Skip to main content

7 things you should know about non-metallic flexible pipe

透视

7 things you should know about non-metallic flexible pipe

2021年4月8日

在一个多个世纪中,用于运输加压流体 - 液体或气体的技术 - 已经不断地从木头上发展到粘土,铅,然后铸铁和currently, steel pipelines. Meet the latest industry disruptor: composite flexible pipe. This next generation of non-metallic pipe is a proven alternative for a fast-growing range of applications.

轻质和柔韧的加固热塑性管可以优化流线和管道网络的核心结构,经济地支持CO的运输2for storage, the movement of hydrogen, or the conversion of existing infrastructure to carry these gases,which will be critical in the energy transition and decarbonization of industry.

At Baker Hughes, we recently announced扩展我们的陆上灵活管道制造能力所以在这里,我们探索这些非金属陆上管道的七个超级大国:

1.灵活

让我们从产品的固有灵活性开始,它会在安装时带来益处,并且在运行时。

This pipe is a very easy product to get into a ditch: you can lift it, you can bend it. If you are trying to do that with steel pipe, you need three or four side booms and a big bulldozer for starters. This意义重大of safety exposure, because steel has that rigidity and weight, so when you are working with anything made from steel, it’s an extra overhead to carry.

灵活性(或合规性)在管道服务时同样重要。不是所有土地,运营商需要铺设管道是整洁而紧凑的。您可能需要交叉各种地理危险,例如山体滑坡,泥浆和沼泽。这提出了钢管的大量风险,并克服它,传统上,运营商传统上依靠大量的额外设计努力,并增加了膨胀环(管道中基本大的U形弯曲)或快速断开连接的弱链路阀门。管道运营商始终努力避免溢油或天然气,甚至盐水,因此责任负担,运营商必须具有额外的灵活性进入其钢管系统。复合管道只是没有相同的水平risk because they are flexible and can easily incorporate bends and loops which would facilitate any ground movement – just using their natural compliance.

Non-metallic article image1
Non-metallic flexible pipeline reel ready for shipment.

2。Robust

力量是相对的,人们将力量混为刚性。这可能最好谈论具有“深刻鲁棒性”的产品。过去20年来复合材料的显着转变的原因是它们可以非常非常坚固。让我们以飞机结构为例。他们没有用在舱壁和座位上使用;现在由金属和非金属复合材料制成翅膀和承载部件。当某些东西以高速命中时,例如鸟击,复合材料比固体或致密材料更多的能量。

一世n the working environments for pipelines, there are high shock loads, heating and cooling cycles and pressure cycles, a material with high ductility will likely be more reliable than something that is rigid.

管道专为极端事件而设计,然后在顶部添加安全因子,以便它们适合给定的职责,但它们可以超出这些设计参数,在短时间内,我们将在短时间内称之为“不安条件”。必须建立足够的安全幅度,以允许那些无法预料的事件,这可能在生命中测试管道的稳健性。

3. Connected

非金属管都连接和可连接。

传统上,应变仪,电子传感器和光纤传感器用于特定应用的钢管,通常是条件监测。但这意味着胶合在结构外部的钢上的东西,甚至可能在绝缘涂层之外。然后,操作员在粘合和光纤传感器或电动仪上完全依赖于保持其生命并导出发生的事情inside管道外部

This superpower for flexible composite pipes is that the optical fibers can be embeddedin结构本身,因为它们与所用的加强材料兼容O.PTICAL-FIRED MOTRINS是一种令人难以置信的通用工具,用于条件监测和完整性评估。标准电信-grade fiber is embedded within the structure with the other fibers and becomes an integral part of the pipe.

O.n a pipe running for 20 miles with embedded optical fiber, we can measure all sorts of things – such as distributed temperature – along that complete distance. For example, if there is a leak from the inside out, or from the outside in, the temperature difference will show up on the monitoring software. We can then investigate that specific location, without the need to dig up miles of pipe.

O.ne capability that is most interesting is the use of optical fibers for vibration monitoring. With an I/O box (input/output) at one end and a reflector at the other, we can interrogate the line signal backwards and forwards. When monitoring the fiber acoustically, vibrations will be detected if for example somebody’s digging in the vicinity. This means in advance of somebody digging a hole near and potentially ‘interacting’ with the pipe, the operator will get a warning. The value of that alarm capability for operators is obvious.

What is less obvious is that operators have a regulatory duty to positively confirm the condition of the pipeline, including that it is holding pressure, shows no signs of being degraded and is still fit for purpose. These on-board monitoring systems allow the operator to do these checks without having to inspect the line either internally, with an intelligent pig, or externally by walking along it. A step forward in the digitalization of operations.

Non-metallic image 2
非金属管的制造工艺。

4. Safe

运营商和服务公司相似致力于将安全视为不可谈判,共同努力,尽量减少发生的事情的概率,并在其确实下减轻任何不利后果。在能源领域,移动重型机械或设备是最危险的活动之一,人们拥有最大的受伤风险。

复合柔性管带在这里带来一个非常简单的超级大器 - 它比钢管轻,它适合卷轴。

这种基本特征降低了损伤的概率和后果。而不是许多装满20-30辆卡车到达一个地点的重型钢管,而是在一辆卡车上有一个非常轻巧的管道。如此统计上,这立即减少了对道路事故的暴露,以及减少与移动钢管接头相关联的升降和丢弃危险。

安装钢管管道涉及焊接,弯曲,侧臂和大量重型设备。复合柔性管安装需要更少。反向铲将打开沟渠,反向铲或少数人可以手动将管道抬到沟槽中,100s of meters of flexible can be laid without interruption for connectors or welding. The reduced number of joints also lowers the risk of a leak during hydrotesting operations.

简而言之,整个施工运行大幅下挫:人们越来越少,设备较少,操作较少,而且经营很简单。

一世n addition, the operational risk of wall thickness loss due to corrosion, one key fact或者钢铁-pipe failure, is non-existent in a non-metallic onshore pipeline.

5.更清洁

The composite pipes are fully recyclable at the end of life and are as simple to replace or remove as they were to install. During installation there is at least 30% less land required for the right-of-way, when dealing with many fewer vehicle movements – this has an environmental benefit as well as improving the owner/operator’s return on investment. Of course, many fewer vehicles for transportation and installation also means lower emissions.

Non-metallic image 3
Close up of the manufacturing process: layer of composite material.

随着复合管的内部非常光滑,这意味着较小的直径管道可以实现流体运输的更好流速,再次影响效率,项目成本和环境足迹。

6. Budget

The project manager is responsible for the budget and their first question is, ‘How much am I spending upfront?’ With non-metallic pipes, the discussion moves from comparing equipment unit costs, which is what the industry normally focuses on, to look instead at total installed cost. When we take the cost of our pipe, the cost of installation and the cost of the operation, we can demonstrate that in most applications, this pipe is significantly – 20-30% and sometimes more – lower than the installed cost of the equivalent steel pipe.

When looking at OPEX, the operator can benefit from a hidden cost advantage: there is no need to inject chemicals into the pipes to prevent corrosion, which can be costly. Oxygen scavengers and wax build up are also not an issue, which eliminates regular intelligent pigging operation. Likewise, external corrosion – requiring a Cathodic Protection system installation and life-long maintenance – are not needed. A consideration of all those ‘traditional’ pipe maintenance itemsgreatly reducesthe operating costs of the pipeline over its life cycle.

7. Advanced

Copphite管子是一个很好的例子the benefits achieved withadvanced配置和manufacturing. We work from a menu of components which can change out quickly. We use the same machinery and, in some cases, the same kind ofbase材料 - 复合纤维胶带和聚合物一世f工况需要,我们可以substitute a high-temperature polymer or an impermeable polymer inside the pipe and leave everything else unchanged.

与添加剂制造一样,用于生产这些管道的技术意味着每个结构可以优化到应用的需要。我们的制造能力可以制造任何直径的管道,通过施加更多或更少的层,加入或减去刚度,增加温度容量等,使压力等级完善,依据其应用。

Non-metallic image 4
Close up of non-metallic pipe section showing composition.

钢管内置于API标准,因此操作员将获得四英寸的管道,六英寸的管道或八英寸的管道,而墙壁厚度以外的差异很小(管道时间表)。抵抗压力所需的实际钢量相对较小,但标准要求添加额外的材料以应对弯曲载荷,以及额外的安全性和腐蚀余量,在标准钢管设计中持续冗余。

复合材料也是一个非常快速的制造过程 - 如果需要,可以在几天内生产一段柔性管。钢管接头可能需要从工厂提前几个月订购,以获得指定的等级,而我们可以在几天内建造各种产品,从同一基础原料中。

Related articles