Patent ID: 12247686

In the drawings like reference numerals refer to like parts.

DETAILED DESCRIPTION

Throughout this description, reference will be made to a flexible pipe. It is to be appreciated that certain embodiments of the present invention are applicable to use with a wide variety of flexible pipe. For example, certain embodiments of the present invention can be used with respect to flexible pipe body and associated end fittings of the type which is manufactured according to API17J. Such flexible pipe is often referred to as unbonded flexible pipe. Other embodiments are associated with other types of flexible pipe.

It will be understood that the illustrated flexible pipes are an assembly of a portion of flexible pipe body and one or more end fittings in each of which a respective end of the pipe body is terminated.FIG.1illustrates how pipe body100is formed from a combination of layered materials that form a pressure-containing conduit. Although a number of particular layers are illustrated inFIG.1, it is to be understood that certain embodiments of the present invention are broadly applicable to coaxial pipe body structures including two or more layers manufactured from a variety of possible materials. The pipe body may include one or more layers comprising composite materials, forming a tubular composite layer. It is to be further noted that the layer thicknesses are shown for illustrative purposes only. As used herein, the term “composite” is used to broadly refer to a material that is formed from two or more different materials, for example a material formed from a matrix material and reinforcement fibres.

A tubular composite layer is thus a layer having a generally tubular shape formed of composite material. Alternatively, a tubular composite layer is a layer having a generally tubular shape formed from multiple components one or more of which is formed of a composite material. The layer or any element of the composite layer may be manufactured via an extrusion, pultrusion or deposition process, or by a winding process in which adjacent windings of tape which themselves have a composite structure are consolidated together with adjacent windings. The composite material, regardless of manufacturing technique used, may optionally include a matrix or body of material having a first characteristic in which further elements having different physical characteristics are embedded. That is to say elongate fibres which are aligned to some extent or smaller fibres randomly orientated can be set into a main body or spheres or other regular or irregular shaped particles can be embedded in a matrix material, or a combination of more than one of the above. Aptly the matrix material is a thermoplastic material, aptly the thermoplastic material is polyethylene or polypropylene or nylon or PVC or PVDF or PFA or PEEK or PTFE or alloys of such materials with reinforcing fibres manufactured from one or more of glass, ceramic, basalt, carbon, carbon nanotubes, polyester, nylon, aramid, steel, nickel alloy, titanium alloy, aluminium alloy or the like or fillers manufactured from glass, ceramic, carbon, metals, buckminsterfullerenes, metal silicates, carbides, carbonates, oxides or the like.

The pipe body100illustrated inFIG.1includes an internal pressure sheath110which acts as a fluid retaining layer and comprises a polymer layer that ensures internal fluid integrity. The layer provides a boundary for any conveyed fluid. It is to be understood that this layer may itself comprise a number of sub-layers. It will be appreciated that when a carcass layer120is utilised the internal pressure sheath is often referred to by those skilled in the art as a barrier layer. In operation without such a carcass (so-called smooth bore operation) the internal pressure sheath may be referred to as a liner. A barrier layer110is illustrated inFIG.1.

It is noted that a carcass layer120is a pressure resistant layer that provides an interlocked construction that can be used as the innermost layer to prevent, totally or partially, collapse of the internal pressure sheath110due to pipe decompression, external pressure, and tensile armour pressure and mechanical crushing loads. The carcass is a crush resistant layer. It will be appreciated that certain embodiments of the present invention are thus applicable to ‘rough bore’ applications (with a carcass). Aptly the carcass layer is a metallic layer. Aptly the carcass layer is formed from stainless steel, corrosion resistant nickel alloy or the like. Aptly the carcass layer is formed from a composite, polymer, or other material, or a combination of materials and components. The carcass layer is usually radially positioned within the barrier layer.

The carcass layer is a “layer” in the sense that a radially innermost and outermost surface are created in single pass at a single manufacturing node. The single manufacturing node may include multiple tape handling sections axially close together so that they are effectively a single node. The node aptly extends over an axial distance of less than 2.5 m. Aptly the node has a length of 1 m or less.

The pipe body includes a pressure armour layer130that is a pressure resistant layer that provides a structural layer that increases the resistance of the flexible pipe to internal and external pressure and mechanical crushing loads. The layer also structurally supports the internal pressure sheath. Aptly as illustrated inFIG.1the pressure armour layer is formed as a tubular layer. Aptly for unbonded type flexible pipe the pressure armour layer consists of an interlocked construction of wires with a lay angle close to 90°. Aptly in this case the pressure armour layer is a metallic layer. Aptly the pressure armour layer is formed from carbon steel, aluminium alloy, stainless steel or the like. Aptly the pressure armour layer is formed from a pultruded composite interlocking layer. Aptly the pressure armour layer is formed from a composite formed by extrusion or pultrusion or deposition. A pressure armour layer is positioned radially outside an underlying barrier layer.

The flexible pipe body illustrated also includes a first tensile armour layer140and second tensile armour layer150. Each tensile armour layer is used to sustain tensile loads and optionally also internal pressure. Aptly for some flexible pipes the tensile armour windings are metal (for example steel, stainless steel or titanium or the like). For some composite flexible pipes the tensile armour windings may be polymer composite tape windings (for example provided with either thermoplastic, for instance nylon, matrix composite or thermoset, for instance epoxy, matrix composite). For unbonded flexible pipe the tensile armour layer is formed from a plurality of wires (to impart strength to the layer) that are located over an inner layer and are helically wound along the length of the pipe at a lay angle typically from about 10° to 55°. Aptly the tensile armour layers are counter-wound in pairs. Aptly the tensile armour layers are metallic layers. Aptly the tensile armour layers are formed from carbon steel, stainless steel, titanium alloy, aluminium alloy or the like. Aptly the tensile armour layers have a microstructure that consists of orientated lamellae. Aptly the tensile armour layers are formed from a composite, polymer, or other material, or a combination of materials.

Aptly the flexible pipe body includes optional layers of tape160which help contain underlying layers and to some extent prevent abrasion between adjacent layers. A tape layer may optionally be a polymer or composite or a combination of materials, also optionally comprising a tubular composite layer. Tape layers can be used to help prevent metal-to-metal contact to help prevent wear. Tape layers over tensile armours can also help prevent “birdcaging” of the tensile armour wires.

The flexible pipe body also includes optional layers of insulation165and an outer sheath170, which comprises a polymer layer used to protect the pipe against penetration of seawater and other external environments, corrosion, abrasion and mechanical damage. Any thermal insulation layer helps limit heat loss through the pipe wall to the surrounding environment. An annulus180is a region associated with the space between the internal pressure sheath110and the outer sheath170. In other words, in the flexible pipe body illustrated inFIG.1, the pressure armour layer130, the first tensile armour layer140, the further tensile armour layer150, the optional layers of tape160, and the optional layers of insulation165are located in the annulus region180. It will be appreciated that in some embodiments, the annulus region180may contain any or none of the layers present in the flexible pipe body illustrated inFIG.1.

Each flexible pipe comprises at least one portion, referred to as a segment or section, of pipe body100together with an end fitting located at least one end of the flexible pipe. A respective end fitting may be used to terminate each end of the flexible pipe body. An end fitting provides a mechanical device which forms the transition between the flexible pipe body and a connector. The different pipe layers as shown, for example, inFIG.1are terminated in the end fitting in such a way as to transfer the load between the flexible pipe and the connector.

FIG.2illustrates a riser assembly200suitable for transporting production fluid such as oil and/or gas and/or water from a sub-sea location221to a floating facility222. For example, inFIG.2the sub-sea location221includes a sub-sea flow line225. The flexible flow line225comprises a flexible pipe, wholly or in part, resting on the sea floor230or buried below the sea floor and used in a static application. The floating facility may be provided by a platform and/or buoy or, as illustrated inFIG.2, a ship. The riser assembly200is provided as a flexible riser, that is to say a flexible pipe240connecting the ship to the sea floor installation. The flexible pipe may be in segments of flexible pipe body with connecting end fittings.

It will be appreciated that there are different types of riser, as is well-known by those skilled in the art. Certain embodiments of the present invention may be used with any type of riser, such as a freely suspended (free-hanging, catenary riser), a riser restrained to some extent (buoys, chains), totally restrained riser or enclosed in a tube (I or J tubes). Some, though not all, examples of such configurations can be found in API17J.FIG.2also illustrates how portions of flexible pipe can be utilised as a jumper250.

FIG.3illustrates a first (left-most inFIG.3) end fitting3001and a further (right-most) end fitting3002arranged in a back-to-back arrangement. The first end fitting3001terminates a respective end of a first segment of flexible pipe body1001and the further end fitting3002terminates a respective end of a further segment of flexible pipe body1002. It will be understood that a still further end fitting may terminate a remaining end of the first segment of flexible pipe body1001or a remaining end of the further segment of flexible pipe body1002. The end fittings3001,3002are connected together via respective connector flanges3101,3102. These are bolted together via bolts (not shown inFIG.3) and have matching seal ring grooves on opposing flange faces.

Each end fitting300further includes a central flange320spaced apart from the connector flange310via a neck region330. An outer jacket340is secured to the central flange and an outer collar350is secured to the jacket340and seals against an outer surface of an outer sheath170of the flexible pipe body100via at least one seal ring. A radially innermost surface of the jacket340is spaced apart from a radially outer surface of a generally cylindrical but slightly flared outwards end of an elongate end fitting body360of the end fitting. An open mouth365of the end fitting body faces associated the segment of flexible pipe body. Tensile armour wires366are terminated in the tapered space367between the outer casing and the end fitting body. Aptly epoxy is located in the tapered space to entomb the ends of the tensile armour wires366. The end fitting300is associated with a central longitudinal axis A-A and the central longitudinal axis of each end fitting is aligned along a common line when the end fittings are arranged in a back-to-back configuration. During use production fluids are transported along a bore provided by the barrier layer or liner of the flexible pipe body and the inner surface of each end fitting300.

The end fittings3001,3002illustrated inFIG.3also each include a respective purge valves3701,3702. It will be appreciated the purge valves are fluidly connected to the annulus region of each respective flexible pipe via respective internal tubes3801,3802that are not filled with epoxy and thus provide a fluid communication pathway of the end fittings that extends between respective purge valves and annulus regions of the flexible pipes. Aptly the respective end fittings may not include purge valves and/or internal tubes.

FIG.3also illustrates how the end fittings3001,3002each include a profiled ring3851,3852that is an example of an annular element. The profiled rings3851,3852are located radially around a region of a portion of respective tensile armour366wires that are located in the tapered space367or cavity of each end fitting3001,3002.FIG.3helps illustrates how an outer surface region of each of the profiled rings3851,3852abuts against an outer surface region of the respective tensile armour wires366.FIG.3also shows how each of the end fittings3001,3002includes an inner collar member3901,3902that is located radially within or beneath the tensile armour wires366. The inner collar members include a respective abutment surface that acts to abut against an outer surface region of respective tensile armour wires366, on an opposite side of the wires366to the side that is in contact with a respective profiled ring3851,3852. Thus, respective tensile armour wires366are gripped between a respective profiled ring3851,3852and inner collar member3901,3902. This will be described in more detail with respect toFIG.4.

FIG.4illustrates a cross-sectional view of a region of an end fitting300in more detail.FIG.4illustrates how a region of respective tensile armour wires are located in an internal tapered space367when a segment of flexible pipe body is terminated in an end fitting. It will be understood that the cavity367is located in between the end fitting jacket and the end fitting body360. It will be appreciated that the cavity367is filled with epoxy resin, or any other suitable fixent, to help secure the tensile armour wires366in the end fitting cavity367. As is shown inFIG.4, the tensile armour wires are bent away from a longitudinal axis of the flexible pipe404at a lift-off point408that is an example of a predetermined location. This is a location in the end fitting300wherein the tensile armour wires366bend away from the longitudinal axis404of the flexible pipe. As is shown inFIG.4, then tensile armour wires366bend back towards the longitudinal axis404of the flexible pipe at a further location412and thus extend over an inner collar body portion416of the inner collar member390and also over an outer surface region of the end fitting body360.

FIG.4shows how the inner collar member also includes an inner collar neck portion420that extends away from the inner collar body portion416(towards the lift-off point408) and has a reduced thickness relative to the inner collar body portion420. As shown inFIG.4, an end region424of the inner collar neck region420, that is distal from the inner collar body portion416, includes a tapered surface428that is an abutment surface.FIG.4shows how the abutment surface428abuts against a radially inner outer surface region432of the tensile armour wires366at or around the lift-off point408. It will be understood that the radially innermost tensile armour wires366extend over the tapered abutment surface428.

FIG.4also helps illustrates how the profiled ring385is arranged radially around a region of the tensile armour wires366, and in particular is arranged radially around the radially outermost tensile armour wires366. It will be understood thatFIG.4illustrates a portion the profiled ring385in cross section. As shown inFIG.4, the profiled ring385, that is an example of an annular element, includes a rigid annular body that is a profiled body436and that has a non-uniform cross section across a whole thickness t of the body extending between a first annular edge440and a further annular edge444that each are the outermost extending edges of the profiled ring385along the width (thickness t) of the profiled ring385.FIG.4illustrates how the profiled ring385includes a generally arcuate guiding surface448that extends between the first annular edge440and along at least a portion of the radially inner surface of the profiled ring385.FIG.4shows how an abutment region452of the guiding surface448is urged against the radially outer surface456of respective tensile armour wires366.FIG.4illustrates how the abutment region452of the guiding surface448contacts the tensile armour wires366at or around the lift-off point408. It will thus be understood how, by urging the profiled ring385towards and into contact with the respective tensile armour wires366during terminating a segment of flexible pipe body in an end fitting300, a region of the tensile armour wires366, that optionally is at or around the lift-off point408, can be gripped between the abutment region452of the profiled ring385and the abutment surface428of the inner collar member390. It will be appreciated how gripping the tensile armour wires366in the end fitting300in this manner prior to entombing the wires366in epoxy resin or the like can help reduce slack in any wires366and/or help provide numerous splayed-out wires366of a tensile armour layer in a more uniform orientation.

FIG.4also helps illustrate how the profiled ring385includes an inset or cut-out region460located on an upper (radially outer) region of the ring385and proximate to the further end region444. The cut-out region460includes a stepped jacked engaging surface region464and cooperates with a complimentary stepped surface region466(or cut-out region) disposed on a radially inner surface of the end fitting jacket340. It will be understood how the position of the stepped surface region466is positioned in the end fitting jacket340such that the engagement between the jacket stepped surface region466and the stepped jacket engaging surface region464urges the abutment region452of the profiled ring385into contact with the respective radially outermost tensile armour wires366and over said wires towards a predetermined position of the profiled ring. Thus, it will be appreciated how providing and securing the end fitting jacket340radially around the end fitting body360acts to slide the profiled ring385towards the lift-off point408, over the radially outer surface of the outermost tensile armour wires366, and into gripping abutment with the outermost tensile armour wires366at or around the lift-off point408.

FIG.4further helps illustrate how the end fitting300includes an outer sleeve member468that includes an outer sleeve body portion472and an outer sleeve neck portion476that extends away from the outer sleeve body portion472, and has a thickness that is less than that of the outer sleeve body portion472. It will be appreciated that the outer sleeve member may comprise an outer collar member. The outer sleeve neck portion is located in a slotted position between the outer sheath170of the segment of flexible pipe body that is terminated in the end fitting300and the radially outermost tensile armour wires366, and optionally over a tape layer160which over-lies the tensile armour wires366. The outer sleeve body portion472of the outer sleeve member468is disposed in a spaced apart relationship with respect to the annular profiled ring385. That is to say that the profiled ring385and the outer sleeve member468are separated by an internal space region480that is an example of a void region. It will be understood how, prior to providing and securing the end fitting jacket340radially around the end fitting body360, the profiled ring385is locatable against or in contact with the outer sleeve member468and can be axially slid long the radially outermost tensile armour wires366towards the lift-off point408to provide the void region480. This will be described in more detail below.

FIG.5illustrates how a profiled ring385can be provided in an end fitting300during a termination process.FIG.5helps illustrate how, prior to providing and securing an end fitting jacket radially around the end fitting body, and subsequent to providing the outer sleeve member468such that the outer sleeve neck portion476is located in a slotted position between the outer sheath170and one or more tensile armour layers140,150of a segment of flexible pipe body, the profiled ring385is provided radially around the outermost tensile armour wires366. That is to say that the profiled ring385radially surrounds an exposed region of the radially outermost tensile armour wires366that is revealed after trimming the outer sheath170, and any overlying tapes160or other appropriate layers, during the termination process. It will be appreciated that both the profiled ring385and the outer sleeve member468are annular and radially surround the tensile armour wires366. It will be understood that the profiled ring385and outer sleeve member468illustrated inFIG.5are shown only as a cross section of part of the circumference of the respective elements. FIG.5shows how, the profiled ring385is provided such that a terminal surface504at the further annular edge444of the profiled ring385is in contact with a terminal end508of the outer sleeve member468that is an end of the outer sleeve body portion472distal to the outer sleeve neck portion476. Thus, the profiled ring is provided against, and abuts against, the outer sleeve member. Aptly the profiled ring385may comprise an annular protrusion which extends under the outer sheath170, coaxially with, or alternatively incorporating what is otherwise shown inFIG.4as the outer sleeve body portion472. That is to say, the profiled ring385may be provided with another annular recessed step, that extends radially inwards of the stepped jacket engaging surface region464, to accommodate, and butt up against, the end of the outer sheath170; the profiled ring385may then extend some distance axially under the outer sheath170, and the terminal end surface region504located at the further edge444of the profiled ring385can thus be located at a position under the outer sheath170and proximate to the outer sleeve neck portion476, where a terminal end508of the outer sleeve member468is can be positioned. The profiled ring385and the shortened outer sleeve member468may be inserted at the same time underneath the outer sheath170, then the profiled ring385may be urged back towards the inner collar390, separating the terminal end508of the outer sleeve member468and the terminal end surface region504located/locatable at the further edge444of the profiled ring385to create the internal space region480underneath the outer sheath170. Such an extension of the profiled ring axially along the flexible pipe body may help to improve stability and rigidity of the profiled ring, particularly20while the armour wires366and516are flexed/bent back around the profiled ring.

FIG.5illustrates how, as part of the termination process, the tensile armour wires366are bent away from the longitudinal axis404of the flexible pipe. That is to say that the tensile armour wires366are bent radially outwards and even sometimes back on themselves (as is shown inFIG.5). This allows for certain components of an end fitting to be provided beneath the tensile armour wires366during termination of the segment of flexible pipe body.FIG.4shows how the tensile armour wires366are bent away from the longitudinal axis404of the flexible pipe along the guiding surface448of the profiled ring385. As shown, the guiding surface448is a generally curved or arcuate outer surface of the profiled ring385that is a generally radially inner facing surface region, and extends over an edge, of the profiled ring385. The guiding surface448thus helps determine the bending radius of a tensile armour wire366when the wire is bent away from the longitudinal axis404of the flexible pipe during the termination process, and helps ensure that the bending radius is greater than a minimum damage bending radius of the wires. This is because the tensile armour wire366cannot bend along the guiding surface448with a radius of curvature that is less than the radius of curvature of the guiding surface448. The guiding surface has a radius of curvature which is related to the wire thickness in the tensile armour wires in a tensile armour wire layer150through a suitable multiplication factor which may be determined by testing of wire sizes and material grades to ensure no permanent damage nor reduction of mechanical properties of the wires result from the bending processes. Thus, the guiding surface448prevents the tensile armour wires366from being bent, away from the longitudinal axis404of the flexible pipe, during a termination process, to a degree that is less than the acceptable or damage minimum radius of curvature that the tensile armour wires can tolerate before potentially experiencing damage, plastic deformation and/or embrittlement. Thus, bending the tensile armour wires366along the guiding surface448helps extend the fatigue life of the tensile armour wires when terminated in an end fitting300.

FIG.5shows how, due to the arrangement of the profiled ring385and associated guiding surface448the position shown inFIG.5, each tensile armour wire366is bent away from the longitudinal axis404of the flexible pipe at a predetermined position512that is a wire bending or folding position. This position is determined by the outer profile of the profiled ring385. The profiled ring thus helps more uniformly bend multiple tensile armour wires366during a termination process.

FIG.5also illustrates how, subsequent to bending the tensile armour wires away from the longitudinal axis, the inner collar member390is located beneath the tensile armour wires366and is secured in place such that the abutment surface428is located at or around (proximate to) the lift-off point428shown inFIG.4. It will be appreciated that the inner collar member390is secured to the end fitting body360, or to other suitable end fitting components, via bolts and/or screws and/or the like. Aptly the wires366and516are not permanently deformed at the predetermined position512when they are flexed or bent away from the longitudinal axis404and around the guiding surface448, so that when the wires are bent back towards, or allowed to flex back towards (or folded back towards) the longitudinal axis404, over the inner collar390, the transition from their layer positions in the flexible pipe body100into the inner cavity367of the end fitting300is as smooth as possible.

It will be understood that subsequent to bending the tensile armour wires366away from the longitudinal axis404of the flexible pipe, and providing the requisite end fitting components such as the inner collar member390, the tensile armour wires366are bent back towards or allowed to flex back towards (or folded back towards) the longitudinal axis404of the flexible pipe so that the innermost tensile armour wires366are splayed out over the abutment surface428of the inner collar member390. Optionally the wires are splayed out but spaced apart from the abutment surface. It will also be understood thatFIG.5illustrates tensile armour wires516of a first layer140that have been allowed to flex (or have been bent back towards) the longitudinal axis404of the flexible pipe and tensile armour wires520of a further layer150that are bent away from the longitudinal axis404of the flexible pipe.

FIG.6illustrates how, from the arrangement shown inFIG.5, tensile armour wires366can be gripped at an end region604of each of the tensile armour wires366that is a region located towards the terminal end of the tensile armour wires366located within the end fitting300at or proximate to the lift-off point428. The wires are gripped between the abutment region452of the profiled ring385and the abutment surface428of the inner collar member390. As is shown inFIG.6, the profiled ring385has been slid, relative to the position shown inFIG.5, in a first direction of motion A (that is away from the outer sleeve member (or more particularly away from the body portion472of the outer sleeve member) and towards the lift-off point408) over a portion of the outer tensile armour wires366that extend substantially parallel with the longitudinal axis404of the flexible pipe and urged into abutment with a portion of the radially outermost tensile armour wires366that are splayed out at or proximate to the lift-off point408. As the profiled ring385is urged/slid away from the outer sleeve body portion472, the void480is provided between the profiled ring385and the outer sleeve member385. The void inFIG.6is empty space however it will be appreciated that the void480may be filled with any suitable material, for example by epoxy resin or the like, subsequent to sliding the profiled ring away from the outer sleeve member. This could be achieved by providing a curable material, for example epoxy resin or the like, into the void region480via one or more inlet ports disposed in the end fitting300.

FIG.6illustrates how an end fitting jacket340is secured radially around the end fitting body360. As described with reference toFIG.4, a stepped or doglegged jacket engaging surface region464of the profiled ring385engages with a corresponding stepped, doglegged or cut-out region466of the outer jacket340located on the radially inner surface of the jacket340. This engagement between the stepped region466of the jacket and the stepped jacket engaging surface region464of the profiled ring acts to urge the abutment region of the profiled ring into abutment with the radially outer most tensile armour wires and effectively locks the profiled ring in place at a desired position. Thus is will be appreciated that by specific positioning the respective jacket cut-out region466and stepped jacket engaging surface region (alongside use of a specifically shaped and sized profiled ring385and inner collar member390respectively), a predetermined gripping or clamping force can be provided on the tensile armour wires366at the end region604between the abutment region (of the profiled ring)452and the abutment surface428(of the inner collar member). It will be appreciated how the tensile armour wires366of multiple tensile armour layers are squeezed, gripped and/or clamped together between the abutment surface428of the inner collar member390and the abutment region452of the profiled ring385due to the compressing abutment of the abutment surface428of the inner collar member390against the radially innermost tensile armour wires366and the compressing abutment of the abutment region452of the profiled ring385against the radially outermost tensile armour wires366. It will be appreciated that, if only a single tensile armour layer is present, the tensile armour wires are clamped between the inner collar member390and profiled ring385by compressing abutment of the abutment surface428of the inner collar member390on the radially inner surface of the tensile armour wires and the compressing abutment of the abutment region452of the profiled ring385on the radially outermost surface of the tensile armour wires.

It will be understood that the profiled ring385may be slid away from the outer sleeve body portion472either prior to providing the outer jacket340to the end fitting300or during providing the jacket340to the end fitting300(via the cooperative abutment between the cut-out region466of the jacket340and the stepped jacket engaging surface region464of the profiled ring385).

It will be appreciated that the gripping or clamping of the tensile armour wires366between the profiled ring385and inner collar member390can help provide a substantially fluid tight sealing of the inner cavity367of the end fitting300. The abutment surface428of the inner collar member390and/or the abutment region452of the profiled ring385may include a polymeric material or the like to further enhance this sealing effect. It will be appreciated that an initial deformable filler or sleeve or film or tape (not shown) may be introduced between the armour wires516of layer140and the armour wires366of layer150at the predetermined position512while the armour wires366are bent away from the longitudinal axis404and after the wires516have been bent back towards, or allowed to flex back towards (or folded back towards) the longitudinal axis404, over the inner collar390, such that when the profiled ring385is urged towards the inner collar member390the filler or sleeve or film or tape is squeezed and moulds around the tensile armour wires, at least partly filling the void spaces between them, to then solidify or harden in situ so as to provide essentially rigid support to the armour wires. It will be appreciated that such a filler or sleeve or film or tape may also be applied as an expanding filler material which takes on the shape of and at least partly fills the gaps between the profiled ring, the armour wires and the inner collar member and then solidifies or hardens in situ. It will be appreciated that this sealing effect can help prevent epoxy resin or the like from flowing out of the inner cavity of an end fitting when filling the cavity with epoxy resin (to entomb and secure the tensile armour wires in the end fitting) in a horizontal filling mode of operation (filling via fluid inlets in the end fitting that are substantially parallel to the longitudinal axis of the flexible pipe).

Aptly the profiled ring is slid away from the outer sleeve member by between a quarter of an inch and an inch, optionally by around half an inch, during terminating a segment of flexible pipe body in an end fitting.

FIG.7illustrates a first step s700of gripping tensile armour wires366during a process of terminating a segment of flexible pipe body in an end fitting. That is to say thatFIG.7illustrates a first step of locating respective end regions of wires of an armour layer of a segment of flexible pipe body at respective desired positions in an end fitting. With similarity toFIG.5and the associated description,FIG.7illustrates how, during a termination step of a segment of flexible pipe in an end fitting, an outer sleeve member468including an outer sleeve body portion472and an outer sleeve neck portion476is provided such that the outer sleeve neck portion is slotted between an outermost layer of tensile armour wires366and a flexible pipe outer sheath170. That is to say that the outer sleeve member sleeve468is located radially around a portion of the radially outermost tensile armour wires366. A profiled ring385is provided radially around a portion of the outermost tensile armour layers and is disposed in contact, in an end-to end configuration, with a terminal end of the outer sleeve member508(at the outer sleeve body portion472) via a terminal end surface region504of the profiled ring385located at the further edge444of the profiled ring385.

FIG.7illustrates how the tensile armour wires366are bent away from the longitudinal axis404of the flexible pipe over a guiding surface448of the profiled ring385that is a generally arcuate surface extending over a substantially radially inner face of the profiled ring385from the first edge440of the profiled ring to the further edge of the profiled ring444. As described with respect toFIG.5, the generally arcuate guiding surface448helps ensure that the radius of curvature of the tensile armour wires366when bent away from the longitudinal axis404of the flexible pipe is not less than a minimum damage bend radius of the tensile armour wires366.FIG.7also helps illustrate how, by bending the tensile armour wires away from the longitudinal axis404of the flexible pipe, the inner collar member390can be provided in a location that will be radially within the tensile armour wires366when the wires366are positioned back over the inner collar member390.

FIG.8illustrates a second step s800of gripping tensile armour wires366during a process of terminating a segment of flexible pipe body in an end fitting. That is to say thatFIG.8illustrates a second step of locating respective end regions of wires of an armour layer of a segment of flexible pipe body at respective desired positions in an end fitting. As is shown inFIG.8, the tensile armour wires have bent back towards, or have been allowed to flex towards, the longitudinal axis404of the flexible pipe and are arranged to extend over a radially outer surface804of the inner collar body portion416of the inner collar member390.

It will be appreciated that the bending radius of the profiled ring guiding surface is designed to be greater than a minimum bend radius of tensile armour wires utilised in flexible pipes to avoid overbending of the wires.

FIG.9illustrates a third step s900of gripping tensile armour wires366during a process of terminating a segment of flexible pipe body in an end fitting. That is to say thatFIG.9illustrates a third step of locating respective end regions of wires of an armour layer of a segment of flexible pipe body at respective desired positions in an end fitting. As shown inFIG.9, an end fitting jacket340is slid radially over the end fitting body360(and radially around the portion of tensile armour wires366to be terminated in the end fitting, radially around the outer sleeve member, radially around the inner collar member390and radially around the profiled ring385). As is illustrated inFIG.9, the cut-out or stepped region466of the end fitting jacket340(located on the radially inner surface of the jacket340) has be slid into engaging abutment with the complimentary stepped jacket engaging surface region464of the profiled ring385(that is located on a radially outward edge region of the profiled ring385).FIG.9shows how, due to the engagement between the profiled ring385and the end fitting jacket340, as the end fitting jacket is slid over the end fitting body360in a first direction A, the profiled ring385is slid over the radially outermost tensile armour wires366in the first direction A. Thus, the profiled ring385is slid away from, and is axially spaced apart from, the outer sleeve member468.FIG.9illustrates how a void region480is provided between the profiled ring and the outer sleeve member.

It will be appreciated that the shaped profile of the rebated region (or inset region) of the end fitting jacket inner surface (that is an example of a first engagement surface region) cooperates with the jacket engagement surface of the profiled ring that is provided by the inset region of the profiled ring. The jacket and profiled ring thus include cooperative mating surfaces. It will be understood that the generally stepped profile of the rebated region of the jacket and the jacket engaging surface of the annular ring ensures that, when the end fitting is assembled and the end fitting jacket is slid over the end fitting body, the profiled ring is urged axially along the tensile armour wires but is not urged radially inwardly and thus is not compressed or forced inwardly. This thus helps prevent damage to the tensile armour wires in end fitting assembly.

FIG.10illustrates a fourth step s1000of gripping tensile armour wires366during a process of terminating a segment of flexible pipe body in an end fitting. That is to say thatFIG.10illustrates a fourth step of locating respective end regions of wires of an armour layer of a segment of flexible pipe body at respective desired positions in an end fitting.FIG.10illustrates how the end fitting jacket340has been slid further over the end fitting body360relative to the position shown inFIG.9. Thus, the profiled ring has been slid further towards the inner collar member (and axially in a first direction away from the outer sleeve member), over the radially outermost tensile armour wires relative to the position shown inFIG.9.FIG.10shows how an abutment region452(that is a portion of the guiding surface448) of the profiled ring385abuts against a radially outer surface of each of the radially outermost tensile armour wires366when the profiled ring385is located in the position shown inFIG.10.FIG.10also shows how the position of the profiled ring385urges the tensile wires366into such a position that the radially inner surface of each of the radially innermost tensile armour wires abut against the abutment surface428of the inner collar member390. It will be appreciated that the various tensile armour layers of the flexible pipe and wires included therein are squeezed together between the profiled ring385and the inner collar member390to thereby clamp or grip the tensile armour wires366between the inner collar member and the profiled ring. It will be understood that the end fitting jacket340is secured to the end fitting body in the position shown inFIG.10to thereby lock the profiled ring385in place.

As shown inFIG.10, the void region is filled with suitable material1004to help provide reinforcement to the portion of flexible pipe body located in this region. As discussed previously, this may be a curable material such as epoxy resin or the like. Alternatively, a split body ring member may be provided between the profiled ring385and the outer sleeve member468. It will be understood that subsequent to the step s1000shown inFIG.10, the inner cavity367of the end fitting300may be filled with a curable material, for example epoxy resin, to entomb the tensile armour wires366.

It will be appreciated that the size of the respective stepped cross sectional surface regions of the jacket and profiled ring are predesigned such that the ring is properly engaged by the jacket and to ensure a predetermined pretension is applied to the tensile wires when the profiled ring is urged against the wires.

As shown inFIG.9, when the tensile armour wires are splayed out over the end fitting body (after being folded back towards the longitudinal axis of the flexible pipe), a gap is present between the abutment surface428of the inner collar member and the radially innermost tensile armour wires. It will thus be appreciated how, by sliding the profiled ring over the outermost tensile armour wires, the tensile armour wires are forced towards and into contact with the abutment surface of the inner collar member. It will thus be understood how, by urging the profiled ring over the wires in this manner, a degree of axial loading is applied to the tensile armour wires which helps reduce any slack in the tensile armour wires and helps orient the wires in a more uniform manner. This also helps reduce the variation of stresses imparted on the tensile armour wires in use.

FIG.11aillustrates the profiled ring385ofFIGS.4to10in more detail. As shown inFIG.11a, the profiled ring385includes a first edge440and a further edge444that is spaced apart from the first edge440across an entire width of the ring385. The first edge440and the further edge444are outwardly most extending edges of the profiled ring and thus define a thickness of the profiled ring385cross section. It will be understood that the profiled ring385has a non-uniform cross section profile along its thickness (that is to say across the width w of the profiled ring385). The cross section of the profiled ring however is substantially constant along the whole circumference of the annular body1104, that is a rigid annular body, of the profiled ring (that is to say around the ring of the annular body1104). Optionally the annular body1104may be non-rigid or at least partly deformable. The radially inner edge region1108of the annular body1104, that extends between the first and further edges440,444, includes a generally arcuate guiding surface448. As described with respect toFIG.5, the guiding surface448is a surface upon which tensile armour wires can be folded or bent away from a longitudinal axis of a flexible pipe during termination of a segment of flexible pipe body. It will be appreciated that the radius of curvature of the guiding surface448is greater than the minimum damage bend radius of tensile armour wires to help prevent damage to tensile armour wires during folding.

FIG.11aalso illustrates how the guiding surface448includes an abutment region452that in use is for urging into contact with a radially outer surface of at least some tensile armour wires of a flexible pipe to help impart a predetermined tension (and optionally grip) the tensile armour wires in an end fitting to thereby help increase the uniformity of tensile armour wires terminated in an end fitting. It will be appreciated that this helps reduce a variation in the amount of stress imparted on each wire.FIG.11ashows how the abutment region452is disposed on a substantially radially inner region of the guiding surface448, but is more proximate to the first edge440than the further edge444.

FIG.11aalso illustrates how a radially outer region of the profiled ring385, proximate to the further edge444, includes a cut-out region (or inset region)460that extends to the further edge444. Thus, the profiled ring385includes a flared-out region1110proximate to the first edge440and located on a radially outermost edge region of the ring385. It will be understood that the cut-out region460provides the stepped jacket engaging surface region464of the profiled ring385for engaging with an end fitting jacket in use.

The profiled ring385ofFIG.11ais made from a metallic material. It will be appreciated that the profiled ring may be instead made from a polymeric material or a ceramic material or a composite material or any other suitable material. The profiled ring is a rigid body. Optionally the profiled ring may not be rigid and may be flexible or semi-flexible.

FIG.11billustrates the cross-sectional profile of the profiled ring ofFIG.11aacross its width w. It will be appreciated that the width w of the profiled ring385may instead be referred to as its thickness or whole thickness.FIG.11bhelps illustrate how the cross section1120of the profiled ring is substantially constant around the of the annular body1104of the profiled ring385. That is to say that the cross section is substantially constant around the whole of the circumference of the annular body. Optionally, the cross section of the annular body may of course not be substantially constant around its circumference and may include or of more circumferential regions in which the cross section1120varies.

FIG.11billustrates how the profiled ring385is a rigid annular body1104that extends circumferentially around a central axis1122. It will be appreciated that the radially inner surface of the profiled ring may include one or more low friction regions to help aid the profiled ring in sliding along tensile armour wires during terminating a segment of flexible pipe in an end fitting. It will be understood that the width or thickness of the profiled ring extends along, or is parallel to, the central axis.

FIG.11cillustrates the cross section1120of the rigid annular body1104(of the profiled ring385) in more detail. The cross section1120shown inFIG.11cis a cross section of the annular body along the central axis1122. The cross section includes a first end region1230and a further end region1234that is spaced apart from the first end region along the central axis1122. The cross section further includes a radially inner edge region1138and a radially outer edge region1142that are radially spaced apart and that are connected between the first end region1130and the further end region1134. As shown inFIG.11c, the cross section1120is generally curved at the first end region1130. The first end region includes a first extremity end (or first annular edge)440that is a terminal end point of the width w of the annular body1104and the further end region includes a further extremity end444(or a further extremity end region that is a further annular edge) that is a remaining terminal end of the width w of the annular body1104.FIG.11cshows how a guiding surface448, in cross section, extends at least partly along the radially inner edge region1138and along the first end region130of the rigid annular body1104. The guiding surface448includes a generally arcuate bend limiting surface portion1132upon which tensile armour wires can be bent away from a longitudinal axis of a flexible pipe during terminating a segment of flexible pipe body in an end fitting, and which limits the curvature of said tensile armour wires to be above a minimum bend radius associated with the wires due to the arcuate shape of the bend limiting surface portion. It will be appreciated that the bend limiting surface portion is a substantially convex surface. It will be appreciated that the guiding surface448also includes the abutment region425which is a region of the rigid annular body for abutting against a plurality of tensile armour wires of a tensile armour layer of a flexible pipe in use.

FIG.11cillustrates how the annular body1104includes a radially inset region460located on the radially outer edge region428and that extends from the further extremity end444(towards the first extremity end440). It will be appreciated that the inset region is an example of a jacket engaging portion. The inset region460provides a jacket engaging surface464(that is an example of an engaging surface and inFIG.11cis a recessed jacket engaging surface or a stepped jacket engaging surface). It will be appreciated that the jacket engaging surface region cooperates with a mating inner surface region of an end fitting jacket in use. Optionally, the jacket engaging surface region may instead be one or more radially extending protruding surface regions or elements that extend radially outwardly and engage with corresponding inner surface profiles of an end fitting jacket.

FIG.11cadditionally illustrates how the further end region of the annular body cross section1120includes the further extremity end444. A trailing surface, that is a collar abutment surface, for abutting against an end fitting outer sleeve member during a tensile armour wire folding/bending process in use is, in cross section, located on the further end region134. It will be appreciated that the trailing surface is a substantially planer surface.

FIG.11dillustrates another perspective view of the profiled ring ofFIGS.4to10.FIG.11dhelps illustrate how the profiled ring385extends circumferentially around the central axis1122.FIG.11dalso helps illustrate how the profiled ring385includes a guiding surface that is generally curved or arcuate and extends over the first end (that faces out of the page from the perspective view shown inFIG.11d) of the profiled ring385. It will be appreciated how tensile armour wires can be splayed out over the first end of the profiled ring (and other proximate regions of the ring) during terminating a segment of flexible pipe body in an end fitting.

FIG.11eillustrates a side-on perspective view of the profiled ring385ofFIGS.4to10.FIG.11eillustrates how the profiled ring is arranged around a central axis1122that extends on (or along) an imaginary plane1160. It will be understood how the imaginary plane shown1122inFIG.11eis one of an infinite number of imaginary planes on which the central axis extends.FIG.11ealso shows how the profiled ring385intersects the imaginary plane1160at two positions1160around the circumference of the profiled ring.

It will be appreciated that the cross section illustrated inFIG.11cis the cross section of the respective intersection positions1160(one of the positions having a cross section that is inverted with respect to the viewpoint shown inFIG.11c).FIG.11ealso helps illustrate how the inset regions460for abutting against an end fitting jacket in use are arranged on the profiled ring.

FIG.11fillustrates a further perspective view of the profiled ring385ofFIGS.4to10.FIG.11fhelps further illustrate how the profiled ring includes an inset region460that is disposed on an outer annular edge of the ring and extends from a further end of the ring. It will be appreciated how the profiled ring is an example of a rigid annular body.

FIG.12illustrates a different annular element that is a substantially uniform ring element1204. That is to say that the ring1204ofFIG.12has a cross section that is substantially uniform or symmetrical across a whole width or thickness t of the ring element1204. It will be appreciated that the ring element1202ofFIG.12is similar to the profiled ring385ofFIGS.11a,11band11cand thus functions in a similar manner as the profiled ring385(to help grip tensile armour wires in an end fitting). The ring element1204of

FIG.12thus includes a guiding surface1208and an abutment region1212that is similar to the corresponding profiles inFIGS.11a,11band11c. The ring element ofFIG.12however does not include a cut-out region (that is shown inFIGS.11a,11band11c). Thus, the ring element1204ofFIG.12must either be manually urged and secured against tensile wires in use, or an end fitting jacket can abut against a terminal edge region1216of the ring element1204in a similar manner to how an end fitting jacket can abut against the jacket engaging surface region shown inFIGS.11a,11band11c.

Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to” and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of the features and/or steps are mutually exclusive. The invention is not restricted to any details of any foregoing embodiments. The invention extends to any novel one, or novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

While certain arrangements of the inventions have been described, these arrangements have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims.

Features, materials, characteristics, or groups described in conjunction with a particular aspect, arrangement, or example are to be understood to be applicable to any other aspect, arrangement or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing arrangements. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some arrangements, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the arrangement, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific arrangements disclosed above may be combined in different ways to form additional arrangements, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.

For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular arrangement. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain arrangements include, while other arrangements do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more arrangements or that one or more arrangements necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular arrangement.

Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain arrangements require the presence of at least one of X, at least one of Y, and at least one of Z.

Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may be used to refer to an amount that is within less than 10% of the stated amount. As another example, in certain arrangements, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15°, 10°, 5°, 3°, 1 degree, or 0.1 degree. The ranges disclosed herein also encompass any and all overlap, sub-ranges, and combinations thereof, and any specific values within those ranges. Language such as “up to,” “at least,” “greater than,” “less than,” “between,” and the like includes the number recited. Numbers and values used herein preceded by a term such as “about” or “approximately” include the recited numbers. For example, “approximately 7 mm” includes “7 mm” and numbers and ranges preceded by a term such as “about” or “approximately” should be interpreted as disclosing numbers and ranges with or without such a term in front of the number or value such that this application supports claiming the numbers, values and ranges disclosed in the specification and/or claims with or without the term such as “about” or “approximately” before such numbers, values or ranges such, for example, that “approximately two times to approximately five times” also includes the disclosure of the range of “two times to five times.” The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred arrangements in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.