Fiber reinforced spoolable pipe

• US 20050189029A1
• Filed: 12/13/2004
• Published: 09/01/2005
• Est. Priority Date: 02/27/2004
• Status: Active Grant

• Current Assignee: Fiberspar Corp. (NOV, Inc.)
• Original Assignee: Fiberspar Corp. (NOV, Inc.)
• Inventors: Quigley, Peter A., Feechan, Michael
• Granted Patent: US 7,523,765 B2
• Time in Patent Office: Days
• US Class Current: 138/125
• CPC Class Codes: E21B 17/20 Flexible or articulated drilling pipes , e.g. flexible or articulated rods, pipes or cables
• CPC Class Codes: F16L 11/082 two layers

Abstract

A spoolable pipe is disclosed, the spoolable pipe having an internal pressure barrier formed about a longitudinal axis, and a reinforcing layer(s) enclosing the internal pressure barrier. In one embodiment, the reinforcing layer(s) can include fibers having at least a partial helical orientation about approximately thirty and about approximately seventy degrees relative to the longitudinal axis, and, the wall can include at least one external layer enclosing the reinforcing layer(s) and having a permeability at least ten times greater than the permeability of the internal pressure barrier. The reinforcing layer(s) can further include a coating. The pipe can also include an energy conductor(s) integrated with and/or located between the internal pressure barrier and/or the reinforcing layer(s).

Claims

1. A spoolable pipe, comprising:

an internal pressure barrier formed about a longitudinal axis;

at least one reinforcing layer enclosing the internal pressure barrier, the at least one reinforcing layer comprising at least two plies of fibers having at least a partial helical orientation relative to the longitudinal axis, wherein at least one abrasion resistant layer is disposed between the at least two plies of fibers; and

an external layer enclosing the at least one reinforcing layer.

2. The spoolable pipe according to claim 1, wherein said at least two plies of fibers have about an equal but opposite helical orientation relative to the longitudinal axis.

3. The spoolable pipe according to claim 1, wherein at least some of said fibers are substantially axially oriented.

4. The spoolable pipe according to claim 1, where the internal pressure barrier includes at least one of:

a thermoset plastic, a thermoplastic, an elastomer, a rubber, a co-polymer, and a composite, where the composite includes at least one of;

a filled polymer and a nano-composite, a polymer/metallic composite, and a metal.

5. The spoolable pipe according to claim 4, where the internal pressure barrier layer comprises at least one of:

high density polyethylene (HDPE), cross-linked polyethylene, polyvinylidene fluoride (PVDF), polyamide, polypropylene, polyethylene terphthalate, and polyphenylene sulfide (PES).

6. The spoolable pipe according to claim 1, where the internal pressure barrier includes a modulus of elasticity greater than about 50,000 psi.

7. The spoolable pipe according to claim 1, where the internal pressure barrier includes a strength greater than about 1,000 psi.

8. The spoolable pipe according to claim 1, where the internal pressure barrier carries at least twenty-five percent of the axial load along the longitudinal axis at a termination.

9. The spoolable pipe according to claim 1, where the internal pressure barrier carries at least fifty percent of an axial load in the longitudinal direction at a termination.

10. The spoolable pipe according to claim 1, where the internal pressure barrier carries at least fifty percent of an axial load in the longitudinal direction at a termination.

11. The spoolable pipe according to claim 1, where the internal pressure barrier carries at least sixty percent of an axial load in the longitudinal direction at a termination.

12. The spoolable pipe according to claim 1, where the at least one reinforcing layer comprises at least one of:

a glass, an aramid, a carbon, a ceramic, a metal, a mineral, and a polymer.

13. The spoolable pipe according to claim 12, where the at least one reinforcing layer comprises glass.

14. The spoolable pipe according to claim 8, wherein the at least one reinforcing layer comprises glass.

15. The spoolable pipe according to claim 13, wherein the glass is one or more of:

e-glass, e-cr glass, and Advantex®

.

16. The spoolable pipe according to claim 1, where the at least one reinforcing layer includes fibers having a modulus of elasticity of greater than about 5,000,000 psi.

17. The spoolable pipe according to claim 1, where the at least one reinforcing layer includes fibers having a strength greater than about 100,000 psi.

18. The spoolable pipe according to claim 1, where the at least one reinforcing layer includes at least four plies.

19. The spoolable pipe according to claim 18, wherein at least one abrasion resistant layer is disposed between each of the at least four plies.

20. The spoolable pipe according to claim 18, where the at least one reinforcing layer includes at least eight plies.

21. The spoolable pipe according to claim 1, where the at least two plies are counterwound unidirectional plies.

22. The spoolable pipe according to claim 1, wherein the abrasion resistant layer comprises a polymer.

23. The spoolable pipe according to claim 1, wherein the abrasion resistant layer comprises a tape.

24. The spoolable pipe according to claim 1, wherein the abrasion resistant layer comprises a fiber.

25. The spoolable pipe according to claim 23, wherein said tape comprises a polymer.

26. The spoolable pipe according to claim 22, wherein the polymer comprises high density polyethylene (HDPE), cross-linked polyethylene, polyvinylidene fluoride (PVDF), polyamide, polypropylene, polyethylene terphthalate, and polyphenylene sulfide (PES), or an elastomer.

27. The spoolable pipe according to claim 1, where the spoolable pipe is spooled to a strain of greater than one percent without loss of burst and tensile strength.

28. A spoolable pipe according to claim 1, where the at least one reinforcing layer includes a water absorbent material or a water resistant material.

29. The spoolable pipe according to claim 1, where the at least one reinforcing layer includes a coating.

30. A spoolable pipe according to claim 29, where the coating includes at least one of:

a polymeric tape, a solution, a gel, an adhesive, and a sizing.

31. The spoolable pipe according to claim 29, where the coating lubricates and lowers the friction coefficient of the fibers.

32. The spoolable pipe according to claim 29, where the coating increases the abrasion resistance of the fibers.

33. The spoolable pipe according to claim 29, where the coating is applied in liquid form to the fibers.

34. The spoolable pipe according to claim 29, wherein the coating comprises a chemical resistant composition.

35. The spoolable pipe according to claim 1, further including at least one energy conductor.

36. The spoolable pipe according to claim 25, wherein the at least one energy conductor being integrated with and located between the internal pressure barrier and the external layer.

37. The spoolable pipe according to claim 1, where the at least one energy conductor includes at least one of:

a light guiding medium, an electric power medium, a data conducting medium, and a hydraulic power medium.

38. The spoolable pipe according to claim 1, further comprising at least one fitting or coupling.

39. The spoolable pipe of claim 38, wherein said fitting or coupling interfaces with said internal pressure barrier and said external layer.

40. The spoolable pipe of claim 38, wherein said fitting or coupling provides for venting of gasses or materials.

41. The spoolable pipe according to claim 1, where the at least one external layer includes at least one of:

a thermoset plastic, a thermoplastic, an elastomer, a rubber, a co-polymer, and a composite, where the composite includes at least one of;

a filled polymer and a nano-composite, a polymer/metallic composite, and a metal.

42. The spoolable pipe according to claim 41, where the at least one external layer includes at least one of:

high density polyethylene (HDPE), cross-linked polyethylene, polyvinylidene fluoride (PVDF), polyamide, polypropylene, polyethylene terphthalate, and polyphenylene sulfide (PES).

43. The spoolable pipe according to claim 1, where the at least one external layer includes a modulus of elasticity greater than about 50,000 psi.

44. The spoolable pipe according to claim 1, where the at least one external layer includes a strength greater than about 1,000 psi.

45. The spoolable pipe according to claim 1, where the at least one external layer includes at least one material applied at least partially helically along the longitudinal axis.

46. The spoolable pipe according to claim 1, where the at least one external layer includes a seamless, perforated thermoplastic.

47. The spoolable pipe according to claim 1, where the at least one external layer includes at least one polymeric tape.

48. The spoolable pipe according to claim 1, where the at least one external layer has a permeability at least five times greater than the permeability of the internal pressure barrier.

49. The spoolable pipe according to claim 1, where the spoolable pipe is spooled to a strain of greater than one percent without loss of burst or tensile strength.

50. The spoolable pipe according to claim 1, where the at least one external layer carries at least twenty-five percent of the axial load along the longitudinal axis at a termination.

51. The spoolable pipe according to claim 50, where the at least one external layer carries at least thirty percent of the axial load along the longitudinal axis at a termination.

52. The spoolabe pipe according to claim 1, wherein at least some of the fibers are partially axially oriented relative to the longitudinal axis.

53. A spoolable pipe, comprising:

an internal pressure barrier formed about a longitudinal axis,

at least one reinforcing layer enclosing the internal pressure barrier, the at least one reinforcing layer including fibers having at least a partial helical orientation relative to the longitudinal axis, and,

at least one external layer enclosing the at least one reinforcing layer and having a permeability at least five times greater than the permeability of the internal pressure barrier.

54. The spoolable pipe according to claim 53, where the at least one external layer has a permeability at least about ten times greater than the permeability of the internal pressure barrier.

55. The spoolable pipe according to claim 53, where the at least one external layer is extruded.

56. The spoolble pipe according to claim 53, where the at least one external layer is perforated.

57. The spoolable pipe according to claim 56, where the at least one external layer has a plurality of perforations.

58. The spoolable pipe according to claim 54, where the at least one external layer is perforated.

59. The spoolable pipe according to claim 53, where the at least one external layer includes at least one of:

high density polyethylene (HDPE), cross-linked polyethylene, polyvinylidene fluoride (PVDF), polyamide, polypropylene, polyethylene terphthalate, and polyphenylene sulfide (PES).

60. The spoolable pipe according to claim 53, where the at least one external layer is discontinuous.

61. The spoolable pipe according to claim 53, where the at least one external layer includes at least one material or coating applied at least partially helically along the longitudinal axis.

62. The spoolable pipe according to claim 53 where the at least one external layer includes at least one material or coating applied at least partially axially along the longitudinal axis.

63. The spoolable pipe according to claim 53, where the internal pressure barrier includes at least one of:

a thermoset plastic, a thermoplastic, an elastomer, a rubber, a co-polymer, and a composite, where the composite includes at least one of;

a filled polymer and a nano-composite, a polymer/metallic composite, and a metal.

64. The spoolable pipe according to claim 53, where the internal pressure barrier layer comprises at least one of:

high density polyethylene (HDPE), cross-linked polyethylene, polyvinylidene fluoride (PVDF), polyamide, polypropylene, polyethylene terphthalate, and polyphenylene sulfide (PES).

65. The spoolable pipe according to claim 53, where the internal pressure barrier includes a modulus of elasticity greater than about 50,000 psi.

66. The spoolable pipe according to claim 53, where the internal pressure barrier includes a strength greater than about 1,000 psi.

67. The spoolable pipe according to claim 53, where the internal pressure barrier carries at least twenty-five percent of the axial load along the longitudinal axis.

68. The spoolable pipe according to claim 53, where the at least one reinforcing layer comprises at least one of:

a glass, an aramid, a carbon, a ceramic, a metallic, and a polymer.

69. The spoolable pipe according to claim 53, where the at least one reinforcing layer includes fibers having a modulus of elasticity greater than about 5,000,000 psi.

70. The spoolable pipe according to claim 53, where the at least one reinforcing layer includes fibers having a strength greater than about 100,000 psi.

71. The spoolable pipe according to claim 68, where the at least one reinforcing layer includes at least two plies.

72. The spoolable pipe according to claim 71, further including an abrasion resistant layer disposed between the at least two plies.

73. The spoolable pipe according to claim 72, where the abrasion resistant layer comprises polymeric tape.

74. The spoolable pipe according to claim 73, where the polymeric tape comprises high density polypropylene, polyethylene terephthalate, polypropylene or an elastomer.

75. The spoolable pipe according to claim 53, wherein the at least one reinforcing layer includes glass.

76. The spoolable pipe according to claim 75, where the glass is selected from at least one of:

e-glass, e-cr glass, or Advantex®

.

77. The spoolable pipe according to claim 75, wherein the at least one reinforcing layer further includes a water absorbent or water resistant material.

78. The spoolable pipe according to claim 53, where the at least one reinforcing layer includes at least four plies.

79. The spoolable pipe according to claim 78, where the spoolable pipe is spooled to a strain of greater than one percent without loss of burst and tensile strength.

80. The spoolable pipe according to claim 53, where the at least one external layer includes at least one energy conductor being at least one of integrated with and located between at least one of the internal pressure barrier and the at least one reinforcing layer.

81. The spoolabe pipe according to claim 72, wherein said abrasion layer comprises a fiber.

82. A spoolable pipe, comprising:

an internal pressure barrier formed about a longitudinal axis,

at least one reinforcing layer enclosing the internal pressure barrier, the at least one reinforcing layer including fibers having at least a partial helical orientation relative to the longitudinal axis, the at least one reinforcing layer including a coating; and

at least one external layer enclosing the at least one reinforcing layer.

83. The spoolable pipe according to claim 82, wherein the coating comprises a silane compound.

84. The spoolable pipe according to claim 82, wherein said coating comprises a sizing treatment.

85. The spoolable pipe according to claim 84, wherein said sizing treatment is in contact with said fibers.

87. The spoolable pipe according to claim 82, wherein said coating comprises an abrasion resistant coating.

88. The spoolable pipe according to claim 87, wherein said coating comprises a water resistant coating.

89. The spoolable pipe according to claim 82, further including a means for venting gasses or liquids.

90. The spoolable pipe according to claim 82, further including an energy conductor.

86. The spoolable pipe according to claim 86, wherein said fibers comprise glass.