END FITTING FOR FLEXIBLE PIPE

The present disclosure relates to an end fitting and method to install the end fitting to a flexible pipe. The method includes disposing a shell mandrel at a free end of the flexible pipe external to a jacket of the flexible pipe and performing a cutback of layers of the flexible pipe to expose an internal pressure sheath of the flexible pipe. An armor layer of the flexible pipe is radially outward from an axial direction of the flexible pipe. At least one internal pressure containment transition component and at least one internal pressure sheath seal are installed on the exposed free end of the flexible pipe. The end fitting is assembled such that the at least one internal pressure containment transition component and at least one seal are assembled with non-radial fasteners having a backward facing direction.

DETAILED DESCRIPTION

Embodiments of the present disclosure are explained below, referring to the attached figures. In embodiments described herein, numerous specific details are set forth in order to provide a more thorough understanding. However, it will be apparent to one of ordinary skill in the art that the claimed invention may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid obscuring the invention.

Historically, during installation of end fittings on flexible pipe, structural damage may occur to elements of the flexible pipe due to a bend back of the tensile armor layers of the flexible pipe necessary to install components of the end fitting. Where the tensile armor layers of the pipe are bent back, stress concentrations and/or excess strains may result, causing structural deformities and/or damage (i.e., fiber breakage or matrix cracking in composite tensile armor layers and strain hardening in steel tensile armor layers that may result in lower fatigue resistance). This may occur in both steel armored flexible pipes and composite armored flexible pipe, such as fiber reinforced composite armored flexible pipe.

Accordingly, one or more embodiments of the present disclosure allow for minimizing the structural stresses and/or strains imposed on the tensile armor elements of the flexible pipe during installation of an end fitting, and also result in an end fitting that is shorter in length than other flexible pipe end fittings known in the art. Although embodiments discussed herein will be in reference to a composite armored flexible pipe, those skilled in the art will appreciate that the procedures and end fittings disclosed herein may be used with steel armored flexible pipe, or other pipe structures known to those having skill in the art.

Referring initially toFIG. 1A, an isometric view of a spoolable pipe100is shown. An internal pressure sheath102, such as a liner, may be wrapped with one or more armor layers and additional structural and/or functional layers. For example, one or more load bearing layers108composed of reinforcement stacks comprising stacks of laminates helically wrapped about the pipe100, may be provided as structural layers of the pipe100. As used herein, load bearing layers will be referred to as armor layers, however, those skilled in the art will appreciate that a load bearing layer may be any type of structural layer that provides structural support and/or pressure resistance to a flexible pipe. When more than one armor layer108is provided, the layers may have one or more orientations of wrapping. Further, one or more armor layers104, composed of helically wrapped reinforcement stacks comprising stacks of laminates, may be wrapped at different, for example higher, lay-angles to form additional armor layers with different functional characteristics. Intermediate sheath and anti-wear layers106and107, such as anti-wear layers, may be disposed between armor layers104and one or more armor layers108and one or more anti-extrusion layers101and103may be disposed between the inner most armor layer104and the internal pressure sheath102. A jacket110may cover the armor layers and other elements of the pipe100to provide external protection. Although described herein with one or more intermediate sheath layers, those skilled in the art will appreciate that a flexible pipe may not have an intermediate sheath layer without departing from the scope of the present disclosure.

Referring now toFIG. 1B, a cross-sectional view of a composite armored spoolable pipe100is shown. An internal pressure sheath102, such as a liner, may be wrapped with one or more armor layers and additional structural and/or functional layers, as described above. For example, armor layers104and one or more armor layers108may be provided as structural layers of the pipe100. Armor layers104and108may be composed of stacks of laminates and/or tape190. Anti-wear layers106and107may be disposed between armor layers104and108and/or between one or more armor layers108. Further, one or more anti-extrusion layers101and103may be disposed between the inner most armor layer104and the internal pressure sheath102. A jacket110may cover the armor layers and other elements of the pipe100to provide external protection.

AlthoughFIGS. 1A and 1Bdepict pipe structures100of a spoolable pipe, these are merely for example only, and those skilled in the art will appreciate that a spoolable pipe may include additional and/or different layers, without departing from the scope of the present disclosure. For example, a spoolable pipe structure may include various combinations of internal pressure sheaths, liners, carcasses, hoop-strength or pressure armor layers, intermediate sheaths, anti-wear layers, lubricating layers, tensile armor layers, anti-extrusion layers, insulation layers, membranes, and/or any other layers as may be included in a spoolable and/or flexible pipe, without departing from the scope of the present disclosure.

Referring again toFIG. 1A, armor layers104and108may provide various structural protection and/or strength to flexible pipe100. For example, the reinforcement stacks of armor layer104may be configured and oriented to form a hoop-strength armor layer and the reinforcement stacks of armor layers108may be configured and oriented to form tensile armor layers. Generally, as used herein, an armor layer may be a tensile armor layer, a hoop-strength armor layer, or other reinforcement and/or structural armor layer of a spoolable or flexible pipe and may be composed of one or more stacks of laminates and/or reinforcement tape, as discussed hereinafter.

The armor layers104and108may comprise helically wrapped stacks of laminated material. The stacks may be made of non-metallic fiber-reinforced tapes that may be laminated and bonded together as a single structural member. The individual layers of the stacks may include UD (unidirectional) tape and/or other structural and/or reinforced tape. Examples of this structure may be found, for example, in U.S. Pat. No. 6,491,779, issued on Dec. 12, 2002, entitled “Method of Forming a Composite Tubular Assembly,” U.S. Pat. No. 6,804,942, issued on Oct. 19, 2004, entitled “Composite Tubular Assembly and Method of Forming Same,” and U.S. Pat. No. 7,254,933, issued on Aug. 14, 2007, entitled “Anti-collapse System and Method of Manufacture,” all of which are hereby incorporated by reference in their entireties. Alternatively, if flexible pipe100represents a flexible steel pipe, armor layers104and108may be helically wrapped steel windings of steel wires. Examples of this structure may be found in ISO 13628-2/API 17J Specification for Unbonded Flexible Pipe, incorporated by reference in its entirety.

In former termination processes, the tensile armor layer108is bent back to accommodate installation of the end fitting. The bending back of the elements of tensile armor layer108may result in relatively high amounts of strain on the elements of the layers, thereby causing matrix cracking or fiber breakage in composite armor, or strain hardening, and/or other types of damage in steel and/or composite armor, all of which may reduce structural capacity or fatigue life of the tensile armor. In order to obtain access to the components of the end fitting, the outer structural layers of the flexible pipe must be bent back significantly from the terminal end of the flexible pipe. The bend back of the outer structural layer allows for access to the underlying layers for installing end fitting components during installation of the end fitting.

One or more embodiments of the present disclosure are directed to installation of an end fitting in order of components from a point along the length of the pipe towards a free end or terminal end of the flexible pipe. Further, one or more embodiments of the present disclosure are directed to installation of end fitting components in a configuration such that any connecting bolts of components of the end fitting are not facing towards the free end of the flexible pipe. For example, when using threaded bolts and/or screws, the treaded end of the bolts and/or screws are not facing towards the free end of the flexible pipe, i.e., facing away from the free end of the flexible pipe. As such, one or more embodiments of the present disclosure may minimize and/or eliminate reduction of structural capacity or fatigue life of the elements of the flexible pipe during installation of an end fitting. Because the direction of installation of elements of the end fitting are reversed, the tensile armor of the flexible pipe may not need to be bent back, but only may require a flaring radially outward from the terminal end of the flexible pipe. When flared, lower strains may be imposed on the flared elements, and fatigue and/or damage may be minimized and/or eliminated.

As used herein, the term “radially” is characterized by a direction extending in a generally radial (or perpendicular) direction to an axis of the pipe and “axially” is characterized as a direction extending along the axis of the pipe. However, it should be understood that items wrapped helically around the pipe may not be purely radially extended from the axis of the pipe during the end fitting installation process, but instead may be moved away in a hybrid direction that is both radial and helical with respect to the longitudinal axis of the pipe (axial direction). Therefore, for purposes of this disclosure, such radial and helical extension will be simply referred to as “radial.” Furthermore, for purposes of this disclosure “forward” will refer to the direction towards a terminal end of the flexible pipe in the axial direction and “backward” will refer to a direction away from a terminal end of the flexible pipe in the axial direction.

Now referring toFIGS. 2-6, schematic cross sectional views of a flexible pipe in various (progressive) stages of the installation of an end fitting assembly, in accordance with one or more embodiments of the present disclosure, are shown. InFIGS. 2-6, the X-axis designates an axial direction (longitudinal axis), and the arrow of the X-axis is in the forward direction (toward the free end or terminal end of the flexible pipe), and the Y-axis designates a radial direction relative to the X-axis. As used herein, the phrase “backward facing” is in the negative X-direction ofFIGS. 2-6. Accordingly, the fasteners described herein are installed with an installation or facing direction in the negative X-direction ofFIGS. 2-6.

Referring now toFIG. 2, a schematic cross sectional view of a flexible pipe100and components of a partial end fitting assembly are shown. As shown inFIG. 2, the end fitting components, in part, consist of a shell mandrel152, an anchor154, and a push ring156configured to drive and/or energize the anchor154. Although described herein as an anchor154, the anchor154may also provide sealing or other characteristics. As shown inFIG. 2, the shell mandrel152, the anchor154, and the push ring156may be installed on and/or exterior to an outer jacket110of the flexible pipe100. The jacket110may provide a protective outer cover for other elements of the pipe, which may include a first armor layer108, an intermediate sheath layer106, a second armor layer104, and a internal pressure sheath102. One or more anti-extrusion layers101and103may be disposed between the liner102and the second armor layer104. The internal pressure sheath102may be an extruded core. In some embodiments, a relatively flexible metal carcass (not shown) may be positioned inside the internal pressure sheath102to prevent collapse resistance of the flexible pipe assembly100.

As described above, the armor layers may be formed from strips of flexible steel or stacks of composite material and may be tensile layers, hoop strength layers, burst layers, and/or other armor layers. The type of armor layer may be determined by the lay angle of the elements of the armor layer with respect to the X-axis.

As shown inFIG. 2, a staggered cut back of the layers of the flexible pipe100has been carried out. Accordingly, the jacket110has a cut back farthest from a free end or terminal end of the pipe100. Forward of the cut back of the jacket110, in sequence approaching the terminal end of the flexible pipe, are the cut backs of the first armor layer108, the intermediate sheath layer106, the second armor layer104, and the internal pressure sheath102. The anti-extrusion layers101and103may be cut back at the cut of the second armor layer104.

Now, referring toFIG. 3, additional components of an end fitting assembly are shown. As shown, an armor layer108is flared radially outward from an axial direction of the pipe100(the X-axis) such that minimal bend back of the stacks or wires comprising the armor layer108occurs. Moreover, to support the jacket110of the flexible pipe100, a jacket support ring115may be installed between the jacket110and the armor layer108. The jacket support ring115may support the jacket110while the armor layer108is flared and/or may support the jacket110when the shell mandrel152is engaged with a flange assembly, as discussed herein. Moreover, the jacket support ring115may be configured to support the jacket110to obtain a required squeeze to enable anchoring and sealing of the jacket layer110when energizing and/or engaging anchor154and push ring156.

As further shown inFIG. 3, internal pressure containment transition components may be installed beneath the flared armed layer108. The internal pressure containment transition components may include an aft cone122, a push plate124, a membrane seal126, and a membrane support ring128. The aft cone122and the push plate124may slide over an intermediate sheath layer106beneath the radially flared armor layer108. The aft cone122and the push plate may be secured together by fasteners123, such as bolts, screws, or other connectors and/or securing means known in the art. As shown, fasteners123are disposed facing in a radial direction. The membrane support ring128may slide beneath the intermediate sheath layer106and on top of a second armor layer104.

The membrane seal126is shown inFIG. 3as having a wedge or triangular shape, with the narrow end facing toward the terminal end of the flexible pipe.

Now with reference toFIG. 4, an end fitting partial assembly, including a shell mandrel152and internal pressure containment transition components, is shown installed on a flexible pipe100. As shown inFIG. 4, the armor layer108is still flared when an inner cone132of the internal pressure containment transition components is installed. The inner cone132may be configured to cover membrane seal126and contact a surface of the push plate124.

The membrane seal126may be energized by securing the inner cone132to the push plate124by fasteners133, such as bolts, screws, or other connectors and/or securing means known in the art. Although shown with bolts or screws133, those skilled in the art will appreciate that other securing means may be used to join the inner cone132with the push plate124and/or energize the membrane seal126. The fasteners133are installed such that the fasteners133face away-from the terminal end of the flexible pipe, in a backward facing orientation, facing in the negative X direction. The fasteners133may have threading configured such that the fastener is threaded in a negative X direction or in a backward facing orientation.

The inner cone132may be configured to house a pressure armor layer clamp134. The pressure armor layer clamp134may hold a pressure armor layer104and anti-extrusion layers101and103within the internal pressure containment transition components and may be installed radially external to the armor layer104.

Now referring toFIG. 5, the internal pressure containment transition components of an end fitting assembly described above may be connected with a flange assembly160. The flange assembly160may be secured to the inner cone132by fasteners161, such as bolts, screws, or other connectors and/or securing means known in the art. Similar to the fasteners133, the fasteners161may be installed with a backward facing orientation. The flange assembly160may be positioned forward of the free end or terminal end of the pipe. A face seal139may be disposed between surfaces of the inner cone132and the flange assembly160, thereby forming a fluid seal between the inner cone132and the flange assembly160when energized. The flange assembly160may provide a fluid seal at the free end or terminal end of the pipe and may provide a connecting end to connect with oil/gas production equipment.

A ring assembly136may be installed forward of and abutting the end of the armor layer104and may be positioned between components of the flange assembly160and the armor layer104. The ring assembly136may be installed radially external to the internal pressure sheath102. As such, the ring assembly136may be configured to cover and/or support a portion of the internal pressure sheath102that is not in contact with a portion of the flange assembly160and also not covered by a portion of the armor layer104.

Prior to installation of the flange assembly160, a liner support ring166may be positioned underneath and interior to the internal pressure sheath102. A push ring162and a seal164may be installed on the internal pressure sheath102. The flange assembly160may be installed on the free end of the flexible pipe and secured to the inner cone132by backward facing fasteners161, such as bolts, screws, and/or other means. During this installation the flange assembly to the inner cone132may drive the push ring162against seal164, thereby energizing the seal164.

Now referring toFIG. 6A, a complete end fitting assembly150is shown installed on a free end or terminal end of a flexible pipe. The end fitting assembly may include a shell mandrel152external to a jacket110of the pipe and a flange assembly160. Internal to the shell mandrel152and the flange assembly160, internal pressure containment transition components may be disposed about and in relation to the interior layers of the flexible pipe. The flange assembly160may be installed terminal to the internal pressure containment transition components on the free end of the pipe. The shell mandrel152, the flange assembly160, and the internal pressure containment transition components of the end fitting assembly may be secured together to form the end fitting assembly.

When the end fitting is assembled with the shell mandrel152, the flange assembly160, and the internal pressure containment transition components, the flared armor layers108may be released to contact the external surfaces of the internal pressure containment transition components, as shown inFIG. 6A. The shell mandrel152may then be secured to the flange160using backward facing fasteners171, such as bolts, screws, and/or other means, as shown inFIGS. 6A and 6B. The anchor154may then be engaged between a push ring156and the jacket110. The flange assembly160may provide a connector for the end fitting such as a flange or hub, so that other tools, elements, and/or fluid conduits may be connected to the flexible pipe at the free end of end fitting. When assembled, the end fitting may have free volume175or voids between components of the end fitting and the flexible pipe. The free volume175may be filled with a thermoset resin or thermoplastic potting system.

As described herein, the end fitting components may include an aft cone, an inner cone, push plates, seals, rings, and fasteners. However, although described with a limited number of components, those skilled in the art will appreciate that the end fitting may include any number of components and/or other elements not described herein without departing from the scope of the present disclosure.

As shown inFIGS. 2-6, the fasteners of the internal pressure containment transition components may be installed such that they have a radial facing (123) or a backward facing orientation (133,161,171). However, those skilled in the art will appreciate that the fasteners may have slightly skewed orientations, having radial and backward facing components, without departing from the scope of the present disclosure. It should be noted that the only fasteners with a forward facing direction may be those connecting push ring (156) and the shell mandrel (152). In particular, none of the fasteners of the internal pressure containment transition components have a direction that is facing towards the free end of the pipe. Accordingly, the non-radial fasteners of the internal pressure containment transition components are configured to have, at least, a direction component that is facing backward or away from the free end of the flexible pipe.

Referring now toFIG. 7, a flow chart of an installation process in accordance with one or more embodiments of the present disclosure is shown. At step710, prior to installing the internal components of the end fitting, an external element of the end fitting, such as a shell mandrel (e.g.,152ofFIGS. 2-6), may be installed on an external jacket (e.g.,110ofFIGS. 2-6) of the flexible pipe (e.g.,100ofFIGS. 2-6). In addition to the shell mandrel, an anchor and a push ring may also be disposed with the shell mandrel on the jacket (e.g.,154and156ofFIGS. 2-6).

Next, at step720, a cutback of the layers (e.g.,102,104,106,108, and110ofFIGS. 2-6) of the flexible pipe may be performed. When cutting back the layers of the flexible pipe, a staggered and/or stepped configuration may be preferred in order to properly install and seal the end fitting to the end of the flexible pipe. Accordingly, the different layers of the flexible pipe may be cut at different locations with respect to a free end or terminal end of the flexible pipe. For example, at step720, the outer jacket (e.g.,110ofFIGS. 2-6) of the flexible pipe may be cut at a first location, farthest from the free end or terminal end of the flexible pipe with respect to all other cuts. The next cut may be of a first armor layer or a load bearing layer (e.g.,108ofFIGS. 2-6), where the cut of the first armor layer may be at a second location, closer to the free end or terminal end of the flexible pipe than the first location. Subsequent layers, such as an intermediate sheath layer (e.g.,106ofFIG. 2), a second armor layer (e.g.,104ofFIG. 2), and an internal pressure sheath (e.g.,102ofFIG. 2) may be cut at third, fourth, and fifth locations, with each location closer to the free end or terminal end of the flexible pipe than the previous cut.

Although described herein as a sequence of cuts occurring at a single time, within the installation process, those skilled in the art will appreciate that the cutback process at step720may occur throughout the installation process, with cutting of particular layers only occurring when necessary. Further, although described herein with the locations of the cuts each occurring at a different location, those skilled in the art will appreciate that some adjacent layers of the flexible pipe may be cut at a single location relative to the free end or terminal end of the flexible pipe.

Next, at step730, the first armor layer, or load bearing layer, may be flared outward from the terminal end of the flexible pipe. The flaring process may involve spreading the individual elements of the armor layer, hereinafter referred to as stacks or wires, radially with respect to the axial direction (i.e., X-axis ofFIGS. 2-6) of the flexible pipe such that the flared stacks or wires appear to be bell-shaped with the open end of the bell occurring at or toward the free end or terminal end of the pipe. The flaring width, or radial amount of flaring, is only necessary to be large enough to place the internal elements of the end fitting beneath the flare, as no access to the end of the end fitting farthest from the terminal end of the flexible pipe is necessary for assembling the end fitting. As such, minimal flaring and, therefore, minimal strains and/or forces may be imparted to the flared stacks or wires.

At step730, prior to flaring, in order to support the jacket when the armor layer is flared, a jacket support ring (e.g.,115ofFIGS. 2-6) may be installed between the layer to be flared and the external jacket. Once flared, the stacks may be held in the flared position by string, wire, and/or any other method, during the installation of the end fitting.

Next, at step740, internal elements of the end fitting may be installed (e.g.,122,124, and132ofFIGS. 2-6). The internal elements may form internal pressure containment transition components of the end fitting, and may further include one or more seals and/or ring assemblies and joining elements, such as bolts, screws, etc. The sequence and direction of assembly of the end fitting allows for the flaring of the armor layer to provide sufficient access to install all elements of the end fitting without imposing excess strains and/or forces on elements of the flexible pipe.

At step750, once the internal elements of the end fitting have been installed on the terminal end of the flexible pipe, the membrane seal within the internal pressure containment transition components may be energized. To energize the membrane seal, an element of the internal pressure containment transition components may be pulled toward the free end or terminal end of the flexible pipe, or, alternatively, an element of the internal pressure containment transition components may be pushed and/or forced in a direction away from the free end of the flexible pipe, towards the push plate. For example, a push plate of the internal pressure containment transition components (e.g.,124ofFIGS. 2-6) may be used to energize the membrane seal by pulling the push plate toward the terminal end of the flexible pipe. The sheaths, as used herein may generally refer to an internal pressure sheath, a liner, an intermediate sheath, an anti-wear layer, an anti-extrusion layer, or other layer of a flexible pipe and may be an element of the flexible pipe disposed between other structural elements of the flexible pipe.

When the membrane seal is energized, a portion of the membrane seal may engage with the membrane, thereby providing a fluid seal between the end fitting and the membrane. In one or more embodiments of the present disclosure, the membrane seal may be a wedge shape and/or triangular in cross-section, as discussed above. When energizing the membrane seal at step750, the push plate or other element may be pulled toward the free end or terminal end of the flexible pipe (forward), or another element may be pushed away from the free end or terminal end of the flexible pipe toward the push plate. As the membrane seal is pulled against the push plate, the membrane seal may compress a surface of the membrane, thereby forming a fluid seal.

Now, with reference toFIG. 8, a flow chart of an installation process in accordance with one or more embodiments of the present disclosure is shown. The end fitting components may include an aft cone (e.g.,122ofFIGS. 2-6), a push plate (e.g.,124ofFIGS. 2-6), an inner cone (e.g.,132ofFIGS. 2-6), and various other elements and components as described above. The internal pressure containment transition components may be interior components of the end fitting and a flange assembly (e.g.,160ofFIGS. 2-6) may be configured to attach to the internal pressure containment transition components. Although described herein with the listed elements, those skilled in the art will appreciate that an end fitting may contain more or fewer elements and/or different elements than those described herein without departing from the scope of the present disclosure.

The procedure described inFIG. 8is conducted, at least initially, with at least one armor layer of the flexible pipe flared. As such, steps710,720, and730ofFIG. 7may be carried out prior to the start of the procedure ofFIG. 8.

At step810, after the armor layer of the flexible pipe is flared, an aft cone and a push plate may be disposed external to an intermediate sheath layer beneath the flared armor layer. The intermediate sheath layer is disposed between two armor layers of the flexible pipe. The aft cone may be installed first, followed by the push plate, with the two elements axially adjacent to and contacting each other. The aft cone and the push plate may be secured together, for example, by bolts, pins, and/or other means known in the art. Further, the two elements may be secured together prior to installation onto the flexible pipe or may be secured together after installation onto the flexible pipe. Moreover, those skilled in the art will appreciate that the two elements need not be secured together during the installation process of the end fitting.

At step820, a membrane seal and a membrane support ring may then be installed axially forward of the push plate. The membrane support ring may be disposed radially beneath the first membrane, and the membrane seal may be disposed radially external to an intermediate sheath layer between two armor layers, such that the intermediate sheath layer is disposed between the membrane support ring and the membrane seal. The membrane support ring may provide rigidity and/or support to the intermediate sheath layer at the time of energizing of the membrane seal. Furthermore, the membrane support ring may prevent the membrane seal from excessive inward deformation of the intermediate sheath layer thereby preventing damage to a layer beneath the intermediate sheath layer. Accordingly, the membrane support ring may also provide a protective barrier for the layer radially beneath the membrane support ring.

Next, at step830, an inner cone of the internal pressure containment transition components may be installed axially forward of the membrane seal, and at least a portion of the inner cone may contact a surface and/or a portion of the push plate. The inner cone and the push plate may be secured together to energize the membrane seal. As such, the membrane seal may be energized during step830.

Next, at step840, a pressure armor clamp and/or a ring assembly may be disposed radially within the inner cone. A sleeve may be disposed radially beneath an internal pressure sheath of the flexible pipe. The sleeve may be installed prior to installation of the ring assembly.

The pressure armor clamp may be disposed within the inner cone and may contact a surface of an inner armor layer, hereinafter referred to as a pressure armor layer. Further, the ring assembly may be disposed within the inner cone and may contact a surface of an internal pressure sheath of the flexible pipe. The ring assembly may contact a terminal end of the pressure armor layer such that the ring assembly may be axially forward of and adjacent to an end of the pressure armor layer. Next, at step850, a flange assembly may be installed axially forward of the inner cone, the ring assembly, and the armor layer clamp. The flange assembly may be secured to the inner cone and/or the internal pressure containment transition components of the end fitting. When installed, the flange assembly may be in contact with a surface of the inner cone. A face seal may be disposed between a forward-facing surface of the inner cone and a backward-facing surface of the flange assembly. When energized, the face seal may form a fluid seal between the inner cone and the flange assembly. Further, the flange assembly may be configured to connect with oil/gas production equipment, enabling a flexible pipe to be connected to the oil/gas production equipment.

At step860, after the flange assembly is secured to the internal pressure containment transition components of the end fitting, the stacks or wires of the armor layer that were flared may be released and the shell mandrel may be secured to the flange assembly. When the shell mandrel is slid forward, the shell mandrel may cover the stacks or wires of the armor layer that were flared. The layers of the armor layer that were flared may be disposed and/or wedged between the internal pressure containment transition components and the shell mandrel of the end fitting. Accordingly, the external armor layer may be covered by the shell mandrel.

Finally, at step870, the armor layers and other layers of the flexible pipe may be secured and/or anchored to the end fitting. The anchoring may occur by filling the volume175, as shown inFIG. 6, between the shell and flange of the end fitting, and any voids therein, with a thermoset resin or thermoplastic potting system. After the resin system is in place, the potting may be cured, thereby forming an anchored and sealed end fitting on the terminal end of a flexible pipe.

Advantageously, an end fitting and methods in accordance with one or more embodiments of the present disclosure may allow for simple installation of an end fitting onto a terminal end of a flexible pipe. The end fitting, in accordance with one or more embodiments of the present disclosure may allow for fasteners, such as bolts, screws, or other connection means to be installed backward facing, such that the internal pressure sheath seal and intermediate sheath seal may be energized. Forward facing bolts as in the prior art require clearance for bolts between the flared or bent back armor layers and the aft cone or internal pressure containment components. Thus, the end fitting can be shorter with backward facing bolts, since this additional clearance is not required.

Further, an end fitting and methods in accordance with one or more embodiments of the present disclosure may allow for minimized and/or eliminated strains imposed on the armor layers of the flexible pipe during end fitting installation. Advantageously, the end fitting and method may provide for flaring of the tensile armor layers. Accordingly, minimal bend back and/or severe strains need be imposed on the armor layers, thereby minimizing potential damage to the tensile armor layers during end fitting installation.

While the disclosure has been presented with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the scope of the present disclosure. Accordingly, the scope of the invention should be limited only by the attached claims.