Hybrid pipe design and method of manufacture
View Patent ↗A hybrid flexible pipe and method of manufacture having one or more web layers over a tubular core and a polymer layer over the web layers and tubular core. A flexible helical reinforcement layer having gaps between strips is wrapped on top of the polymer layer. A second flexible helical reinforcement layer having gaps between strips is helically wrapped around the first helical reinforcement layer in the opposite direction. A sheath layer is positioned as the outermost layer. A first flexible helical anti-extrusion layer having a first anti-extrusion strip can be helically wrapped around the first flexible helical reinforcement layer in substantially the same direction as the first flexible reinforcement layer and a second flexible helical anti-extrusion layer having a second anti-extrusion strip can be helically wrapped around the at least one second flexible helical reinforcement layer in substantially the same direction as the second flexible helical reinforcement layer.
1. A hybrid flexible pipe, comprising:
a. a tubular core having a longitudinal passage for internal fluid;
b. at least one web layer comprised of a plurality of webbed wires positioned on top of said tubular core;
c. a polymer layer over said at least one web layer;
d. at least one first flexible helical reinforcement layer comprised of a first strip being helically wrapped on top of said polymer layer;
e. said at least one first strip is wrapped to form a first gap between consecutive wraps of said first strip;
f. at least one second flexible helical reinforcement layer comprised of a second strip is helically wrapped around said at least one first helical reinforcement layer in a direction substantially opposite to that of said first strip;
g. said at least one second strip is wrapped to form a second gap between consecutive wraps of said second strip; and
h. a sheath layer positioned as the outermost layer.
2. A hybrid flexible pipe according to claim 1 wherein:
a. a first flexible helical anti-extrusion layer comprised of a first anti-extrusion strip is helically wrapped around said at least one first flexible helical reinforcement layer; said first anti-extrusion strip is wrapped in substantially the same direction as said first strip; said first anti-extrusion strip substantially covers said first gap between the consecutive wraps of said first strip; and
b. a second flexible helical anti-extrusion layer comprised of a second anti-extrusion strip is helically wrapped around said at least one second helical reinforcement layer; said second anti-extrusion strip is wrapped in substantially the same direction as said at least one second strip; said second anti-extrusion strip substantially covers said second gap between the consecutive wraps of said second strip.
3. A hybrid flexible pipe according to claim 2 wherein a polymer layer is helically wrapped without gaps between wraps on an outer side of said second flexible helical anti-extrusion layer.
4. A hybrid flexible pipe according to claim 1 wherein said polymer layer is fused with said tubular core and with said at least one web layer.
5. A hybrid flexible pipe according to claim 1 wherein said polymer layer is attached with adhesive to said tubular core and to said at least one web layer.
6. A hybrid flexible pipe according to claim 1 wherein a polymer tape layer is helically wrapped without gaps between wraps on an outer side of said second flexible helical reinforcement layer.
7. A hybrid flexible pipe according to claim 1 wherein a plurality of web layers are positioned on said tubular core.
8. A method of manufacturing a hybrid flexible pipe, comprising the steps of:
a. adding at least one web layer around a tubular core having a longitudinal passage for internal fluid;
b. positioning a polymer layer over said at least one web layer;
c. wrapping at least one first flexible helical reinforcement layer comprising a first strip on top of said polymer layer;
d. forming a first gap between consecutive wraps of said first strip;
e. wrapping at least one second flexible helical reinforcement layer comprising a second strip around said at least one first helical reinforcement layer in a direction substantially opposite to that of said first strip;
f. forming a second gap between consecutive wraps of said second strip; and
g. positioning a sheath layer as the outermost layer.
9. A method of manufacturing a hybrid flexible pipe according to claim 8 , comprising the additional steps of:
h. wrapping a first flexible helical anti-extrusion layer comprised of a first anti-extrusion strip around said at least one first flexible helical reinforcement layer in substantially the same direction as said at least one first strip;
i. substantially covering said first gap between the consecutive wraps of said first strip with said first anti-extrusion strip;
j. wrapping a second flexible helical anti-extrusion layer comprised of a second anti-extrusion strip around said at least one second flexible helical reinforcement layer in substantially the same direction as said at least one second strip; and
k. substantially covering said second gap between the consecutive wraps of said second strip with said second anti-extrusion strip.
10. A method of manufacturing a hybrid flexible pipe according to claim 8 , comprising the additional step of:
wrapping a polymer tape layer without gaps around an outermost helical reinforcement layer.
11. A method of manufacturing a hybrid flexible pipe according to claim 8 comprising the additional step of positioning a plurality of web layers on said tubular core.