Manufacturing Defects in Thermoplastic Composite Pipes and Their Effect on the in-situ Performance of Thermoplastic Composite Pipes in Oil and Gas Applications

Abstract

Thermoplastic composite pipes (TCP) are a form of fibre reinforced thermoplastic pipes that have proven benefits such as being lightweight and non-corrosive. However, during manufacturing, certain defects are induced because of certain parameters which eventually affect TCP performance in-service. Current manufacturing techniques are challenged with on-the-spot detection as the pipe is regularly monitored. When a defect is noticed, the process stops, and action is taken. However, stopping the process is costly; hence it is vital to decrease downtime during manufacturing. Potential solutions are through process optimisation for defect reduction and an in-depth understanding of the effect of parameters that cause defect formation in the pipe. This article provides an overview of manufacturing influence on the end performance. This is intimately linked to the material features, properties, and performance in-service. The material features are the determinants for the manufacturing technique to be used. For TCP, it is a melt fusion bonding process involving heating and consolidation among other factors such as the consolidation speed and pull force. Thermal behaviour is essential at this phase as it determines the curing rate and this study indicates that laser heating is the better heat source in efficiency terms. Defects such as fibre misalignments, voids, and delamination are induced during manufactuirng are explored. The sources of these defects have been discussed herein as well as the secondary defects caused by them with the consideration of residual stress impact. The presence of manufacturing defects has been identified to influence the strength and stiffness, interlaminar shear strength, toughness, and creep performance. In addition the study shows there is a need to explore the state of the art in defect characterization during manufacturing for TCP. The in-situ characterization aims to derive high-quality TCP with reduced defects and need for repairs, and increased production rate in safe and eco-friendly conditions while maintaining the current manufacturing process. Graphical abstract

Biopolymer Composite Materials in Oil and Gas Sector

“…The outer layer protects the pipe from external influences, and the liner contains the liquid transported through the pipe. The reinforcing layer can be attached to the liner, thus bonded, loose fit, or unbonded [86]. The tube consists of a thermoplastic liner, overwound with an epoxy-based structural thermosetting laminate.…”

Materiales, métodos y normativa para refuerzos de material compuesto en reparación de tuberías y equipos a presión

“…El supervisor capacitado debe observar todos los aspectos de la preparación in situ y la aplicación del material, incluida la preparación de superficies, la mezcla de componentes epoxi, la aplicación de imprimaciones, la aplicación de epoxis, la instalación de telas de fibra, el curado de compuestos y la aplicación de recubrimientos protectores, existen además herramientas de software, hojas de cálculo y aplicaciones web que ayudan a diseñar sistemas de reparación [35]. A manera de comprobación, se puede realizar una inspección visual, usar el golpeteo con un martillo o varilla de metal escuchando el eco para detectar vacíos y delaminaciones; asimismo, se pueden identificar discontinuidades en el refuerzo con el uso de un detector de holidays de alto voltaje, al igual que evaluar la adherencia del refuerzo en los extremos de la reparación (lejos del defecto que ha sido reforzado) [36].…”

Overcoming Challenges in the Powder Metallurgy Process of Metal Matrix Composites

“…These three main categories of composites provide a basis for classifying and understanding the different types of composite materials based on their reinforcement mechanisms and structural configurations. Each category has its unique advantages and applications, allowing for a wide range of possibilities in engineering materials with tailored properties [7].…”