present in the flexible pipe 10 of the invention.
• the water permeability of the material constituting the sealing layer 22 can be measured by the weight loss technique. This method for measuring the permeability of a liquid is described in particular in the publication “Emmanuel RICHAUD, Bruno FLACONN ⁇ CHE, Jacques VERDU - Biodiesel permeability in polyethylene - Polymer Testing - Vol. 31, p.170-1076 - 2012. Knowing the water permeability of the material, it is then possible to calculate the permeability of the sealing layer 22 by applying the following formula:
• the thickness of the sealing layer 22 (expressed in cm).
• the sealing layer 22 is formed from a thermoplastic material.
• the polymer forming the sealing layer 22 is chosen from an optionally crosslinked polyolefin, such as polyethylene or polypropylene; a thermoplastic elastomer (TPE) such as thermoplastic polyurethane (TPE-U or TPU) or styrenic copolymers (TPE-S or TPS) or vulcanized polypropylene and ethylene-propylene-diene (PP-EPDM) copolymers (TPE -V or TPV); a polyamide such as PA11 or PA12; or a fluoropolymer such as polyvinylidene fluoride (PVDF) or else copolymers of polyvinylidene fluoride and polyhexafluoropropylene (PVDF-HFP).
• TPE thermoplastic elastomer
• TPE-U or TPU thermoplastic polyurethane
• TPE-S or TPS styrenic copoly
• the sealing layer 22 comprises a polymer chosen from PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamide-imide ), PEI (polyetherimide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenyleneether), PPS (polyphenylene sulfide) LCPs ( liquid crystal polymers), PPA (polyphthalamide) and/or their mixtures or else a mixture of one or more of these with a polysiloxane, PTFE (polytetrafluoroethylene) or PFPE (perfluoropolyether).
• PEK polyetherketone
• PEEK polyetheretherketoneketone
• the sealing layer 22 may for example comprise a mixture of polyaryletherketone and a polysiloxane, such as those described in application WO2019/150060.
• the sealing layer 22 comprises at least 50% by mass of the polymer defined above (or of the mixture thereof when it is a mixture), more preferably at least 75% by mass , even more preferably at least 80% by mass, typically at least 90% by mass, relative to the total mass of the sealing layer 22.
• the sealing layer 22 consists of one of the polymers defined above or of one of the mixtures of these and of fillers and/or additives.
• the polymer of the sealing layer 22 is advantageously of the same nature as that of the matrix 40, more advantageously of the same nature as that of the matrix 40 and that of the sheath 20.
• the polymer of the sealing layer 22 and the polymer of the matrix 40, and optionally the polymer of the tubular sheath 20 are capable of melting and forming an intimate mixture, without phase separation, after cooling.
• the sealing layer 22 is made of a thermoplastic material.
• the sealing layer 22 is devoid of reinforcing materials.
• sealing layer 22 is continuous.
• continuous is meant in the sense of the invention that the structure of the sealing layer 22 is identical at all points.
• the sealing layer 22 does not include radial through holes which could facilitate the passage of a fluid, in particular water, through the layer.
• a sealing layer 22 having a closed porosity is thus considered to be homogeneous within the meaning of the invention.
• the thickness of the sealing layer is for example between 1 mm and 20 mm, preferably it is less than or equal to 15 mm.
• the sealing layer 22 is formed in one piece from a tubular sheath made of polymer material.
• the sealing layer 22 is made from a discontinuous structure, for example from a strip of assembled polymer material.
• the sealing layer 22 is formed of a tubular sheath, it is advantageously obtained by extruding a thermoplastic material around the composite reinforcing structure 21, the material being chosen in particular from the polymers mentioned above.
• the thickness of the sealing layer 22 is typically from 3 to 15 mm, preferably from 4 mm to 10 mm.
• the sealing layer 22 is formed from a strip of assembled polymer material, it is advantageously made by winding thermoplastic strips of a polymer as described above, followed by a step of welding the thermoplastic strips.
• the turns of a first layer are contiguous (edge to edge without overlap) and the turns of an upper layer are arranged so as to have an overlap of two adjacent strips, lower ensuring the sealing of the layer of sealing 22.
• the thickness of the sealing layer 22 is typically less than 3 mm, advantageously less than 2 mm, even more advantageously less than 1 mm
• the sealing layer 22 is not linked to the composite reinforcement structure 21 and is devoid of reinforcement materials.
• the polymer forming the sealing layer 22 is chosen from a polyolefin, optionally crosslinked, such as polyethylene or polypropylene; a TPE thermoplastic elastomer such as thermoplastic polyurethane (TPE-U or TPU) or styrenic copolymers (TPE-S or TPS) or vulcanized polypropylene and ethylene-propylene-diene (PP-EPDM) copolymers (TPE-V or POS); a polyamide such as PA11 or PA12; a fluorinated polymer such as polyvinylidene fluoride (PVDF) or even copolymers of polyvinylidene fluoride and polyhexafluoropropylene (PVDF-HFP).
• a polyolefin optionally crosslinked, such as polyethylene or polypropylene
• TPE-U or TPU thermoplastic polyurethane
• TPE-S or TPS styrenic copolymers
• the sealing layer 22 is then formed of a tubular sheath obtained by extrusion of a thermoplastic material around the composite reinforcing structure 21 .
• the sealing layer 22 then has a thickness of typically 3 to 15 mm, preferably 4 mm to 10 mm.
• the sealing layer 22 is bonded to the composite reinforcing structure 21 and is devoid of reinforcing materials.
• the sealing layer 22 comprises a polymer chosen from PEK (polyetherketone), PEEK (polyetheretherketone), PEEKK (polyetheretherketoneketone), PEKK (polyetherketoneketone), PEKEKK (polyetherketoneetherketoneketone), PAI (polyamide-imide), PEI (polyether-imide), PSU (polysulfone), PPSU (polyphenylsulfone), PES (polyethersulfone), PAS (polyarylsulfone), PPE (polyphenyleneether), PPS (polyphenylene sulfide ) LCPs (liquid crystal polymers), PPA (polyphthalamide), copolymers of these and/or mixtures thereof or a mixture of one or more of these with a polysiloxane, PTFE (polytetrafluoroethylene) or PFPE (perfluoropolyether).
• sealing layer 22 comprises PEEK (polyetherketone),
• the polymer of the sealing layer 22 is of the same nature as that of the matrix 40, more advantageously of the same nature as that of the matrix 40 and that of the sheath 20.
• the sealing layer 22 is then produced by extrusion or by winding thermoplastic strips previously obtained by pultrusion (or extrusion by pulling), typically by winding at least two thermoplastic strips, and the sealing layer 22 has a lower thickness to 3 mm, advantageously less than 2 mm, even more advantageously less than 1 mm.
• the flexible pipe 10 comprises an internal armor ply 24, and an external armor ply 25 around which the outer sheath 30 is arranged.
• Each layer of armor 24, 25 comprises longitudinal armor elements 50 wound at a long pitch around the axis A-A' of the pipe.
• long-pitch wound it is meant that the absolute value with respect to the axis A- A' of the helix angle is less than 55°, typically between 25° and 45°, and sometimes between 20 ° and 45°.
• the weave elements 50 of a first ply 24 are wound generally at an opposite angle relative to the weave elements 50 of a second ply 25.
• the angle of winding relative to the axis A-A 'of the armor elements 50 of the first ply 24 is equal to + a, a being between 25° and 45°
• the winding angle relative to the axis A-A' of the armor elements 50 of the second ply 25 placed in contact with the first ply 24 is for example ⁇ a, with a comprised between 25° and 45°.
• the armor elements 50 are for example formed by metal wires. Alternatively, the armor elements 50 are formed by flat composite yarns or tapes reinforced with carbon fibers.
• the composite reinforcement structure 21 can have a low tensile strength and tends to elongate under the effect of axial forces, the armor plies 24, 25 take up the axial forces and thus prevent the elongation of the composite reinforcement structure 21 .
• the tensile armor plies 24, 25 better resist axial compression under the external pressure conditions of the deep sea.
• the angle a of winding of the armor elements 50 of absolute value comprised between 25° and 55° taken in combination with the angle p of winding of the composite strips 44 of absolute value comprised between 60° and 80° allows compression of the composite reinforcing structure 21, reducing the minimum bending radius (“minimal bending radius” or “MBR”).
• MRR minimum bending radius
• the allowable tensile deformation at the upper surface of the tubular assembly formed by the internal sheath 20 and the composite reinforcing structure 21 is greater than 1%. This deformation induces the wrap radius compatible with most fabrication and installation equipment.
• the outer sheath 30 is intended to prevent the permeation of fluid from the exterior of the flexible conduit 10 to the interior. It is advantageously made of a polymer material, in particular based on a polyolefin, such as polyethylene, based on a polyamide, such as PA11 or PA12, based on a fluorinated polymer such as polyvinylidene fluoride ( PVDF), or based on an elastomeric thermoplastic comprising a polyolefin, such as polyethylene or polypropylene, combined with an elastomer of the type SBS (styrene butadiene styrene), SEBS (styrene ethylene butadiene styrene), EPDM (ethylene propylene diene monomer), polybutadiene, polyisoprene or polyethylene-butylene.
• a polyolefin such as polyethylene
• a polyamide such as PA11 or PA12
• a fluorinated polymer such as
• the thickness of the outer sheath 30 is for example between 5 mm and 15 mm.
• Each anti-wear layer 26 is formed, for example, of a polyolefin such as a polyethylene (PE) or a polypropylene (PP), a polyamide such as PA-11 or PA-12, a fluorinated polymer such as polyvinylidene fluoride (PVDF), a polyaryletherketone (PAEK) such as polyetheretherketone (PEEK) or polyetherketoneketone (PEKK), or even a polymer material comprising a sulphonated group such as polysulphone (PSU), polyethersulfone (PES) or polyphenylsulfone (PPSU).
• An anti-wear layer 26 is placed between the sealing layer 22 and the first tensile armor ply 24.
• Another anti-wear layer 26 is placed between the armor plies 24, 25, advantageously as indicated in the API Standard 17J, 4th edition May 2014.
• the reinforcing tape 28 is formed, for example, of an anti-buckling layer of high resistance in order to limit the buckling of the tensile armors 24, 25 in the event that the pipe is subjected to the reverse bottom effect phenomenon.
• This layer is for example made of aramid.
• the ribbon is wound around the outermost armor ply 25, between the armor ply 25 and the outer sheath 30, advantageously as indicated in the API 17J Standard, 4th edition May 2014.
• the method according to the invention comprises the following steps:
• the sheath 20 is manufactured and/or is provided in the installation.
• the sheath 20 undergoes a preliminary pre-compaction step.
• Sheath 20 is then heated to bring its outer surface to a temperature above 100°C, and in particular between 100°C and 350°C.
• the sheath 20 must have the most cylindrical shape possible.
• Such a device is for example described in WO 2019/180050.
• a plurality of reinforcing layers are then formed around sheath 20 from strips 44.
• a plurality of strips 44 are unwound in parallel around the sheath 20.
• Guide elements can be used to maintain the strips 44 parallel to each other, with a controlled clearance.
• the parallel strips 44 are then heated, advantageously to a temperature between 150° C. and 500° C., said temperature depending on the nature of the thermoplastic polymer constituting the matrix 40 of the strips 44.
• the heating temperature of the strips 44 is advantageously between 350°C and 500°C.
• the heating temperature of the strips 44 is advantageously between 180° C. and 280° C., preferentially between 200° C. and 250°C. This advantageously leads to the at least partial fusion of the matrix 40.
• the strips 44 are wound helically around the outer surface defined by the sheath 20.
• the absolute value of the winding helix angle p of each composite strip 44 with respect to the axis A-A' of the pipe 10 is for example between 50° and 85°, preferably between 55° and 80°. °. This allows the composite reinforcement structure 21 to accommodate radial elongations due to the radial forces generated under the effect of the internal pressure, and adequate cooperation with the armor plies 24, 25.
• a train of rollers as defined is driven in rotation and is applied to the strips 44 so as to compact them.
• the successive rollers define a compaction generator which rests on the strips 44.
• the strips 44 are compacted in a uniform manner, avoiding the disorganization of the fibers 42 present in the matrix 40, while ensuring an effective distribution of the molten material of the matrix 40 to form a composite reinforcing structure 21 which is continuous and sealed.
• the composite reinforcement structure 21 undergoes a post-compaction step during which the external surface of the composite reinforcement structure 21 is softened by heating, then compacted again by the trains of rotating rollers.
• the rollers of the roller trains roll in a helical path along the respective strips 44, ensuring minimal disruption of the reinforcing fibers 42.
• the pre-compaction, tubular structure formation and post-compaction operations are repeated to form several concentric reinforcement layers with other strips 44, as described above.
• the composite reinforcement structure 21 is thus manufactured layer by layer, each new outer layer having a thickness substantially equal to that of a strip 44. These operations can be repeated several tens of times, in particular when the strip or strips 44 have a thickness significantly less than the final thickness of the wall of the composite reinforcement structure 21 desired.
• the characteristics of the strips 44 and/or the laying and/or compacting parameters can be modified each time a new layer is added. For example, it is possible to modify the helix angle of the strips 44, in particular to cross the fibers of two superimposed layers.
• the sealing layer 22 is then formed around the composite reinforcement structure 21 .
• the sealing layer 22 is formed by extrusion of a thermoplastic chosen from the polymers mentioned above.
• the thermoplastic material is extruded directly onto the composite reinforcing structure 21 .
• the thickness of the sealing layer 22 is typically from 3 to 15 mm, preferably from 3 mm to 10 mm.
• the sealing layer 22 is formed by winding around the composite reinforcing structure 21 thermoplastic strips of a polymer as described above, followed by welding of the strips.
• the turns of a first layer are contiguous (edge to edge without overlap) and the turns of an upper layer are arranged so as to have an overlap of two lower adjacent bands ensuring the sealing of the tubular sheath 20.
• the strips 44 forming the composite reinforcing structure 21 and the thermoplastic strips forming the sealing layer 22 are wound with the same winding angle relative to the axis AA' of the pipe 10.
• the absolute value of the The winding helix angle of each composite strip 44 and of each thermoplastic strip with respect to the axis A-A' of the pipe 10 is for example between 50° and 85°, preferably between 55° and 80°.
• the sealing layer 22 is obtained by winding at least two thermoplastic strips around the composite reinforcing structure 21 .
• Thermoplastic tapes are typically prepared by extruding the thermoplastic material.
• the sealing layer 22 is a two-layer arranged around the composite reinforcement structure 21 in which each layer comprises the winding of at least two thermoplastic strips prepared by extrusion of the thermoplastic material.
• thermoplastic strips are carried out according to any known method, typically by heating the junction zones between the strips to a temperature of between 150° C. and 500° C., the temperature depending on the nature of the thermoplastic polymer constituting the strips.
• the heating temperature is advantageously between 350°C and 500°C.
• the thermoplastic strips are made of PVDF (melting point of the order of 180°C)
• the heating temperature is advantageously between 180°C and 280°C, preferably between 200°C and 250°C.
• thermoplastic strips are welded out by LASER radiation.
• the welding of the thermoplastic strips allows the formation of a continuous sealing layer 22.
• the thickness of the sealing layer 22 is typically less than 3 mm, advantageously less than 2 mm, even more advantageously less than 1 mm.
• the method of the invention allows the manufacture of flexible pipes 10 in which the sealing layer 22 is bonded or not bonded to the composite reinforcement structure 21, depending on the method used to form the sealing layer 22.
• the sealing layer 22 is formed by winding thermoplastic strips around the composite reinforcing structure 21, followed by the welding the strips together. In this case, the sealing layer 22 obtained is bonded to the composite reinforcing structure 21 .
• the sealing layer 22 is formed by extrusion of a thermoplastic material.
• the bonded or unbonded character of the sealing layer 22 depends on the temperature at which the extruded thermoplastic material and the composite reinforcement layer 21 are brought into contact.
• the resulting sealing layer 22 is not bonded to the composite reinforcement structure 21 .
• the extruded thermoplastic material and the composite reinforcement layer are brought into contact at a temperature greater than or equal to the melting temperature of the thermoplastic material, the resulting sealing layer 22 is bonded to the composite reinforcement structure. 21 .
• the method of the invention leads exclusively to the formation of a sealing layer 22 not bonded to the structure. reinforcement composite 21 .
• the armor elements 50 of the tensile armor plies 24, 25 are then wound around the sealing layer 22, in a manner not bonded with the sealing layer 22.
• an anti-wear layer 26 is interposed between the sealing layer 22 and the first ply of tensile armors 24, and between each ply of tensile armors 24, 25.
• a reinforcing tape 28 is wrapped around the outermost tensile armor ply 25.
• the outer sheath 30 is formed around the armor plies 24, 25.
• the compaction provided by the rollers during the formation of the composite reinforcement structure 21, then during the post-compaction step reinforces the mechanical properties of the composite reinforcement structure 21, in particular by providing interlaminar mechanical resistance. increased, a greater rate of crystallinity, and a reduced rate of porosity.
• the composite reinforcement structure 21 is therefore mechanically more robust and has improved sealing against the fluid intended to circulate in the internal passage 13.
• the presence of the sealing layer 22 limits, preferably completely prevents, the entry of external water into the interior of the flexible pipe 10 of the invention. It makes it possible in particular to protect the composite reinforcing structure 21 against the harmful effects of water, in particular by avoiding the formation of discontinuities.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Rigid Pipes And Flexible Pipes (AREA)
• Laminated Bodies (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=74125472

Family Applications (1)

Country Status (5)

Families Citing this family (1)

Family Cites Families (16)

• 2020
  • 2020-11-09 FR FR2011472A patent/FR3116099B1/fr active Active
• 2021
  • 2021-11-09 WO PCT/EP2021/081133 patent/WO2022096748A1/fr active Application Filing
  • 2021-11-09 AU AU2021375743A patent/AU2021375743A1/en active Pending
  • 2021-11-09 US US18/251,999 patent/US20240019051A1/en active Pending
  • 2021-11-09 EP EP21799307.0A patent/EP4241003A1/de active Pending

Also Published As

Similar Documents

Legal Events