WO2017108501A1

WO2017108501A1 - Method for manufacturing a pipe and a tubular structure that are mechanically lined

Info

Publication number: WO2017108501A1
Application number: PCT/EP2016/080788
Authority: WO
Inventors: Jean-Louis Saltel; Romain Neveu; Samuel THIEBAULT
Original assignee: Saltel Industries
Priority date: 2015-12-23
Filing date: 2016-12-13
Publication date: 2017-06-29
Also published as: FR3046213A1; FR3046213B1

Abstract

The invention relates to a method for manufacturing a mechanically lined pipe for transporting fluids, comprising the steps of: • a) inserting a cylindrical internal liner (12) into an external tube (11); • b) inserting an expanding tool (2) into said internal liner (12); • c) inflating the expanding tool (2) so as to firstly cause the radial plastic deformation of at least one part of the internal liner (12) until it comes into contact with the inner surface of the external tube (11), and then to cause the radial elastic deformation of at least one part of the external tube (11); • d) deflating the expanding tool (2); • e) moving the expanding tool (2) in said internal liner (12); • f) repeating steps (c) and (d) for each of said at least one part of the internal liner (12) so as to shape the mechanically lined pipe, and • g) withdrawing the expanding tool (2).

Description

Process for manufacturing a mechanically jacketed pipe and tubular structure

1. Field of the invention

The invention relates to the field of pipes and tubular structures with internal lining adapted to the transport of fluids, and in particular corrosive fluids.

The invention relates in particular, but not exclusively, to submarine tubular conduits and structures.

The invention applies more particularly, but not exclusively, to the field of oil production or gas.

2. Solutions of the prior art

It is known to use pipes for the transport of corrosive fluids under high pressure.

For example, the inner wall of these pipes may be in direct contact with highly corrosive hydrocarbons extracted from a petroleum field. Under these very severe conditions, the inner wall of these pipes in which hydrocarbons circulate must be able to maintain its integrity for a service life of at least 20 years.

It is known and it is known to protect against corrosion the inner wall of these pipes with a corrosion resistant alloy inner liner (called "C A" in English for "corrosion resistant alloy").

According to a particular known approach, a pipe of this type can be mechanically lined (this type of pipe is called "mechanically lined pipe" in English):

- By positioning, coaxially or not, in an outer tube (called "Mother Pipe" in English) carbon steel, an internal lining (called "lined pipe" in English) of diameter slightly less than the outer pipe, then

by carrying out the radial plastic expansion of the inner liner so that it fits tightly by a metallic contact against the inner wall of the outer tube.

The radial expansion of the inner liner can be implemented by hydroforming, applying a hydraulic pressure of the order of 400 to 1200 bar, by for example, inside the jacket until the latter plastically deforms and comes into close contact with the outer tube. This radial expansion of the inner liner beyond its elastic limit is continued until elastically deforming the outer tube. The hydraulic pressure is then interrupted, which causes the elasticity of the outer tube which contracts around the liner (itself expanded against the inner surface of the outer pipe), causing the two parts to shrink. The outer tube and the inner liner are then mechanically linked (we speak of "mechanical bond" in English).

A disadvantage of this approach is that there is a risk that water remains present between the outer tube and the liner after hydroforming, which weakens the mechanical connection between these two parts.

This approach leads to jacketed conduits of a length equal to 12m conventionally, which should then be connected together while ensuring continuity of protection against corrosion.

To do this, the jacketed pipes are placed coaxially and assembled by welding. More specifically, a circumferential weld is implemented over the entire thickness of the outer tube and the inner liner. It can result:

- a risk of contamination due to the welding of different materials (carbon steel for the outer tube and corrosion-resistant alloy for the inner liner), - a one-off risk of corrosion because the carbon material of the outer tube can be contact with the corrosive fluid inside the pipe and

- A risk of crack propagation on the thickness of the weld, which creates a zone of weakness, which can lead to a leak at the junction between two pipes assembled end to end.

3. Presentation of the invention

The present invention aims to solve the weaknesses of prior pipe lining techniques for the transport of corrosive fluids.

To do this, the invention proposes, in a first aspect, a method of manufacturing a mechanically jacketed pipe for the transport of fluids, characterized in that it comprises the steps of:

a) inserting an inner liner into an outer tube;

b) inserting an expander tool within the inner liner; c) inflating the expander tool so as to initially cause the radial plastic expansion / deformation of at least a portion of the inner liner until it comes into contact with the inner surface of the outer tube, then the radial elastic expansion / deformation of at least a portion of the outer tube;

d) deflation of the expander tool;

e) moving the expander tool in said inner liner;

f) repeating steps (c) and (d) for each of said at least a portion of the inner liner to form the mechanically lined pipe, and g) removing the expander tool.

The expansion tool may be a tool equipped with an elastic peripheral tubular membrane inflated hydraulically by a fluid under pressure, designated by the English term "packer". The expander tool works step by step, with successive phases of inflation / deflation / advance of its peripheral tubular membrane.

After lining a portion of the outer tube, the membrane is deflated and moved to be repositioned to a new area of the outer tube to be lined.

The radial plastic expansion operation of each portion of the inner liner is continued until elastically deforming the outer tube.

The expansion is then interrupted by deflating the expander tool, which causes the elasticity of the outer tube which contracts around the inner liner (which is itself expanded against the inner surface of the outer tube) to shrink. outer tube on the inner liner.

After this operation, the outer tube and the inner liner undergo constraints of different nature. Thus, the method of the invention makes a power of the outer part (outer tube) and a compression of the inner part (inner liner).

The outer tube and the expanded inner liner are then mechanically linked (we speak of "mechanical bond" in English).

This mechanical connection is a tight fit between the cylindrical outer surface of the inner liner and the cylindrical inner surface of the outer tube, making disassembly impossible without damaging the two parts. This method of manufacturing a mechanically jacketed pipe is inexpensive, precise and relatively easy to implement compared to solutions of the prior art (hydroforming in particular).

The method of the invention can be implemented on site in which the outer tube to be lined is already arranged, and is suitable for lining tubes of various lengths.

According to a particular aspect of the invention, the inflation of the expander tool causes the radial elastic expansion / deformation of at least a portion of the outer tube.

The diameter of the liner is smaller than that of the outer tube. Once the liner deformed plastically by the expander tool, the expansion of the liner is continued to cause a slight elastic deformation of the outer tube.

The expansion is then interrupted thereby forcing the outer tube on the liner and assemble the tube and liner by hooping.

According to an alternative embodiment, the inflation of the expander tool is continued until causing the radial plastic expansion / deformation of at least a portion of the outer tube.

According to a particular aspect of the invention, the manufacturing method comprises, prior to step c) and up to step d), a step of heating said outer tube.

This operation consists of heating the outer tube to expand it, the cooling coming to constrain the outer tube on the inner liner.

The invention also relates to a mechanically jacketed pipe according to the manufacturing method described above.

According to a particular aspect of the invention, the inner liner is made of a material resistant to corrosion.

According to a particular aspect of the invention, the outer tube is made of carbon steel.

The invention applies more particularly, but not necessarily, to pipes used on the surface or under water for the transport of petroleum products, gas, water or corrosive liquids. This doubled bimetallic pipe consists of, for example, an outer tube of carbon steel and an inner sleeve of corrosion resistant metal. The corrosion-resistant liner (about 3 mm thick, for example) is mechanically bonded along its entire length to the inner surface of the outer pipe with lower corrosion resistance.

The present invention also aims to solve the weaknesses of prior art welding of jacketed pipes placed end to end.

To do this, the invention proposes, according to a second aspect, a method of manufacturing a tubular structure or duct mechanically jacketed.

According to the invention, the method comprises the steps of:

a) welding at least a first pipe and a second pipe placed end to end so as to form an outer tube of predetermined length; b) welding a plurality of end-to-end internal liners to form an inner liner having a length greater than the predetermined length of the outer tube;

c) inserting said inner liner within said outer tube, a first end of the inner liner protruding from a first end of the outer tube;

d) inserting a deflated expander tool within said inner liner; e) inflating the expander tool from the second end of the inner liner so as to initially cause the radial plastic expansion / deformation of at least a portion of the inner liner until it comes into contact with the inner surface of the outer tube, then the radial expansion / deformation of at least a portion of the outer tube;

f) deflation of the expander tool;

g) moving the expander tool in said inner liner;

h) repeating steps (e) and (f) for each of the portions of said inner liner, and

i) removal of the expander tool.

Thus, the welding of the outer tube (called "Mother Pipe" in English) is performed before the expansion of the internal lining (called "Lined Pipe" in English). Welding Pipes for forming the outer tube is made on a homogeneous metal, which is not in contact with the corrosion resistant alloy (CA) of the inner liner.

Welding of the liners for forming the inner liner is performed prior to sliding the inner liner into the outer tube. Again, the welding of the liners for forming the inner liner is made of a homogeneous material that is not in contact with the metal of the outer tube.

According to a particular aspect of the invention, steps a and b) are repeated until the predetermined length of the tubular structure (or pipeline, or "pipeline") is reached.

It may be envisaged to weld other pipes to elongate the outer tube after insertion of the inner liner into the outer tube. It is preferable, however, that the inner liner still protrudes from the end of the outer tube once this is done.

According to a particular aspect of the invention, during step c), the welds of said inner liners are not arranged opposite the welding of said first and second pipes along the longitudinal axis of the tubular structure.

The welds of two sections of the outer tube and two sections forming the inner liner are preferably not located at the same level (or facing). In this way, if a crack propagates on one of the materials of the outer tube or inner liner, it will be stopped when it reaches the second material. This preserves the integrity of the tubular structure during a service life of at least 20 years.

The method is easy to implement, of satisfactory cost and ensures effective holding of pipe sections, especially at their junction.

In other words, the junction of the pipes forming the pipeline is not weak.

According to a particular aspect of the invention, the inflation of the expander tool causes the radial elastic expansion / deformation of at least a portion of the internal liner.

According to an alternative embodiment, the inflation of the expander tool causes the radial plastic expansion / deformation of at least a portion of the inner liner. According to a particular aspect of the invention, the manufacturing method comprises a step of heating said outer tube.

The invention also relates to a mechanically jacketed tubular structure obtained according to the manufacturing method described above.

Such a tubular structure can be used in "onshore" or "offshore" operations.

It is suitable for transporting fluids, for example pressurized gas, between a platform located on the surface and the seabed.

The tubular structure of the invention comprises an internal liner capable of withstanding highly corrosive media, mechanically bonded to an outer tube having good mechanical strength and high crush resistance.

4. List of figures

Other features and advantages of the described technique will appear more clearly on reading the following description of several embodiments, given as simple illustrative and non-limiting examples, and the appended drawings, among which:

Figure 1 schematically illustrates the establishment of the elements forming a mechanically jacketed pipe according to the invention;

Figure 2 is a schematic sectional view of a mechanically jacketed pipe according to the invention;

Figures 3 to 5 schematically illustrate different steps of the method of manufacturing a mechanically jacketed pipe according to a first embodiment of the invention;

Figures 6 and 7A to 7D schematically illustrate different steps of the method of manufacturing a mechanically jacketed pipe according to a second embodiment of the invention;

FIGS. 8A to 8G schematically illustrate different steps of the method of manufacturing a pipe according to the invention;

FIG. 9 is a detailed view of a pipe according to the invention showing the weld between two pipes of the outer tube, and

Figure 10 is a detail view of a pipe according to the invention showing the welding between two liners of the inner liner. 5. Description

5.1 Structure of the pipe

FIG. 2 is a sectional view of a tubular bimetallic pipe 1 intended to convey corrosive fluids in particular.

This pipe 1 is particularly suitable for the transport of hydrocarbons in the context of underwater oil production facilities and for this purpose has a high corrosion-resistant lining which is in direct contact with the fluid flowing in the pipe. 1.

This pipe 1 is mechanically lined according to a method which will be described later. It comprises an outer tube 11 of carbon steel (of the X65 type, for example) whose inner cylindrical surface is coated with an inner liner 12 made of material (preferably an alloy, such as AISI 304L or AISI 316L, for example) resistant to corrosion.

This pipe 1 thus has a wall in two thicknesses so that the pipe 1 is able to resist corrosion and that it is, moreover, a robust structure resistant to mechanical stresses when in use.

This pipe 1 has a length of about 12 meters and a diameter of between 10 cm and 155 cm (between 4 and 60 inches). It can be assembled end to end with other pipes of the same type to form a tubular structure (or pipeline, or pipeline).

5.2 Manufacturing processes of the pipe

With reference to FIGS. 3 to 5, the method of manufacturing such a pipe according to a first approach is presented.

In a first step, illustrated in Figure 1, the inner liner 12 is disposed in the outer tube 11 coaxially, the diameter of the inner liner 12 being smaller than the diameter of the outer tube 11. The length of the inner liner 12 is equal to that of the outer tube 11.

An expansion tool 2 is then placed in the inner liner 12. This type of tool is usually referred to as "packer".

Such an expansion tool 2 is adapted to be inserted inside the inner liner 12, in the deflated state, and be positioned in a given zone of the inner liner 12 that is to be expanded (FIG. 3). The expansion tool 2 is supplied with high pressure liquid, able to radially expand its peripheral tubular membrane outwards, so that it is pressed against the wall of the inner liner 12 and also causes radially outwardly expanding plastic, until the outer surface of the inner liner 12 is applied over a certain length against the inner surface of the outer tube 11 (Figure 4).

Although this is not illustrated in these figures, the radial expansion operation of each portion of the inner liner 12 is continued until elastically deforming the outer tube 11 without reaching the plastic deformation phase of the latter.

The expansion is then interrupted by deflating the expansion tool, which causes the elasticity of the outer tube 11 which contracts around the internal liner 12 (itself expanded against the inner surface of the outer tube 11), and an elastic return. hooping of the outer tube 11 on the inner liner 12.

The outer tube 11 and the inner liner 12 undergo constraints of different nature. Thus, the method of the invention realizes a tensioning of the outer part (outer tube 11) and a compression of the inner part (inner liner 12).

The outer tube 11 and the inner liner 12 expanded are then mechanically linked (we speak of "mechanical bond" in English).

This mechanical link is a tight fit between the cylindrical outer surface of the inner liner 12 and the cylindrical inner surface of the outer tube 11, making disassembly impossible without damaging the two parts 11, 12.

Once the zone of the outer tube 11 has been jacketed, the expansion tool 2 is deflated and moved so as to be repositioned into a new zone to be expanded (FIG. 5).

The expansion tool 2 is connected to the surface by a rod for handling, its proper positioning, and the control members for inflating and deflating. For this purpose, a conduit for supplying and discharging the inflation liquid can be integrated into the rod.

This is done by lining the entire length of the outer tube 11 by the radial deformation of the expansion tool 2 (packer), working step-by-step and left to right in the figures, with successive phases of inflation, deflation and advance of the expansion tool 2.

In relation to FIGS. 6 and 7A to 7D, the method of manufacturing a pipe 1 according to a second approach is presented.

This second approach implements the same steps as the first approach described above. However, prior to inflation of the expansion tool 2 in the inner liner 12, the outer tube 11 is heated to cause its expansion and a slight expansion of its diameter in its elastic limit (the heating is illustrated schematically on the Figures 6 and 7A to 7C by arrows located on the periphery of the outer tube 11).

Figure 6 shows the expansion tool 2 disposed in the inner liner 12 before inflation, the outer tube 11 being heated.

Figures 7A to 7D are sectional views of the pipe 1 which show the different steps of the lining of the pipe 1, the expansion tool 2 is not illustrated for the sake of clarity.

Thus, the heating of the outer tube 11 is carried out to cause a slight expansion of its diameter in its elastic limit (FIGS. 7A and 7B).

The inner liner 12 is then expanded by inflating the expansion tool 2 until it comes into contact with the inner surface of the outer tube 11 (Fig. 7C).

The expansion tool 2 is still slightly inflated so that the inner liner 12 is further expanded, the diameter of the outer tube 11 also being slightly expanded (in FIG. 7C, the forces applied by the inner liner 12 on the outer tube 11 are represented by arrows located on the periphery of the inner surface of the inner liner 12). The expansion and heating of the outer tube 11 are controlled so that the diameter of the outer tube 11 does not extend beyond its elastic limit.

When the expansion and heating of the outer tube 11 are interrupted, the body of the outer tube 11 contracts around the inner liner 12 on the one hand with the cooling (in Figure 7D, the forces applied by the outer tube 11 on the internal liner 12 are represented by arrows located on the periphery of the outer surface of the outer tube 11) and on the other hand with the elastic return of the outer tube 11.

The lining of the outer tube 11 is carried out in successive steps, by moving the expansion tool 2 progressively from one end to the other of the outer tube 11, always in the same direction.

This second approach realizes a tensioning of the outer part (external tube 11) and a compression of the inner part (internal liner 12), resulting in a mechanical connection between these two parts 11, 12. More precisely, the interruption of the expansion by the tool 2 and the heating of the outer tube 11 cause the elastic return of the latter which contracts around the inner liner 12 (which is itself expanded against the inner surface of the outer tube 11), which causes a hooping of the two parts 11, 12.

In each of these two approaches, the difference in diameter between the outer tube 11 and the inner liner 12 is chosen according to whether it is desired to expand elastically or plastically the outer tube.

5.3 Method for manufacturing a mechanically jacketed tubular structure

In the following, with reference to FIGS. 8A to 8G, is presented the method of manufacturing a pipe 100 of great length (several kilometers, for example) which is adapted to convey fluids such as hydrocarbons. To do this, the outer tube 110 of the pipe 100 is provided with an inner liner 120 manufactured using a material which, by its constitution and properties, is likely to provide effective protection against aggressiveness diverse environments.

The inner liner 120 is made of a corrosion resistant material, and the outer tube 110 is carbon steel in this example.

Line 100 is obtained by firstly connecting several pipes coaxially (between 2 and 4, for example) so as to obtain an outer tube 110. In the example of FIG. 8A, a first pipe 110A is coaxially connected by a first solder 111A peripheral to a second pipe 110B, the latter being coaxially connected by a second peripheral weld 111B to a third pipe HOC. In parallel, several jackets are coaxially connected so as to obtain an internal liner 120. In the example of FIG. 8B, several jackets 120A to 120E are connected end-to-end through 121A 121D peripheral welds.

Once the welds of the outer tube 110 and the inner liner 120 are performed separately, the inner liner 120 is disposed within the outer tube 110, as shown in FIG. 8B.

Note that the length of the inner liner 120 is greater than the length of the outer tube 110, so that the left ends of the outer tube 110 and the inner liner 120 are located in the same radial plane, the right end of the inner liner 120 protruding from the right end of the outer tube 110.

A deflated expander tool 2 is then placed within the inner liner 120, at the level of the first pipe 110A and the liner 120A which are facing each other.

The expander 2 is then inflated so as to initially cause the radial expansion / deformation of a part of the inner liner 120 (in this case of the liner 120A) until this portion comes in contact with the inner surface of a portion of the outer tube 110 (in this case the first pipe 110A). The inflation of the expander 2 is continued until the elastic expansion / elastic deformation of the first pipe 110A (FIG. 8C) is achieved.

The expander tool 2 is then deflated, which causes, as explained above, the elastic return of the first pipe 110A which contracts around the liner 120A.

The expander tool 2 is moved from left to right (FIG. 8D) and these steps are repeated to liner the second pipe 110B with the liner 120B (FIG. 8E).

Then, as illustrated in FIG. 8F, a new pipe 110D is connected to the free end of the HOC pipe via a peripheral weld 111C, the length of the inner liner 120 always being greater than the length of the outer pipe 110.

As illustrated in FIG. 8G, the pipe 100 consists of several mechanically jacketed pipes assembled end to end.

The expander tool 2 is moved from left to right (the expander tool is not shown in FIGS. 8E-8G for the sake of clarity) to line the third HOC pipe with the liner 120D (FIG. 8E). Once the pipe 100 mechanically jacketed, the expander tool 2 is then removed.

Figure 9 is a detailed view of a pipe 100 according to the invention showing the weld 111A between two pipes 110A and 110B of the outer tube 110.

Figure 10 is a detailed view of a pipe 100 according to the invention showing the weld 121A between two liners 120A and 120B of the inner liner 120.

It is noted that the welds of the pipes forming the outer tube 110 are made separately from the welds forming the inner liner 120.

In particular, the weld 111A of the two pipes 110A and 110B intended to partially form the outer tube 110 (called "Mother Pipe" in English) is performed separately from the weld 121A 120A shirts and 120B of the inner liner 120 ..

The weld 111A of the two pipes 110A and 110B is carried out on a homogeneous metal, which is not in contact with the corrosion resistant alloy (C A) of the inner liner 120, and in particular of the liner 120B.

The weld 121A 120A and 120B shirts intended to partially form the inner liner 120 is performed before sliding the inner liner 120 in the outer tube 110. Again, the welding of the shirts 121 and 122 is made with a homogeneous material (l corrosion resistant alloy in this case) which is not in contact with the metal of the outer tube.

As seen in FIGS. 8A to 8G, 9 and 10, the welds 121A to 121E and the welds 111A to 111C are preferably not located at the same level (or facing) along the longitudinal axis of the pipe. 100, and therefore do not come to flatten against each other once the pipe 100 mechanically jacketed (Figure 8G). In this way, if a crack appears at one of the welds of the outer tube or inner liner, it can not propagate to the other weld. This preserves the integrity of the tubular structure during a service life of at least 20 years.

The method is easy to implement, of satisfactory cost and ensures effective holding of the tubes forming the pipe especially at their junction, both mechanically and with regard to corrosive agents and / or abrasives.

According to a particular implementation, each portion of the outer tube is heated before proceeding to lining. The difference in diameter between the outer tube and the inner liner is chosen according to whether it is desired to elastically or plastically expand the outer tube.

5.4 Other aspects and variants

Such pipeline and associated pipelines are used for the exploitation of oil and gas deposits, particularly onshore or offshore.

They can also be used to transport chemicals, corrosives and / or abrasives, or any other type of fluid.

They can be immersed in water, in the marine environment for example, or buried in the ground.

Claims

A method of manufacturing a mechanically jacketed pipe (1) for transporting fluids, characterized in that it comprises the steps of:

a) inserting a cylindrical inner liner (12) within an outer tube (11);

b) inserting an expander tool (2) within said inner liner (12); c) inflating the expander tool (2) so as to initially cause the radial plastic deformation of at least a portion of the inner liner (12) until it comes into contact with the inner surface the outer tube (11), then the radial elastic deformation of at least a portion of the outer tube (11);

d) deflating the expander tool (2);

e) moving the expander tool (2) in said inner liner (12); f) repeating steps (c) and (d) for each of said at least a portion of the inner liner (12) to form the mechanically jacketed conduit (1), and

g) removal of the expander tool (2).

2. Method according to claim 1, characterized in that the inflation of the expander tool (2) is continued to cause the radial elastic deformation of at least a portion of the outer tube (11).

3. Method according to claim 1 or 2, characterized in that it comprises, prior to step c) and up to step d), a step of heating said outer tube.

4. Conduit (1) mechanically jacketed according to the manufacturing method of one of claims 1 to 3.

5. Line (1) according to claim 4, characterized in that the inner liner (12) is made of a material resistant to corrosion.

6. Line (1) according to claim 4 or 5, characterized in that the outer tube (11) is carbon steel.

7. A method of manufacturing a tubular structure (100) mechanically jacketed, characterized in that it comprises the steps of:

a) welding at least a first pipe (110A) and a second pipe (110B) placed end to end to form an outer pipe (110) of predetermined length;

b) welding a plurality of inner liners (120A, ..., 120E) end to end to form an inner liner (120) having a length greater than the predetermined length of the outer tube (110);

c) inserting said inner liner (120) within said outer tube (110), a first end of the inner liner (120) protruding from a first end of the outer tube (110);

d) inserting an expanding tool (2) deflated within said inner liner (120);

e) inflating the expander tool (2) from the second end of the inner liner (120) so as to initially cause the radial plastic deformation of at least a portion of the inner liner (120) to it comes into contact with the inner surface of the outer tube (110), and then the radial elastic deformation of at least a portion of the outer tube (110);

f) deflation of the expander tool (2);

g) moving the expander tool (2) in said inner liner (120); h) repeating steps (e) and (f) for each of the portions of said inner liner (120), and

i) removal of the expander tool (2).

8. The manufacturing method according to claim 7, characterized in that steps a and b) are repeated until the predetermined length of the tubular structure (100) is reached.

9. The manufacturing method according to claim 7 or 8, characterized in that during step c), the welds (121A, ..., 121D) of said internal liners (120A, ..., 120E) are not disposed opposite the weld (111A) of said first and second pipes (110A, 110B) along the longitudinal axis of the tubular structure (100).