Abstract:
The hose couplings of this invention can be used to connect sections of large bore reinforced hose to make it more resistant to damage that can be caused by axial and bending forces encountered during normal usage. This extends the service life of the hoses of this invention which include such couplings. The present invention more specifically reveals a hose assembly comprising a reinforced hose having at least one reinforcement layer and a coupling on at least one end of the hose, said coupling comprising a tubular body which is adapted for fitting into the end of said large bore hose, said tubular body having a tail end which is adapted to lie inwardly from the end of the hose, said tubular body having an outer end which is adapted to extend beyond an axial end of the hose, the outer surface of said tubular body being provided with a plurality of axially spaced retention beads, and at least one hose carcass anchor which is affixed to the tubular body at a point on or outward from the last retention bead toward the outer end of the tubular body, wherein the hose carcass and/or load bearing extensions of the hose carcass extend through and around the carcass anchor.

Description:
[0001]    This application claims benefit of U.S. Provisional Patent Application Ser. No. 61/235,460, filed on Aug. 20, 2009. The teachings of U.S. Provisional Patent Application Ser. No. 61/235,460 are incorporated herein by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    Large bore reinforced hose can be utilized in a wide array of applications. One important application for large bore reinforced hose that is of growing importance in the world today is in loading and unloading oil tankers and floating production storage and offloading units (FPSOs). Such hose has an inside diameter of 5 cm or greater and typically has an inside diameter ranging from 20 cm to 80 cm. Such hose for offshore applications is also typically designed to include a floatation medium to provide the hose with sufficient buoyancy so that it will float on the surface of water. Hose for offshore applications typically has reserve buoyancy when filled with sea water which is within the range of 10% to 40%. A reserve buoyancy of at least 20% is frequently demanded by customers. Because vast reserves of petroleum are located under water in many locations around the world including under the North Sea, the Gulf of Mexico, off the coast of Brazil, and off the coast of California there is a growing demand for large bore reinforced floating hose. 
         [0003]    Transferring the crude oil from FPSOs to shuttle tankers at sea is an extremely demanding task because of the persisting relative movement between the vessels. During times of adverse weather conditions, such as high waves, high winds, and storms at sea, this tack becomes even more difficult. Floating hoses typically run from the bow and/or the stern of FPSOs to shuttle tankers. Modern shuttle tankers may have a bow manifold for charging crude oil, but many conventional shuttle tankers have a charging device consisting of a midship manifold for intake of the oil load. For this reason a relatively long loading hose is needed, from the FPSO-vessel to the midship manifold on the shuttle tanker. The separation between the vessels, between the stern of the FPSO and the bow of the shuttle tanker is generally about 50 to 200 meters, and the extension of the floating hose is normally between about 150 and 300 meters. 
         [0004]    When the floating hoses are not being used to transfer petroleum they can be allowed to remain floating on the water after being released from the tankers. However, in such cases where the floating hose is left on the water the floating hose may be damaged by being struck by ships, sea creatures or by the movement from waves in stormy weather. In any case, hose wear occurs due to continual wave action. This can lead to a loss of the buoyancy and/or primary carcass failure and over time the hose can begin sink. 
         [0005]    In the alternative, the floating hose can be hoisted onto the FPSO for storage until it is again needed for offloading crude oil to a shuttle tanker. This can be done by using a wench to pull the floating hose onto a reel. This protects the hose from exposure to waves and the inherent wear associated therewith. It also eliminates the danger of the floating hose being struck by a ship as it is floating at sea. However, pulling the hose onto a reel puts the couplings that connect different sections of hose under a tremendous amount of stress. At the point where the coupling is being pulled onto the reel it experiences a particularly high level of stress and compressive forces. Over time, these forces can cause the hose to fail at or near the point where it is attached to a coupling. In any case, large bore reinforced hoses are prone to failure at their couplings. This is also the case where large tensile loads are encountered in catenary and deep water submarine applications. 
         [0006]    Today, there is a need for couplings for large bore reinforced hoses that are more resilient and which are capable of being incorporated into hoses that are more durable and capable of being repeatedly pulled onto reels and more resilient to high tension and bending loads. It would accordingly be desirable to develop couplings for large bore reinforced hoses that are more resistant to failure and which have a longer service under harsh service conditions, such as being repeatedly pulled onto reels. 
       SUMMARY OF THE INVENTION 
       [0007]    The hose couplings of this invention can be used to connect sections of large bore reinforced hose to make them more resistant to damage and to provide longer service life. These couplings can be used in conjunction with virtually any reinforced hose and are particularly beneficial when used in conjunction with hose that has a propensity to being damaged by virtue of being subjected to axial and bending forces, such as those encountered while being spooled on a reel. More specifically, hose utilizing the couplings of this invention is not as susceptible to being damaged or destroyed by the forces normally encountered during normal usage. This extends the service life of hoses of this invention which include such couplings. 
         [0008]    The present invention more specifically discloses a coupling for a large bore hose, said coupling comprising a tubular body which is adapted for fitting into the end of said large bore hose, said tubular body having a tail end which is adapted to lie inwardly from the end of the hose, said tubular body having an outer end which is adapted to extend beyond an axial end of the hose, and at least one hose carcass anchor which is affixed to the tubular body, wherein the carcass anchor is adapted for the hose carcass and/or load bearing extensions of the carcass to extend through and/or around the carcass anchor. 
         [0009]    The subject invention also reveals a coupling for a large bore hose, said coupling comprising a tubular body which is adapted for fitting into the end of said large bore hose, said tubular body having a tail end which is adapted to lie inwardly from the end of the hose, said tubular body having an outer end which is adapted to extend beyond an axial end of the hose, the outer surface of said tubular body being provided with a plurality of axially spaced retention beads, and at least one hose carcass anchor which is affixed to the tubular body at a point on or outward from the last retention bead toward the outer end of the tubular body, wherein the carcass anchor is adapted for the hose carcass and/or load bearing extensions of the carcass to extend through and around the carcass anchor. 
         [0010]    The present invention further discloses a hose assembly comprising a reinforced hose having at least one reinforcement layer and a coupling on at least one end of the hose, said coupling comprising a tubular body which is adapted for fitting into the end of said large bore hose, said tubular body having a tail end which is adapted to lie inwardly from the end of the hose, said tubular body having an outer end which is adapted to extend beyond an axial end of the hose, and at least one hose carcass anchor which is affixed to the tubular body, wherein the hose carcass and/or load bearing extensions of the hose carcass are affixed to the carcass anchor. For instance, load bearing extensions of the hose carcass which are comprised of steel wire or cable can be welded or clamped onto the carcass anchor. Fabric or polymeric cords or fibers can also be clamped onto the carcass anchor or wound around and/or through it. Virtually any attachment means that is capable of securely affixing the load bearing extensions of the hose carcass to the carcass anchor can be used. 
         [0011]    The subject invention also reveals a hose assembly comprising a reinforced hose having at least one reinforcement layer and a coupling on at least one end of the hose, said coupling comprising a tubular body which is adapted for fitting into the end of said large bore hose, said tubular body having a tail end which is adapted to lie inwardly from the end of the hose, said tubular body having an outer end which is adapted to extend beyond an axial end of the hose, and at least one hose carcass anchor which is affixed to the tubular body, wherein the hose carcass and/or load bearing extensions of the hose carcass extend through and/or around the carcass anchor. 
         [0012]    The subject invention further reveals a hose assembly, sometimes referred to as the “hitching post assembly,” comprising a reinforced hose having at least one reinforcement layer and a coupling on at least one end of the hose, said coupling comprising a tubular body which is adapted for fitting into the end of said large bore hose, said tubular body having a tail end which is adapted to lie inwardly from the end of the hose, said tubular body having an outer end which is adapted to extend beyond an axial end of the hose, the outer surface of said tubular body being provided with a plurality of axially spaced retention beads, and at least one hose carcass anchor which is affixed to the tubular body at a point on or outward from the last retention bead toward the outer end of the tubular body, wherein the hose carcass and/or load bearing extensions of the hose carcass extend through and around the carcass anchor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a cross sectional illustration of the coupling of this invention which is attached to the end of a hose. 
           [0014]      FIG. 2  is a view of the hose helix anchoring to a fitting ring with fabric. 
           [0015]      FIG. 3  is a first view illustrating anchoring a second set of main reinforcements to a ring. 
           [0016]      FIG. 4  is a second view illustrating anchoring a second set of main reinforcements to a ring. 
           [0017]      FIG. 4   a  also illustrates the embodiment of the invention shown in  FIG. 4  with a series of anchoring fabrics being shown as extending through a series of slots in the coupling before they are folded back upon themselves and cured into the hose carcass in the manufacturing process. 
           [0018]      FIG. 5  illustrates a coupling having a carcass anchor which is a plurality of pins that extend radially from the tubular body of the coupling. 
           [0019]      FIG. 6  is a cutaway view showing a coupling having a carcass anchor which is a plurality of pins that extend radially from the tubular body of the coupling with the carcass and reinforcing fabric extending through and around the carcass anchor. 
           [0020]      FIG. 7  is a first view that illustrates a coupling with an anchoring helix to fitting with steel cable. 
           [0021]      FIG. 8  is a second view illustrates a coupling with an anchoring helix to a fitting with steel cable. 
           [0022]      FIG. 9  is a third view illustrates a coupling with an anchoring helix to a fitting with steel cable. 
           [0023]      FIG. 10  is a first view illustrating an anchoring helix to a fitting with steel bars. 
           [0024]      FIG. 11  is a second view illustrating an anchoring helix to a fitting with steel bars. 
           [0025]      FIG. 12  illustrates an anchoring helix to a fitting ring with a chain. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0026]    The couplings of this invention can be beneficially used in conjunctions with hoses of different sizes and that are designed for a wide variety of purposes. However, the couplings of this invention are of particular benefit for use in conjunction with large bore hoses having an inside diameter of at least 5 cm and which typically has an inside diameter ranging from 20 cm to 80 cm and an outside diameter which is within the range of about 40 cm to about 150 cm, such as floating hose that is used in transferring crude oil and other liquids over water (in filling and unloading tanker ships), catenary systems and deep water submarine applications. 
         [0027]    The couplings of this invention can be used in conjunction with floating hose having a carcass with an inside and an outside, a floatation medium surrounding the hose carcass and an outer cover. They may also be used in a single carcass hose that is either designed for floating, submarine applications or as a catenary system. This type of floating hose typically has an inside diameter which is within the range of about 30 cm to 80 cm and an outside diameter which is within the range of about 40 cm to about 150 cm. For instance, many commercial floating hoses of this type have an inside diameter of 50 cm (20 inches) and an outside diameter of 95 cm (38 inches). 
         [0028]    The carcass is of a tubular shape and is typically comprised of a base submarine hose complete with end fittings. The hose carcass is surrounded by a floatation medium which is typically comprised of several layers of closed cell foam. The closed cell foam can be multiple layers of a polymeric foam, such as polyurethane or polyethylene foam. The floatation medium will have a density and a total volume that is sufficient to provide the floating hose  1  with a reserve buoyancy when filled with sea water which is within the range of 10% to 40%. The floating hose will more typically have a reserve buoyancy when filled with sea water which is within the range of 15% to 35%. In most cases the floating hose will have a reserve buoyancy when filled with sea water of about 25%. In fact, many specifications call for a reserve buoyancy of at least 20%. 
         [0029]    The floating hose includes a carcass and can optionally include a second carcass to attain a higher level of safety, performance and better durability. The hose carcass is typically comprised of a cured rubber which can be reinforced with a polymeric fabric, such as nylon or polyester, and/or steel reinforcements. For instance, the hose carcass can be reinforced with Kevlar® aramid fiber. The hose carcass will typically be comprised of a cured rubber, such as natural rubber, synthetic polyisoprene rubber, styrene-butadiene rubber (SBR), polyneoprene rubber, styrene-isoprene rubber, polybutadiene rubber, styrene-isoprene-butadiene rubber, nitrile rubber, carboxylated nitrile rubber, ethylene-propylene-diene monomer rubber (EPDM), or a mixture thereof. The hose carcass will also typically include one or more liners. To provide desired levels of chemical resistance such liners will generally be comprised of a nitrile rubber. To attain excellent heat resistance, oil resistance, and chemical resistance fluoroelastomers, such as Viton® fluoroelastomer, can be used in making the liners as well as thermoplastic liners such as crosslinked polyethylene. 
         [0030]    The floatation medium can be provided by wrapping multiple layers of closed cell foam around the hose carcass. A thin layer of rubber is preferably laid between the carcass and the floatation medium. The floatation medium will normally be about 6 cm to about 18 cm thick. In other words, the floatation medium will extend outwardly from the carcass about 6 cm to about 18 cm. The floatation medium will preferably be about 10 cm to about 15 cm thick and will most preferably be about 12 cm to about 14 cm thick. 
         [0031]    The floatation medium is surrounded outwardly with the outer cover of the hose. The outer cover is normally comprised of textile breakers with a rubber cover (a textile reinforced rubber cover). The outer cover can optionally include a polyurethane coating. In any case, the outer cover is designed to contain and protect the floatation medium from water damage and environmental conditions. 
         [0032]      FIG. 1  shows a coupling of this invention which is attached to the end of a hose to make a hose assembly  1 . In this illustration the hose  2  is used in conjunction with the coupling to make a hose assembly  1 . The coupling includes a tubular body  3 , a tail end  4 , an outer end  6 , a first retention bead  7 , a second (last) retention bead  8 , and a carcass anchor  9 . Such couplings can contain more than two beads and/or one or more anchors if desired. On the other hand, in some applications it may be desirable for the coupling to contain no retention beads or only a single retention bead. In the embodiment of the invention shown in  FIG. 1  the end of the hose  5 , including the hose carcass  10  and reinforcing fabric therein, extends around and through the carcass anchor  9 . The carcass anchor  9  can be a series of pins that extend radially from the tubular body  3 . The term pins as used in this context is intended to include bolts, rods or bars that extend radially outwardly from the tubular body of the coupling. The carcass anchor  9  can also be a ring that is affixed to the tubular body through a plurality of rods or plates that extend outwardly from the tubular body to the ring. In another embodiment of this invention, the carcass anchor  9  is in the form of metal wires or cables, such as steel wires or cables, that are attached directly to the coupling and which extend into the hose carcass. In most cases reinforcing elements within the hose carcass, such as reinforcing fabric and/or cords, will extend through and/or around the carcass anchor. 
         [0033]      FIG. 2  illustrates a hose helix anchored to a fitting ring with fabric. In this figure, the anchoring fabric  11  extends through and around the fitting ring  12  and anchors the hose helix wire  13  which is spirally wrapped around the carcass to the tubular body of the hose. The flange  14  of the coupling is conventional and used to connect multiple hoses together through fitting  15  which is anchored to the carcass  16  of the hose via the anchoring fabric  11  which is interwoven through and around the helix wire  13 . Accordingly,  FIG. 2  illustrates one embodiment of the subject invention wherein a carcass anchor, in this case the anchoring fabric  11 , is used as a load bearing extension which extends through and around a carcass anchor which in this case is fitting ring  12 . 
         [0034]      FIG. 3  illustrates another anchoring mechanism wherein the main body reinforcement  17  is anchored to a fitting ring  18  with fabric  19  which is the main reinforcement that runs the full length of the hose. In this figure, the fabric  19  extends through and around the fitting ring  18  and anchors the main body reinforcement  17  which is spirally wrapped around the carcass to the tubular body  20  of the hose. The flange  21  of the coupling is conventional and can be used to connect multiple hoses together through fitting  22  which is anchored to the carcass of the hose via the anchoring fabric  19  which is attached to or a part of the main body reinforcement  17 . Accordingly,  FIG. 3  illustrates one embodiment of the subject invention wherein a carcass anchor, in this case the anchoring fabric  19 , is used as a load bearing extension which extends through and around a carcass anchor which in this case is fitting ring  18 .  FIG. 4  illustrates an alternative embodiment in which supplemental fabric strips  23  are used to anchor the main body reinforcement  17 . In this embodiment of the invention the supplemental fabric strips can be of any length and do not necessarily extend throughout the entire length of the hose.  FIG. 4   a  shows another view of the embodiment illustrated in  FIG. 4  wherein the fabric strips  23  extend through a series of slots  48  in the coupling retaining ring  49 . The illustration shown in  FIG. 4   a  depicts the coupling in one step of its manufacturing process before the fabric strips are folded back upon themselves and cured into the hose carcass as illustrated in  FIG. 4 . It should be noted that the fabric strips can optionally be wrapped around helix wires or can be simply folded or cured into the body of the hose. 
         [0035]      FIG. 5  illustrates a coupling  24  having a carcass anchor which consists of a plurality of pins  25  which extend radially from the tubular body  26  of the coupling  24  which includes a flange  26  which is adapted for attaching the hose to other hose segments.  FIG. 6  shows a coupling for a large bore hose which has the coupling illustrated in  FIG. 5  attached thereto. In this embodiment of the invention the body of the coupling  27  has a multitude of pins  25  radially affixed thereto wherein the reinforcement fabric  28  is wrapped around the pin  25  and secured with binding wires  29 . The helix wires  30  are situated past the pins  25  toward the flange end of the hose  31  to further secure the hose carcass to the coupling. 
         [0036]      FIG. 7  illustrates a large bore hose having a coupling in accordance with one embodiment of this invention. In this embodiment of the invention the coupling  32  is anchored to the hose carcass  33  through an anchoring wire  34  which is interwoven through the helix wire  35  and secured to the coupling  32 . In this embodiment the anchoring wire  34  extends over a bead of the hose carcass  36 .  FIG. 8  illustrates a specific embodiment for anchoring the anchoring wire  34  to the coupling  32 . In this particular embodiment the anchoring wire  34  extends through a series of holes  37  (only one hole is shown in this figure) in the coupling  32  and is bent back on itself and secured with a clamping device  38 . Typically, a series of anchoring wires are affixed to the coupling by being passed through a multitude of holes in the coupling.  FIG. 9  illustrates a further means for affixing the anchoring wire  34  to the coupling  36  which involves passing the anchoring wire  34  through a pipe  39  which is affixed to the coupling  36  via a secure attachment means (such as through a weld). Normally, a series of pipe segments  39  are attached to the coupling to facilitate affixing a multitude of anchoring wires to the coupling. As can be seen in this embodiment of the invention the anchoring wire  34  is woven through the helix wires  35  as previously explained. 
         [0037]      FIG. 10  and  FIG. 11  illustrate still another embodiment of this invention. In this embodiment a series of steel strips  40  are securely affixed to the coupling  41  by an effective means such as being welded. The steel strips  40  are formed to conform with beads  42  and other structural irregularities of the hose. The steel strips are affixed to the helix wire  43  by some effective attachment means such as a series of welds. 
         [0038]      FIG. 12  illustrates still another embodiment of this invention.  FIG. 12  shows the coupling  44  without the body of the hose being shown. In this embodiment of the invention steel chains which are comprised of a series of chain links  45  are used as the carcass anchor. The chains are attached to the coupling  44  either through welding or by being run through a series of holes in the coupling. The chain links are then affixed to the hose carcass (not shown) by passing the helix wires  46  through the chain links  45 . The coupling  44 , of course, includes a conventional flange  47  for attaching the hose to a fluid inlet or outlet or another hose. 
         [0039]    The key to this invention is providing the coupling with anchors that allow the hose carcass or a load bearing extension of the carcass to extend through and around the anchors. This allows for the stress associated with tensile loading to be delivered directly to the coupling through the carcass anchors rather than through the interface between the hose and the tubular body of the coupling as is the case with the coupling designs of the prior art. The carcass anchors will normally extend into the hose no further than the cement line behind the first retention bead. In many cases, the carcass anchors will not extend into the hose as far as the first retention bead. 
         [0040]    In one embodiment of this invention the carcass anchor is a plurality of pins that extend radially from the tubular body. In another embodiment of this invention the carcass anchor is a ring which is affixed to the tubular body through a plurality of rods or plates that extend outwardly from the tubular body to the ring. The outer surface of the tubular body is provided with at least one retention bead. For instance, the outer surface of the tubular body can include two retention beads or a plurality of axially spaced retention beads. The carcass anchor is attached to the tubular body at a point on or outward from the retention bead toward the outer end of the tubular body. 
         [0041]    The reinforcing fabric of the hose carcass can extends through and/or around the carcass anchor. In on embodiment of this invention the carcass anchor is a plurality of pins that extend radially from the tubular body. In another embodiment of this invention the carcass anchor is a ring which is affixed to the tubular body through a plurality of rods or plates that extend outwardly from the tubular body to the ring. Typically, the hose assembly will be void of longitudinal supports. The carcass wire can be a metal wire or cable, such as a steel wire or cable, which is directly attached to the coupling. 
         [0042]    The outer surface of the tubular body is typically provided with at least one retention bead and can include two retention beads. In some cases, it may be desirable for the outer surface of the tubular body of the coupling to include a plurality of axially spaced retention beads. The carcass anchors are normally situated outwardly toward the end of the hose from the first retention bead. For instance, the carcass anchors are situated outwardly toward the end of the hose from the cement line behind the first retention bead. Normally, the carcass anchor is attached to the tubular body at a point on or outward from the last retention bead toward the outer end of the tubular body. 
         [0043]    While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention.