Immobilised insert
A method and apparatus are disclosed. The method includes the steps of providing an elongate sheet having a uniform thickness and a first and further spaced apart long edge, to a first pair of a plurality of spaced apart pairs of opposed forming roller elements, and via the pairs of roller elements, progressively forming a cross-sectional profile in the sheet that comprises a body portion comprising a folded central region of the sheet and a first and further wing portion that each extend away from the body portion and terminate at a respective long edge of the sheet, and securing adjacent regions of the wing portions and/or opposed regions of the body portion together thereby providing a windable elongate tape element having laterally immobilised wing portions.
1. A method of manufacturing an elongate tape element for bridging a gap between windings of a flexible pipe body layer, comprising the steps of:
providing an elongate sheet having a uniform thickness and a first and further spaced apart long edge, to a first pair of a plurality of spaced apart pairs of opposed forming roller elements;
via the pairs of roller elements, progressively forming a cross-sectional profile in the sheet that comprises a body portion comprising a folded central region of the sheet and a first and further wing portion that each extend away from the body portion and terminate at a respective long edge of the sheet; and
securing adjacent regions of the wing portions and/or opposed regions of the body portion together thereby providing a windable elongate tape element having laterally immobilised wing portions.
2. The method as claimed in claim 1 , further comprising:
securing regions together by welding the regions together via a fusion welding or solid state welding process.
3. The method as claimed in claim 2 , further comprising:
welding the regions together continuously along a whole length of the tape element thereby providing a continuous weld along the tape element.
4. The method as claimed in claim 3 , further comprising:
providing a substantially smooth abutment surface to the elongate tape element, said abutment surface comprising an outer surface portion of the weld and a respective outer surface portion of each of the first and further wing portions.
5. The method as claimed in claim 2 , further comprising:
welding regions together repeatedly as a row of spaced apart spot welds along a length of the tape element.
6. The method as claimed in claim 2 , further comprising:
welding the regions together in a single pass as the folded sheet having the formed cross-sectional profile with the folded central region passes proximate to at least one welding station.
7. The method as claimed in claim 2 , further comprising:
securing adjacent regions together subsequent to the step of progressively forming the cross-sectional profile via the pairs of roller elements.
8. The method as claimed in claim 2 , further comprising:
welding regions together via a single sided process.
9. The method as claimed in claim 2 , further comprising:
welding regions together in an open or closed butt joint.
10. The method as claimed in claim 2 , further comprising:
welding regions together in an open or closed flanged joint.
11. The method as claimed in claim 2 , further comprising:
welding regions together to provide a single-flare V-groove weld.
12. The method as claimed in claim 2 , further comprising simultaneously relieving residual stress in the sheet having the formed cross-sectional profile with the folded central region via heat generated during the welding process.
13. The method as claimed in claim 1 , further comprising:
securing regions together by bonding the regions together via an adhesive or mechanical bond, or via a process selected from the group consisting of an adhesive bonding process, a brazing process, a soldering process, or a thermal spraying process.
14. A method of manufacturing flexible pipe body, comprising the steps of:
helically winding at least one armouring tape over an underlying layer; and
helically winding an elongate tape element manufactured per the method as claimed in claim 1 over the underlying layer whereby at least a region of the body portion of the elongate tape element is located between adjacent windings of the armouring tape.
15. The method as claimed in claim 14 , further comprising:
securing regions together by welding the regions together via a fusion welding or solid state welding process; and further comprising welding the regions together continuously along a whole length of the tape element thereby providing a continuous weld along the tape element.
16. The method as claimed in claim 15 , further comprising simultaneously relieving residual stress in at least one region of the sheet having the formed cross-sectional profile with the folded central region as the sheet is welded.
17. An elongate tape element for bridging a gap between windings of a flexible pipe body layer, manufactured per the method as claimed in claim 1 .
18. Flexible pipe body comprising a layer including a winding of the elongate tape element as claimed in claim 17 ; wherein, said layer comprises a carcass layer that further includes a winding of a self-interlocking armouring tape.
19. The method as claimed in claim 1 , further comprising heating the folded central region or at least one other region of the cross-sectional profile of the sheet to thereby relieve residual stress in the folded sheet material.