AU626870B2

AU626870B2 - Flexible reinforced hose of an aluminium alloy

Info

Publication number: AU626870B2
Application number: AU35628/89A
Authority: AU
Inventors: Jose Mallen Herrero; Andre Sugier
Original assignee: IFP Energies Nouvelles IFPEN
Current assignee: IFP Energies Nouvelles IFPEN
Priority date: 1988-05-09
Filing date: 1989-05-02
Publication date: 1992-08-13
Anticipated expiration: 2009-05-02
Also published as: FR2631097A1; EP0372041A1; BR8906954A; DK4890A; NO900039L; CA1339726C; WO1989011057A1; DK4890D0; EP0372041B1; NO301733B1; AU3562889A; FR2631097B1; DK173346B1; NO900039D0

Description

35628 89 OPI DATE 29/11/89 AOJP DATE 04/01/90 APPLN. I D PCT NUMBER PCT/FR89/00214 Pcr

ORGAN!

DEMAND2E INTERNATIONALE PUBLIEE EN VERTU DU TRAITE DE COOPERATION EN MATIERE DE BREVETS (PCTI) (51) Classification internationale des brevets 4 Numiro de publication internationale: WO 89/ 11057 F16L 11/16 Al (43) Date de publication internationale: 16 novembre 1989 (16.11.89) (21) Numrnio de ]a demande internationale: PCT/FR89/00214 (74) Repr~sentant commun: INSTITUT FRANQAIS DU PE- TROLE; 4, avenue de Bois-Pr~au, F-92502 Ruei-Mal- (22) Date de d~p6t international: 2 mai 1989 (02.05.89) maison (FR).

Dounes relatives i ]a prioritk: (81) Etats d&signis: AT (brevet europ~en), AU, BE (brevet euro- 88/06242 9 mai 1988 (09.05.88) FR p~en), BR, CH (brevet europ~en), DE (brevet europ~en), DK, FR (brevet europ~en), GB (brevet europ~en), IT (brevet europ~en), JP, LU (brevet europ~en), NL (brevet (71) D~posant-, (pour tous les Etats d~sign~s sauf US): INSTITUT europ~en), NO, SE (brevet europ~en), US.

FRANQAIS DU PETROLE [FR/FR]; 4, avenue de Bois-Pr~au, F-92502 Ruell-Malmaison CO- FLEXIP [FR/FR]; 23, avenue de Neujilly, F-75 116 Paris Publi~e Avec rapport de reclherchze internationale.

Avant !'expiration du rklai pr~vu pour la ,nodijication des (72) inventeurs; et revendications, sera republi~e si de willes mnodifications sour Inventeurs/D~posapts (US seulement) SUGIER, Andr& repues.

[FR/FR]; 34, avenue de la Chataigneraie, F-92500 Rue il Malmaison MALLEN HERRERO, Jose [FR/FR]; 29, boulevard des Batignolles, F-75008 Paris (FR).

268 (54)Title: FLEXIBLEJ- AN ALUMINIUM ALLOY (54) Titre: TUBE FLEXIBLE COMPORTANT UN ALLIAGE D'ALUMINIUM (57) Abstract A flexible reinforced tube comprises one or more of the following components: a compressive strength reinforcement a tensile strength reinforcement and/or a carcass comprising a braced hoop. At least one of said components comprises an aluminium alloy of the 2000, 5000, 6000 or 7000 series.

(57) Abrege RA, a pr~sente invention concerne une conduite flexible arm~e comportant un ou plusieurs des composants suivants, une ar- Aur ritane 1 apression. une armure de resistance Ai la traction et/ou une carcasse comportant un feuillard Z '/W6 le se caracterise en ce qu'au momns I'un desdits composants comporte un alliage d'aluminium. des series 2000, 5000, 6000

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-1- FLEXIBLE REINFORCED HOSE OF AN ALUMINIUM ALLOY The present invention relates to a new type of construction of flexible reinforced hose, being relatively light in weight compared with those of prior art while retaining correct performances, especially of a mechanical nature.

The invention is applicable, in particular, to the fabrication of flexible hose for transport of liquids under pressure, such as water or hydrocarbons.

For numerous applications of such hose, it is frequently desirable and occasionally necessary to have available light flexible hose, especially for applications in the depths of the sea.

The flexible hose according to certain variants of embodiment in accordance with the present invention may be laid, especially, in the sea at great depths of the water.

Actually, one of the problems encountered during the laying of such hose at great depths, results from the weight of the suspended flexible hose.

The stresses in the flexible hose as the result of its 20 weight increase progressively as it approaches the surface of the water after leaving the bottom.

Thus, it is at the level of support of the flexible hose at the surface that the greatest stresses are encountered in the flexible hose.

One of the means for reducing this stress is to reduce the weight of the flexible hose while essentially retaining its mechanical strength, as proposed by the present invention.

According to the present invention there is provided a reinforced hose including at least one of a pressureresistance reinforcement, a tensile-strength reinforcement, '43

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-2and an inner carcass, wherein at least one of the pressureresistance reinforcement, the tensile-strength reinforcement and the inner carcass includes at least one elongated element and wherein said at least one elongated element has undergone a work hardening operation and is composed of an aluminium alloy.

It will be understood that, for preference, these elongated elements may be wound helically to form the flexible hose which may or may not have a plastics covering.

The present invention relates, in a general manner, to all flexible hose which have a metallic sheathing and are used in conditions such that the weight of this sheathing can create difficulties.

More specifically, the flexible hose under these conditions of use are limited by the density of the metallurgical material constituting the elements of the sheathing, generally steel, due to the fact that, if the cross-section of these elements is increased for the purpose of S" increasing the mechanical strength of the flexible hose, 20 this results in an increase in weight of the flexible hose and, consequently, an increase in the stresses applied to the flexible hose, as a function of which the dimensions of the elements constituting the sheathing are determined.

It is thus that an extremely interesting application for the invention is in relation to flexible hose intended for submarine petroleum production, at a medium or significant depth of water, which comprises, on the one hand, the hose which ensures the liaison between the submarine bottom and the surface (generally designated by the term "risers") and, on the other hand, the hose which should be laid on the bottom from the surface to ensure the liaison (over a distance which can vary considerably, depending upon the circumstances), for example, between a submarine well-head and the lower end of the "riser", or else a connecting j device ("manifold") between a plurality of ducts and which 3 constitutes the "footing" of the riser.

This type of hose is used to transport crude petroleum or the gas produced by submarine oil/gas wells at very high pressures (500 bar, for example), or to transport gas or water injected under pressure into the production site formation, or to forward the petroleum or the gas after preliminary treatment on the production platform onto land or into the collection vessels for further disposal (offshore loading stations, for example), or again to ensure the control functions at the submarine well-head (hydraulic or electrical lines known as "umbilicals").

In the actual present state of the art, all the known flexible hose which is utilised, or could be utilised, for the applications described in the foregoing for which the internal diameters can vary, for example, between approximately 1 inch (2.54 centimetres) and approximately inches (50.8 centimetres), and for the more current present-day applications, between 3 inches (7.62 :centimetres) and 10 inches (25.4 centimetres) or 12 inches S 20 (30.48 centimetres) are fabricated by starting with ooo sheathing elements exclusively of steel (carbon steels, stainless steels, steel alloys).

When the depth of the water in which the hose is to be laid "is relatively small, of the order of 100 metres to 200 or 300 metres (which corresponds, even today, to the cases most frequently met with under actual operating conditions), the depth of the water does not play an essential role as a parameter for the dimensions of the structure of the flexible hose, which is determined chiefly by the maximum value envisaged for the internal pressure in the flexible hose.

On the contrary, already at this time, certain submarine oil-fields are put into production at depths of water in the range between 500 and 800 metres, and the tendency to Soperate at even greater depths is evident, with various i T 0 -4 projects exceeding a depth of 1000 metres of water.

Now, in the present state of the art, the characteristics of the flexible hose sheathed in steel, which is the only one available in practice for the applications under consideration, are as follows: based upon a depth of water which may vary, depending upon the particular case, from 400 to 700 metres approximately, it is necessary to take special precautions, which have a significant influence on the costs, by reinforcing the metallic structure of the flexible hose and/or utilising special procedures and equipment for laying the hose at the site, the ultimate limit of the depth of water which can be reached with presently-known flexible hose is estimated to be of the order of 600 to 1000 metres, or at the maximum, slightly more than 1000 metres for diameters less than 6 inches, with the limit varying according to the particular case as a function of the diameter of the flexible hose, of the maximum operating pressure, 20 and of various other parameters which have an influence on the dimensions of the flexible hose such as the characteristics of the liquid transported, as well as the environmental conditions and also the conditions for the actual laying operation.

Thus, the need exists at the present time for a novel technical solution of the problem and this is becoming more and more important.

In a more general manner, the present invention finds application in those cases where the weight of the flexible hose actually available creates constraints in their utilisation. Thus, for example, in the case of highpressure flexible hose utilised at the working sites for f petroleum exploration, such as injection flexible hose (rotary hose), control lines for the well (kill line, choke i line), putting them into operation and their manipulation would be facilitated if lighter flexible hose were available.

The present invention could find another interesting application for floating flexible hose which is utilised, particularly, in loading and unloading plants at sea for connecting a buoy anchored offshore to a tanker moored to the buoy. The decrease in weight of the structure resulting from the use of aluminium allows for substantial reduction of the dimensions of the buoy or other floating members which have to be attached to the flexible hose to keep them afloat and which have several disadvantages (cost, bulkiness, displacement by sea currents and winds).

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The invention which allows for the implementation of flexible hose with great mechanical strength and light weight may also find application in aeronautics space engineering.

The utilisation of aluminium instead of steel under conditions where th' invention is applicable is, furthermor:e, very advantageous for many different special applications, for example for realisation of frameworks of "binding strips" applied in certain cases for mechanical protection to the outside of the flexible hose by winding the binding strip around the external plastic sheathing.

In addition, in certain cases, the replacement of steel (whatever the type of steel envisaged) by an aluminium alloy can provide interesting advantages. Thus, for example, the interior carcase with which some flexible hose are furnished, especially those intended for the transport of crude petroleum from deposits ("rough bore flexible hose) which are subject to corrosion by the liquid transported can, in certain cases, provide economical benefits when compared with the cost of stainless steel which would otherwise be necessary.

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-6- Furthermore, the utilisation of aluminium could prove interesting in certain cases where there exists the risk of pollution of the liquid transported by the material forming the internal wall of the flexible hose, which excludes the use of steel (or, at least, carbon steel, apart from stainless steel which could probably be utilised, but would be very much more costly), thus, for example, in the case of aqueducts or hose for transporting certain chemical products.

Other situations could also occur where certain properties of aluminium provide an advantage when compared with steel and thus create a possible interesting application of the invention, for example because of the non-magnetic property of aluminium.

The flexible hose in accordance with the present invention may be employed in certain overhead installations, such as, for example, overhead lines for transport of liquids, e especially in cold regions and for the transport of cold liquids. Actually, they possess good resistance to i 20 mechanical shock at low temperatures, whereas currently used steels fracture because of loss of resilience at low temperatures close to -20 0

C.

For this type of application, the flexible hose in accord- 2. "ance with the present invention can consist of aluminium 25 for all the components (carcase, reinforcement, armouring sheath) or only for those exposed to temperatures close to, less than, -20 0

C.

In summary, the invention can find application in all those cases where, on the one hand, aluminium possesses advantages when compared with steel (light-weight, resistance to corrosion) and, on the other hand, the relatively great mechanical demands made upon the flexible hose (internal pressure, external pressure, effect of crushing, axial thrust load. necessitate the 3,4 "1 5 employment of an armouring sheath for the product (drawn

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7 wires, filaments, cables, strips) offering high mechanical resistance compared with those obtainable when steel is used.

It is a matter of realisation of flexible hose which are lighter in weight than those currently available, of which the armouring sheath consists of steel elements and, equally, it is a matter of realisation of flexible hose with materials capable of resisting certain particular effects, for which various solutions have already been proposed.

Thus, for example, certain techniques have been developed by the present applicants which allow for realisation of the armouring filaments for the flexible hose in a composite material consisting of fibres embedded in a plastic resin (FR-2.283.768, FR-2.312.356 and EP-263.860).

The utilisation of composite organic material allows for further lightening of the structure of the flexible hose and, in particular in the case if applications in deep seas referred to previously, it makes possible the exploitation 20 of submarine oil fields at great depths of water. However, these composite materials with an organic matrix are relatively expensive and, by comparison, aluminium is much j more economical.

It has been established that the utilisation of alloys in application of the invention, in the case of applications S- to hose for use in submarine petroleum production described i previously, will allow for realisation of installations in depths of water which may reach and exceed 1500 metres, so that aluminium may be envisaged for use in the applications referred to previously, a very important development beyond that permitted by the use of steel, by accepting the fact that certain cases require performances even more stressresistant than those covered by the utilisation of 1 composite materials.

"ZY O /y NT 8 For satisfying the requirements existing in the domain of light-weight flexible hose, the previous practice did not allow for the utilisation of aluminium. Actually the dimensions of such flexible hose led to cumbersome products and a deterioration of mechanical performance, so that the gains from lighter weight were annulled.

The present invention proposes selection and treatment of the aluminium and a structure of the flexible hose which allows for substantial decrease in weight of the flexible hose by bringing together of utilisable products and perfection of their performance.

The invention relates more particularly to the various elements of the metallic armouring sheath of the flexible hose which can be utilised in the applications previously described.

In terms of the invention, the use of an aluminium alloy may be especially realised under any one or nther, and no :matter what the combination, of the conditions which o: characterise the invention, for the elements of the oe S 20 armouring sheath of the flexible hose, as follows: 1 The filaments comprising said armouring sheath with tensile resistance and to the effects of depth of water (this sheath likewise be able to absorb all or part of circumferential pressure as a function of the angle of the reinforcement winding which may vary, in the limit, between a few degrees and approximately 80 degrees, but which is, in general, between 10 and approximately 65 degrees.

These filaments have a cross-section which may be circular, or possibly elliptical, or (very currently) rectangular with, preferentially, rounded corners (the filaments being, in accordance with the present invention, made from ani aluminium alloy IVT0

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9 2 The elements constituting the so reinforcing sheath resistant to traction and to the effects of depth of water, realised in the form of strands or cables, are themselves fabricated by helicoidal winding (cabling) of the filaments made, in accordance with the present invention, of aluminium. In the case of utilisation of strands or cables as armouring elements, it is current practice to dispose them inside a compact mass of elastomeric material, 3 The filaments, or "profiles" constituting the "pressure reinforcing" of which the function is to resist the effects of internal pressure, as well as the effects of crushing (in particular those related to the operations of laying the flexible hose in the case of submarine work) and the effects of external pressure. These profiles are, currently, realised in the form of filaments with rectangular cross-section, preferably with rounded corners.

0* 0 They are currently realised in the form of a layer or of two layers of profiles with a cross-section showing notches and projecting portions in such a manner as to produce a 20 mutual hooking effect, sometimes designated as "binding", such that: i one layer of one or several filaments with a Z crosssection, for example the profile currently designated by the name "Zeta" (see, for example, the description of a 25 profile of this genus in the French Patent FR-2.052.057 of Chiers-TCBH), two layers of filaments with a U cross-section, the shanks of the interior U being directed towards the exterior in such a manner that they are intercalated with the shanks of the U, directed towards the interior, of the external layer, and other possible designs. 1 d 'N t J l.

10 It should be noted that the "pressure armouring" can be realised by a combination of a plurality layers of one or other of the types described in the foregoing.

The profiles or filaments constituting the "pressure armouring" are wound around following angles of approximately 80 to 90 degrees with respect to the axis of the flexible hose.

4 The elements constituting the external carcase of the flexible hose and comprising structures realised by lapping of a continuous strip or structures constituted by binding or interlocking filaments similar to those described for the "pressure armouring" (Figs. 3 and the lapping being effected in such a fashion as to exploit, amongst other things, the arms of the shapes of the strips to allow for the binding of the adjacent spirals.

The lapping may be achieved with the use of very varied designs. o.

A very well-known form is described in the French Patent S: Application EN-83/19.474 (Binding strip) which describes a S 20 method of realisation of a flexible tube made from binding i3 strips applicable to the flexible hose in accordance with the present invention. These "binding strips"are currently used as the internal carcase of the flexible hose, in H particular in the case of transport of crude petroleum from S" 25 deposits, to avoid the "implosion" of the internal plastics sheath. p 4* 0 6 They can equally well be used as pressure-resistant reinforcement, when they are wound around the interior leak-proof sheath.

These structures of binding strips or binding or interlocking filaments may also be utilised as protection for the exterior of the flexible hose. i S The element constituting the carcase may equally well i* 0 11 consist of binding or interlocking filaments, such as filaments with a Z cross-section, especially "Zeta" filaments.

Thus, the present invention relates to an reinforced flexible hose comprising one or several of the following components: a pressure-resisting reinforcement, a tensileresistant reinforced and/or an internal carcase.

It is characterised in that at least one of said components comprises one or several elongated elements such as a profile, a cable, a filament or strip, said element having undergone a working operation such as drawings, rolling or hammering and consisting of an aluminium-based alloy.

The aluminium alloy may be one of the series 2000, 5000, 6000 or 7000.

When the flexible hose in accordance with the present i invention includes a pressure-resistant armouring and/or a 9 tensile-resistant armouring, one at least of said armourings should comprise at least one elongated element of an aluminium alloy of one of the series 2000, 5000, 6000 w or 7000 and, for preference in one of the following grades: 2014, 2017, 2024, 2117, 2618, 5050, 5052, 5056, 5082, 5086, 5154, 5183, 5754, 6005, 6060, 6061, 603, 6066, 6070, 6082, ;p 6351, 7001, 7020, 7049, 7050, 7075, 7175, 7178 or 7475. The elongated aluminium alloy should have a resistance to 25 rupture under tensile (Rm) at least equal to 300 Mpa and, for preference, at least equal to 350 MPa.

When the flexible hose in accordance with the present invention includes an internal carcase, this should comprise at least one elongated element comprising of an aluminium alloy of one of the series: 1000, 2000, 3000, 4000, 5000, 6000, 7000 and, for preference in one of the following grades: 1100, 1180, 3103, 5050, 5052, 5056, 5083, T 5456, 6060, 6061, 6082, 6083 or 6106.

c i* I 12 When the flexible hose in accordance with the present invention includes an internal carcase, this should comprise at least one elongated element comprising an aluminium alloy having a resistance to rupture under traction (Rm) at least equal to 200 MPa and, for preference, at least equal to 250 MPa and an elastic limit at 0.2% Re 02 at least equal to 150 MPa and, for preference, at least equal to 190 MPa.

When the flexible hose in accordance with the present invention includes an internal carcase containing at least one elongated element comprising of an aluminium alloy, this elongated element should be a profile or a binding or interlocking filament, especially of the "Zeta" type of 'Z' cross section.

The aluminium alloy utilised in accordance with the present invention should be subjected to a dissolution heat treatment.

The elongated element comprising of aluminium alloy in accordance with the present invention should have undergone S 20 a work hardening operation as the final treatment precede and/or followed by tempering.

This work hardening should be a cold hardening having a rate of 3% at least in the case of utilisation of an i aluminium alloy of the series 2000, 6000, 7000, or a rate 25 of 20% at least in the case of utilisation of an aluminium :alloy of the series 5000.

This work hardening should, for preference, be a cold hardening having a rate between 3% and 40% and preferably between 5% and 25% in the case of utilisation of an aluminium alloy of the series 2000, 6000 or 7000.

This work-hardening could equally-well be a cold hardening having a rate between 20% and 90% and, for preference, S between 40% and 70% in the case of utilisation of an 13 aluminium alloy of the series 5000.

The elongated element of aluminium alloy in accordance with the present invention should have been subjected to rolling or stretching.

This elongated element should have been subjected to a partial or total tempering or to a hardening and tempering of which the characteristic parameters are a function of said rate of hardening and/or of the nature of the alloy.

The component comprising aluminium in accordance with the present invention may be coated with an alloy which protects it against corrosion.

The component comprising aluminium in accordance with the present invention may be coated with a thermoplastic film, especially a polyethylene, a polyamide, a polyvinylidene fluoride or a polypropylene, or an elastomer or a rubber.

The component consisting essentially of aluminium may have a ductility at least equal to 3%.

One at least of the components may comprise aluminium of the series 2000 or 7000 having a ductility between 6% and I 20%, for preference between 10% and 20%. i One at least of the components may comprise of aluminium of the series 5000 or 6000 having a ductility at least equal ."to 6%.

The flexible hose in accordance with the present invention should include a carcase, a sheath and reinforcement, said

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carcase comprising a binding strip or a binding filament, especially of the "Zeta" type, and said armouring includes an element which is a profile, a cable or a filament.

l This binding strip or filament of the carcase may comprise 3 an aluminium alloy of the series 2000, 3000, 4000, 5000, T OLI _g

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14 6000 or 7000, and/or said elongated element of said armouring may comprise an aluminium alloy of the series 2000, 5000, 6000 or 7000.

The carcase may be constituted of a steel binding strip or filament.

The armouring may comprise steel.

The tensile-resistant armouring may comprise essentially of steel and said spiral winding may comprise essentially of an aluminium alloy.

The flexible hose in accordance with the present invention may include an anti-friction sheath which should, for preference, be leak-proof and electrically insulating, this sheath being disposed between the vault and the tractionresistant armouring.

The flexible hose in accordance with the present invention may include a tensile-resistant reinforcement comprising at least two layers of filaments, cables or profiles and, in 2 additi. there should be a layer or sleeve of antifriction material intercalated at least between said two S 20 layers.

The tensile-resistant reinforcement and said spiral winding may consist essentially of an aluminium alloy of the series 2000, 5000, 6000 or 7000.

The flexible hose in accordance with the present invention may include an external strip or external binding filaments, consisting optionally of aluminium.

a The flexible hose in accordance with the present invention may include at least one internal sheath comprising plastics material, such as a polyamide, a polyvinylidene fluoride, or an elastic material such as rubber or a Ssynthetic elastomer.

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1 ~-Nr 0 44 The flexible hose in accordance with the present invention may include a pressure-resistant reinforcement containing at least one layer formed from a profile optionally having a cross-section of interlocking shape, such as a or a fabricated from an aluminium alloy of the series 2000, 5000, 6000 or 7000.

The flexible hose in accordance with the present invention may include a composite material with an organic matrix, especially for constitution of an elongated element.

The terms utilised for designation of the metallurgical states and the thermal and mechanical treatments of the aluminium alloys are defined in the Standards NF 02 006 and NF 02 011.

These are, in particular: state F primary state of fabrication, r state O state H softened, state T tempered, work-hardened and optionally partially hardened state by heat treatment heat treatment considered as a combination of all or part of the following treatments immersion, tempering, maturation, drawing tempering with optional application of plastic deformations.

0 It will be understood that, in the present invention, the elongated elements, for which it is proposed touse an aluminium alloy, generally have a mechanical function.

Sometimes they could have a supplementary function, due to the fact of their anti-corrosion characteristics.

The earliest realisations of prototypes have confirmed that the fabrication of flexible hose containing aluminium i? 16 structural elements can be effected without any particular difficulty when compared with known flexible hose with steel armouring. In particular, we have found that, in the case of solid profiles of relatively complex cross-section, of the "shaped filament" type such as "Zeta" filaments, the fabrication, as envisaged in principle by the present invention, of such profiles in aluminium is much simpler and less costly than is the case with carbon steels currently used in flexible hose for high-performance.

It has also been confirmed that the utilisation of aluminium allows for the fabrication, without difficulty, of profiled filaments, including profiles of the "Zeta" type, which have larger dimensions than those which are possible when working with steel. This is due, in particular, to the fact that the filaments and profiles in steel are prepared by starting with "wire rods" of which the diameter is limited to approximately 20 millimetres by the actual state of the equipment and methods of fabrication employed by the various suppliers.

20 Under these conditions, the production of "Zeta" filaments, for example, is limited to a maximum thickness of approximately 10 millimetres in the case of steel. As .opposed to this, in the case of aluminium, limitative measurements do not exist, due to the fact that the ranges .effectively, that the "Zeta" filaments may be produced without difficulty in thicknesses which may be as great as 160 or 200 millimetres. i The advantage gained from the possibility of fabricating S 30 very thick aluminium profiles is, in particular, that it allows for the realisation of pressure-resistant reinforcement with only a single layer of very thick "Zeta" filaments in the case where the internal pressure is high and the diameter relatively large and the thickness required exceeds that obtainable with steel. This makes it S obligatory to produce the pressure-resistant armouring in Li 22 _v 17 steel by the superposition of two layers of filaments (for example, an inner layer of "Zeta" filaments and an outer layer of rectangular band filaments) with a substantial increase in the cost of fabrication. This can be avoided by using aluminium.

Furthermore, the possibility of obtaining very thick "Zeta" filaments, thanks to aluminium, presents in certain cases the advantage of being able to roll-up the flexible hose on a very small radius without the risk of disruption.

The present invention will be better understood and its advantages will be more clearly apparent from the following description of non-limitative examples illustrated in the accompanying drawings, in which: Fig. 1 depicts the structure of a flexible hose comprising an internal carcase of binding strips or of binding- or interlocking-filaments i, a leak-proof sheath 2, a layer of binding or interlocking filaments 3, an internal sheath 4, armourings 5, a ribbon 6 and an external sheath 7, e.

S. Fig. 2 is a section through a strip of folded linkages, and Fig. 3 and Fig. 4 depict a section through interlocking and overlapping profiles respectively which could equally-well be designated interlocking or overlapping filaments.

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S ao :The examples No. 1 to No. 13 relate to a flexible hose realised with the configuration represented in Fig.l, that is to say, it comprises successive layers, namely an interlocked internal carcase 1 which can be interlocked folded strips or interlocked or overlapped filaments, intended to avoid crushing of the tube when an external force, which can be distributed or localised, is applied to the hose the expression used by technical personnel is "in order to avoid collapse" a sheath 2 of nylon ("Rilsan"), a layer of interlocked "Zeta" filaments or 1 overlapped profiles (Figs. 3 and an internal sheath 4

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1k 18 of nylon, reinforcement 5 wound at 35 degrees in relation to the axis of the flexible hose, a ribbon 6 followed by an external sheath 7 of nylon.

The sheath may, or may not, be leak-proof.

The mechanical characteristics are expressed as maximum resistance to traction Rm in MPa, as elastic limit at 0.2% elongation Re in MPa, and elongation on 50 mm

A%.

In the Tables given in the examples, there are the following successive columns: SNumbering of the layers Description, nature and dimension (in millimetres) of layers, Rm in MPa, kg/m weight in kilograms per metre of flexible hose, SD.i. internal diameter in millimetres, STh. thickness of layer in millimetres, SThe floatability factor is defined by: weight in air when empty (kg/m) external volume x 1.02 (density of sea water) The limiting axial load of damage referred to in the tables under the rubric "limit of damage in tension" is defined for the theoretical case of a linear flexible hose subjected to an axial tensile force.

The "theoretical depth of laying" referred to in the Tables is a limit determined here as equal to the quotient of the 4

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19 "limit of damage in tension" divided by the linear weight of the flexible hose full of water when suspended in water.

Since the flexible hose is normally laid full of water, this value corresponds to the length of hose suspended below the surface, so that the total apparent weight of the flexible hose will be equal to the theoretical axial load corresponding to the limit of damage of the flexible hose assumed to be linear. This theoretical value allows for the determination of the order of magnitude of the limit of depth of water which is acceptable in actual practice by taking in account: an adequate safety coefficient. Under actual conditions of the technology and, in particular, as a function of the different regulations applicable, this safety coefficient is currently taken to have a value of 2, various factors during the laying operations which have the effect of increasing the stresses in the component elements of the structure of the flexible hose compared with a linear hose subjected to a simple axial load.

20 These overload factors can be divided into two categories: the manipulation of the flexible hose below the surface brings about an increase in the stresses in the I vicinity of the flexible hose where it is held by the laying equipment which may be of several different 25 types: winches (utilisation limited in the case of heavy loads associated with great depths of water), capstans, caterpillar-track tensioning devices (two-or three-track), or all types of linear hoists associated with a system of securing the flexible hose to absorb the axial load, and likewise, in general, one zone (or simply a fixed support in the form of a curved gutter) to ensure the passage of the flexible hose over its top edge, :NT (0 the dynamic forces determined by the movements of a floating support utilised for the laying as a function of the conditions of the sea, the envisaged limits being capable of being expressed in terms of the vertical acceleration in the form of a coefficient of apparent increase in weight.

Thus, as already stated, the order of magnitude of the maximum admissible depth of water for the laying as a function of the limit of damage under the influence of the weight of the flexible hose may be evaluated, by way of a summary estimation, by starting with the "theoretical depth of laying" referred to in the Tables, by dividing this latter by a global reduction coefficient which takes into account both the safety coefficient and the overloading factors connected with the laying operations which may vary from single to double, depending upon the circumstances (manoeuvring the flexible hose with the laying equipment and vertical acceleration of the floating support). In practice, the global reduction coefficient of the 20 admissible load thus defined may vary from slightly more .than 2 in the most favourable case up to a maximum which may exceed 4.

In order to interpret, in a simple and concrete fashion, S* the theoretical reference values appearing in the Tables, 25 the average value of 3 should be adopted for the C9 coefficient, which allows for comparison of respective 9e performances of the different flexible hose referred to in the examples, even though the depth limit of the water thus determined does not have, for each of the flexible hose, anything other than a very approximate significance in terms of absolute values. However this may be, the theoretical figures given in the Tables do allow for a comparison of the different examples amongst themselves.

The "collapse pressure" referred to in the Tables ,,74 35 corresponds to the limit of resistance to crushing of the flexible hose under the influence of the external tv T I V ~NT_ 21hydrostatic pressure, determined by the depth of the water.

Owing to the fact that the structure is calculated on the basis of the hypothesis that the annular space may find itself subjected to the external pressure (by accidental piercing of the external sheath, for example), this value is conditioned by the resistance to crushing of the internal carcase in the case of the "rough bore" type of flexible hose which are described here as examples.

The acceptable maximum depth of the water for a flexible hose may be determined directly, from the point of view of its resistance to external pressure, by applying to the "collapse pressure" translated into depth of water (pressure of the hydrostatic column as a function of the density of the sea water), a safety coefficient of which corresponds to the regulations which are actually applicable.

The evaluation of the maximum depth of water is acceptable for a flexible hose such as that described in the examples.

*6 0 0 0 The summary method of evaluation referred to, at the level of relative values, allows the estimation of the order of magnitude of the respective performances of the various flexible hose being compared, it being understood that the absolute value of the acceptable depth for each one of them may vary considerably as a function of the circumstances.

25 The mechanical properties indicated for the structural elements of the flexible hose described in the examples are relative to the state in which said structural elements in aluminium are found, once the last of the successive

S•

°operations of the specified thermal and/or mechanical treatments for each example have been completed, that is to say, at the moment where they are about to be rolled up on a bobbin, ready to be installed on the machine utilised for the fabrication of the flexible hose.

i; Due to the fact that the various metallic reinforcement

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22 elements of the flexible hose envisaged by the invention are, in general, placed in position on the flexible hose in such a manner that they assume a helicoidal configuration imposed by the geometry of the flexible hose and the angle of winding of the armouring without having to be subjected to appreciable residual stresses, that is to say, they are placed in position and wound around by plastic, and not elastic, deformation, these elements should be subsequently subjected to a complementary cold-forming operation. This relates equally well to the case of strips which are formed by folding in spiral profiling tools (see, for example, FR- 2.555.920) as is the cnse, for example, in the preformation operations of the reinforcing filaments described in FR-2.258.733. The crushing of the metal implicates this latter operation of cold deformation for modifying the mechanical properties such as referred to in the examples.

There results from this, in particular, an increase in the elastic limit which may, in certain cases, not be negligible, principally when the element in aluminium being 20 loaded into the fabrication machine for the flexible hose is in the tempered state. The practical consequence of this situation is that the values characterising the mechanical resistance of the flexible hose are at a minimum, while the real values, in certain cases, may be more or less greater S 25 than the values referred to here in the examples.

Example 1 relates to an optimised flexible hose which does not contain aluminium.

Example No. 1 A flexible hose is fabricated with an internal diameter of 8 inches (203.2 millimetres) consisting of an internal carcase constituted of strips of stainless steel AISA 304 of 2 millimetres thickness having Rm 540 MPA and Re= 450 MPa, of an inner nylon sheath 6 millimetres in thickness, a layer of zeta interlocking filaments 6.2 millimetres in thickness made from FM 15 steel having the characteristics: Rm 780 MPa, A two layers of reinforeced wound at

NI'

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i 23 an angle of 35 degrees made from FM 15 steel, an outer nylon sheath 7 millimetres in thickness.

This flexible hose, constituted in this manner, possesses the following characteristics: Description 1 Carcase in stainless steel 304 strips 80 x 2 mm 2 Nylon internal sheath 3 "Zeta" FM 15 steel 4 Nylon inner sheath Armourings at 350 FM steel 2.5 mm thick 6 Ribbon 7 Nylon outer sheath Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth Rm MPa kg/m D.i. mm Th.mm 31 4.9 31.2 5 203.2 223.2 233.2 247.6 10.0 6.2 0.75 30.0 259.6 0.5 269.6 6.4 271.1 Imperial 8.00 11.22 0.379 0.687 73.2 97.4 29.2 53.4 units in in cf/ft cf/ft lb/ft lb/ft lb/ft Ib/ft r o c Metric units 203.20 mm 285.10 mm 35.18 1/m 63.84 1/m 108.9 kg/m 144.9 kg/m 43.4 kg/m 79.5 kg/m 1.66 369 bars 108 bars 170,250 dan 2.141 m 5350 psi 1570 psi 382,685 Ibs As already stated, this flexible hose is optimised in its design and materials utilised.

Example No. 2 A flexible hose is fabricated similar to that in Example No. 1, but in layer No. 3 the FM 15 steel "Zeta" interlocking filaments 6.2 mm in thickness are replaced by aluminium alloy 7049 "Zeta" interlocking filaments 8 millimetres in thickness in state T6 of mechanical 24 characteristics Rm 620 MPa, A The flexible hose obtained possesses the following characteristics: Description 1 Carcase in stainless steel 304 strips 80 x 2 mm 2 Nylon internal sheath 3 "Zeta" aluminium 4 Nylon inner sheath 5 Armourings at 350 FM steel 2.5 mm thick 6 Ribbon 7 Nylon outer sheath Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth Rm MPa kg/m D.i. mm Th.mm 31 4.9 14.3 5 30.5 0.5 6.4 203.2 223.2 235.2 251.2 263.2 273.2 274.7 10.0 0.75 Imperial units 8.00 in 11.37 in 0.379 cf/ft 0.705 cf/ft 62.3 lb/ft 86.5 lb/ft 17.2 lb/ft 41.4 lb/ft 5386 psi 1570 psi 388,638 lbs Metric units 203.20 mm 288.70 mm 35.18 1/m 65.46 1/m 92.6 kg/m 128.7 kg/m 25.5 kg/m 61.6 kg/m 1.38 371 bars 108 bars 172,898 daN 2806 m It was confirmed that this has performances equivalent to those of the all-steel flexible hose described in Example No. 1. A decrease in weight of 22.5% of the flexible hose full of sea water in sea water has been achieved and that the theoretical laying depth has increased from 2141 metres to 2868 metres.

A flexible hose with approximately equivalent mechanical characteristics may be obtained by replacing the 7049 aluminium alloy in state T6 with a 7178 aluminium alloy in state T6 or preferably in state T76 (double tempering treatment for 3 hours at 116-127 0 C and for 15 hours at 157-

I

'i i: i 25 160°C) which improves its corrosion resistance under tension, by a 7075 aluminium alloy in state T6 or a 7001 aluminium alloy in state T73 (double tempering treatment), a 7175 aluminium alloy in state T66, or a 7475 aluminium alloy in state T6.

Example No. 3 A flexible hose is fabricated similar to that in Example No. 1, but in layer No. 3 the FM 15 steel "Zeta" interlocking filaments 6.2 mm in thickness are replaced by aluminium alloy 2017A "Zeta" interlocking filaments millimetres in thickness in state T3, having undergone work-hardening before tempering, of mechanical characteristics Rm 500 MPa, A 9%.

The flexible hose obtained under these conditions possesses the following characteristics: Description 1 Carcase in stainless steel 304 strips 80 x 2 mm 2 Nylon internal sheath 3 "Zeta" aluminium 4 Nylon inner sheath 5 Reinforcements at 35° FM steel 2.5 mm thick 6 Ribbon 7 Nylon outer sheath Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth Rm MPa kg/m D.i. mm Th. mm 31 4.9 17.4 5.1 203.2 223.2 235.2 255.2 10.0 10.0 780 31.0 0.5 6.5 Imperial units 8.00 in 11.52 in 0.379 cf/ft 0.724 cf/ft 64.8 Ib/ft 89.0 lb/ft 18.4 lb/ft 42.6 lb/ft 5398 psi 1570 psi 392,805 Ibs 267.2 277.2 0.75 278.7 Metric units 203.20 mm 292.70 mm 35.18 1/m 67.29 1/m 96.3 kg/m 132.4 kg/m 27.4 kg/m 63.4 kg/m 1.40 372 bars 108 bars 174,752 daN 2756 m a S26 It was confirmed that for identical characteristics of bursting pressure and collapse pressure, a flexible hose has been obtained with a decrease in weight of 20.2% of the flexible hose full of s a water in sea water compared with the all steel flexible nose of Example No. 1 and that the theoretical laying depth has decreased from 2756 metres to 2140 metres.

A flexible hose with approximately equivalent mechanical characteristics may be obtained by using 2017A aluminium alloy in state T4 following a final work-hardening of or by using the alloys 2014, 2024 and 2618 in the same states as the 2017A.

A flexible hose with identical characteristics may be obtained by using certain aluminium alloys of the series 700, namely 7075, 7050, preferably in the states T73 or T76, providing a good resistance to corrosion, followed, or not, by a final work-hardening from 5% to 20% (state T73X).

Example No. 4 A flexible hose is fabricated similar to that in Example 20 No. 1, but in layer No. 3 the FM 15 steel "Zeta" Sinterlocking filaments 6.2 mm in thickness are replaced by 6061 aluminium alloy "Zeta" interlocking filaments 12 millimetres in thickness in state T3, of mechanical characteristics Rm 410 MPa, A The flexible hose obtained under these conditions possesses the following characteristics: Description Rm MPa kg/m D.i. mm Th. mm 1 Carcase in stainless steel 304 strips 80 x 2 mm 540 31.0 203.2 10.0 2 Nylon internal sheath 4.9 223.2 3 "Zeta" aluminium 500 20.8 235.2 12.0 4 Nylon inner sheath 5.2 259.2 Reincements at 350 FM steel 2.5 mm thick 780 31.3 271.2

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27 Ribbon Nylon outer sheath 281.2 282.7 0.75 Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Bursting pressure collapse pressure Damage limit in traction Theoretical laying depth Imperial units 8.00 in 11.68 in 0.379 cf/ft 0.744 cf/ft 67.2 lb/ft 91.4 lb/ft 19.6 lb/ft 43.8 lb/ft 5386 psi 1570 psi 412,147 lbs Metric units 203.20 mm 296.70 mm 35.18 1/rn 69.14 1/rn 100.0 kg/rn 136.1 kg/rn 29.2 kg/rn 65.2 kg/rn 371 bars 108 bars 183,357 daN 2812 m :0 0 0 It was confirmed that for equivalent performances of bursting pressure and collapse pressure, a flexible hose has been obtained with a decrease in weight of 18% of the flexible hose full of sea water in sea water and that the theoretical laying depth is 2812 metres.

A flexible hose with equivalent mechanical characteristics and weight may be obtained by replacing the 6061 alloy which may be used in state T8 or in state T6 or T9 by an alloy of the 6000 series, namely the alloys 6063, 6082 used in the same states as the 6061 alloy.

A flexible hose with equivalent mechanical characteristics may be obtained with alloys of the 5000 series, especially the 5056 alloy in state H3X, that is to say, having undergone a tempering for desensitisation to corrosion at 230-240 0 C followed by work-hardening, or in state Hi and the 5082 alloy in state Hi.

Example No. A flexible hose is fabricated similar to that in Example No. 1, but the layer of FM 15 steel "Zeta" interlocking filaments 6.2 mm in thickness is replaced by a layer 5082 Saluminium alloy "Zeta" interlocking filaments 14 milli- 12 "s 28 metres in thickness in state HI, of which the mechanical characteristics are the following: Rm 350 MPa, A 13%.

The flexible hose obtained under these conditions possesses the following characteristics: Description 1 Carcase in stainless steel 304 strips 80 x 2 mm 2 Nylon internal sheath 3 "Zeta" aluminium 4 Nylon inner sheath Reinforcements at 350 FM steel 2.5 mm thick 6 Ribbon 7 Nylon outer sheath Characteristics Internal diameter External diameter Internal volume External volume 20 Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Bursting pressure 25 Collapse pressure Damage limit in traction Theoretical laying depth Rm MPa kg/m D.i. mm Th. mm 31.0 4.9 24.4 5.3 31.9 0.5 6.7 203.2 223.2 235.2 263.2 275.2 285.2 286.7 10.0 14.0 0.75 Imperial units 8.00 in 11.84 in 0.379 cf/ft 0.764 cf/ft 70.3 lb/ft 94.6 lb/ft 21.5 lb/ft 45.7 Ib/ft 5386 psi 1570 psi 419,965 Ibs Metric units 203.20 mm 300.70 mm 35.18 1/m 71.02 1/m 104.7 kg/m 140.8 kg/m 32.0 kg/m 68.0 kg/m 371 bars 108 bars 186,835 daN 2747 m It was confirmed that by using an aluminium alloy "Zeta" filament 14 millimetres in thickness a flexible hose has been obtained with a decrease in weight of 14.5% of the flexible hose full of sea water in sea water compared with the flexible hose of Example No. 1 and the theoretical laying depth is 2747 metres.

A flexible hose with identical mechanical characteristics and weight may be obtained by replacing the 5082 alloy by the alloys 5086, 5154, 5754, 5052 in state HI or by the alloys 6005A, 6081, 6181, 6351, 6060, 6066, 6070 in state HI, T4 or T6 or T8 or T9, the 7020 alloy in state T6.

v- _e -j i i i"l_ 29 A flexible hose with equivalent mechanical characteristics may be obtained with alloys of the 5000 series, especially the 5056 alloy in state H3X, that is to say, having undergone a tempering for desensitisation to corrosion at 230-240 0 C followed by work-hardening, or in state H1 and the 5082 alloy in state H1.

Example No. 6 A flexible hose is fabricated similar to that in Example No. 1, but in layer No. 3 the FM 15 steel "Zeta" interlocking filaments 6.2 mm in thickness are replaced by 5052 aluminium alloy "Zeta" interlocking filaments 16 millimetres in thickness in state H1, the final workhardening being 45%, with mechanical characteristics Rm 310 MPa, A 9%.

The flexible hose obtained under these conditions possesses the following characteristics:

B

B.

B

B.

B B B

B

Description 1 Carcase in stainless steel 304 strips 80 x 2 mm 2 Nylon internal sheath 3 "Zeta" aluminium 4 Nylon inner sheath 5 Reinforcements at 350 FM steel 2.5 mm thick 25 6 Ribbon 7 Nylon outer sheath Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Rm MPa kg/m D.i. mm Th. mm 31.0 4.9 28.4 5.4 32.3 0.5 6.8 203.2 223.2 235.2 267.6 279.2 289.2 290.7 10.0 16.0 0.75 Imperial units 8.00 in 12.00 in 0.379 cf/ft 0.785 cf/ft 73.3 lb/ft 97.6 lb/ft 23.1 lb/ft 47.4 Ib/ft 5386 psi Metric units 203.20 mm 304.70 mm 35.18 1/m 72.92 1/m 109.2 kg/m 145.2 kg/m 34.4 kg/m 70.5 kg/m 1.46 371 bars i:

I

j i i 30 Collapse pressure Damage limit in traction Theoretical laying depth 1570 psi 423,475 lbs 108 bars 188,397 daN 2672 m It was confirmed that for identical characteristics of bursting pressure and collapse pressure, a flexible hose has been obtained with a decrease in weight of 11.3% of the flexible hose full of sea water in sea water and that the theoretical laying depth is 2672 metres.

A flexible hose with approximately equivalent mechanical characteristics may be obtained by replacing the 5052 alloy by the alloys 2017, 2117, 5050, 5154, 5754 in state H1, the alloys 5056, 5082, 5086 and 5183 in state F or H.

Example No. 7 A flexible hose is fabricated similar to that in Example No. 1, but in layer No. 1 the internal carcase of AISI 304 stainless steel strips 2 mm in thickness is replaced by 5052 aluminium alloy strips 3.5 millimetres in thickness in state H1, with mechanical characteristics Rm 320 MPa and Re 290 MPa.

The flexible hose obtained under these conditions possesses the following characteristics: a a a a Description 1 Carcase in aluminium strips 140 x 3.5 mm 25 2 Nylon internal sheath 3 "Zeta" FM 15 4 Nylon inner sheath Reinforcements at 350 FM steel 2.5 mm thick 6 Ribbon 7 Nylon outer sheath Rm MPa kg/m D.i. mm Th. mm 19.3 5.2 35.8 5.3 31.8 0.5 6.7 203.2 238.2 250.2 263.6 275.6 285.6 287.1 17.5 6.7 0.75 Characteristics Internal diameter External diameter Internal volume Imperial units 8.00 in 11.85 in 0.403 cf/ft Metric units 203.20 mm 301.10 mm 37.41 1/m -31 External volume 0.766 cf/ft 71.21 1/m Empty weight in air 70.2 Ib/ft 104.5 kg/m Weight full of sea water in air 96.0 lb/ft 142.9 kg/m Empty weight in sea water 21.5 lb/ft 32.0 kg/m Wt. full of sea water in sea water 47.3 lb/ft 70.4 kg/m Floatability factor when empty in sea water 1.43 Bursting pressure 5365 psi 370 bars Collapse pressure 1537 psi 106 bars Damage limit in traction 407,937 Ibs 181,484 daN Theoretical laying depth 2578 m It was confirmed that for characteristics of bursting pressure and collapse pressure, equivalent to those of Example No. 1, a flexible hose has been obtained with a decrease in weight of 11.4% of the flexible hose full of sea water in sea water and that the theoretical laying depth is 2578 metres.

Although a flexible hose with identical characteristics is I obtained whatever the grade and the state of the aluminium 20 used to fabricate the internal carcase, it is preferable to utilise the alloys possessing the best resistance to corrosion, in particular the alloys 1100, 1180, 3003, 5052, 41%. 5056, 5083, 5456, 6060, 6061, 6082, 6083, 6106. Alloys of the 2000 series as well as the 7000 series may also be 25 utilised.

S**9 Example No. 8 A flexible hose is fabricated similar to that in Example 1 .No. 1, but in layer No. 1 the internal carcase of AISI 304 stainless steel strips 2 mm in thickness is replaced by Al S 30 3103 aluminium alloy "Zeta" filaments 12 millimetres in thickness in state H1, with mechanical characteristics Rm 250 MPa and Re 220 MPa, and in layer No. 3 the thickness of the FM steel "Zeta" filaments is increased to 6.4 millimetres.

The flexible hose obtained under these conditions possesses the following characteristics: 32 1 2 3 4 6 7 Description Alurr.inium "Zeta" filaments Nylon internal sheath "Zeta" FM 15 Nylon inner sheath Reinforcements at 350 FM steel 2.5 mm thick Ribbon Nylon outer sheath Rm MPa kg/m 250 18.6 4.6 780 32.7 5.1 D. i. mm 203.2 227.2 239.2 252.0 264.0 274.0 275.6 Th. mm 12.0 6.4 30.6 0.5 6.5 0.75 Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth Imperial units 8.00 in 11.40 in 0.349 cf/ft 0.709 cf/ft 66.2 lb/ft 88.6 lb/ft 21.1 lb/ft 43.4 lb/ft 5428 psi 1768 psi 391,495 lbs Metric units 203.20 mm 289.50 mm 32.43 1/m 65.82 1/m 98.5 kg/m 131.8 kg/m 31.3 kg/m 64.5 kg/m 1.46 374 bars 122 bars 174,169 daN 2700 m It was confirmed that for characteristics of bursting pressure and collapse pressure, identical to those of Example No. 1, the use of an internal carcase of aluminium alloy "Zeta" filaments 12 millimetres in thickness increased the collapse pressure to 122 bars and decreased the weight by 18.8%, with the theoretical laying depth being 2697 metres.

The Al 3103 alloy may be replaced by any other alloy of the series 1000, 2000, 3000, 4000, 5000, 6000 and 7000.

Example No. 9 An 8 inch flexible hose is fabricated similar to that in Example No. 1, but in layer No. 3 the "Zeta" filaments in FM 15 steel 6.2 millimetres in thickness are replaced by 2017 aluminium alloy "Zeta" filaments 10 millimetres in 33 thickness in state T4 which have undergone a final workhardening of 10%, with mechanical characteristics Rm 510 MPa and A Also, in layers 5, the FM 15 steel armourings 4 millimetres in thickness have been replaced by 6061 aluminium alloy in state T9 with a final workhardening of 8% after tempering and with Rm 450 MPa and A 6%.

The flexible hose obtained under these conditions possesses the following characteristics: i i

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i

C

Description 1 Carcase in stainless steel 304 strips 80 x 2 mm 2 Nylon internal sheath 3 "Zeta" aluminium 4 Nylon inner sheath Reinforcements at 350 aluminium 4.0 mm thick 6 Ribbon 7 Nylon outer sheath 20 Characteristics Internal diameter External diameter Internal volume External volume 25 Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth 31.0 4.9 17.4 5.1 17.1 0.5 6.7 203.2 223.2 235.2 255.2 267.2 283.2 284.7 10.0 10.0 0.75 Rm MPa kg/m D.i. mm Th. mm Imperial units 8.00 in 11.76 in 0.379 cf/ft 0.704 cf/ft 55.6 lb/ft 79.8 lb/ft 7.3 lb/ft 31.5 lb/fte 5386 psi 1570 psi 315,318 lbs Metric units 203.20 mm 298.70 mm 35.18 1/m 70.07 1/m 82.7 kg/m 118.7 kg/m 10.8 kg/m 46.9 kg/m 1.15 371 bars 108 bars 157,813 daN 2991 m It has been confirmed that the use of aluminium alloys at the level of layers No. 3 and No. 5, for identical performances, the decrease in weight is 41% compared with the flexible hose of Example 1 and the theoretical layer depth has increased from 2141 metres to 2991 metres.

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I n 1 2'3- 34 Example No. An 8 inch flexible hose is fabricated similar to that in Example No. 1, but FM 15 steel is replaced by aluminium alloys.

The internal carcase of AISI 304 stainless steel strips is replaced by an internal carcase of interlocking "Zeta" filaments 12 millimetres in thickness of 6061 aluminium alloy strips in state T4, then work-hardened, with mechanical characteristics Rm 350 MPa and Re 290 MPa and in layer No. 3 the "Zeta" filaments in FM 15 steel 6.2 millimetres in thickness are replaced by 2017 aluminium alloy "Zeta" filaments 10 millimetres in thickness in state T3 work-hardened by 15% before tempering (Rm 510) and, in layers 5, the FM 15 steel reinforcing filaments have been replaced by 2017 aluminium alloy filaments in the same state as the "Zeta" filaments in layer 3.

The flexible hose obtained under these conditions possesses the following characteristics: C C

C.

20 1 2 3 4 Description Carcase in aluminium Nylon internal sheath "Zeta" aluminium Nylon inner sheath Reinforcements at aluminium 4.0 mm thick Ribbon Nylon outer sheath Rm MPa kg/m 350 18.6 4.6 510 17.4 5.2 D.i. mm 203.2 227.2 239.2 259.2 271.2 287.2 288.7 Th. mm 12.0 10.0 0.75 6 7 17.3 0.5 6.8 Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Imperial units 8.00 in 11.92 in 0.349 cf/ft 0.775 cf/ft 42.4 lb/ft 69.8 lb/ft -2.1 lb/ft 20.2 lb/ft Metric units 203.20 mm 302.70 mm 32.43 1/m 71.96 1/m 70.6 kg/m 103.9 kg/m -3.1 kg/m 30.1 kg/m I 35 Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth 5500 psi 1768 psi 417,895 lbs 0.96 370 bars 122 bars 185,915 daN 6176 m It has been confirmed that, for a flexible hose with the same bursting pressure as that in Example No. 1, a decrease in weight of 62.1% is achieved and the collapse pressure is greater than 122 bars and the theoretical laying depth reaches 6176 metres.

Example No. 11 A flexible hose is fabricated similar to that in Example No. 10, but the "Zeta" filaments 12 millimetres in thickness in layer No. 1 are replaced by "Zeta" filaments 14 millimetres in thickness.

The flexible hose obtained under these conditions possesses the following characteristics: Description Carcase in aluminium Nylon internal sheath "Zeta" aluminium Nylon inner sheath Reinforcements at 350 aluminium 4.0 mm thick Ribbon Nylon outer sheath Rm MPa kg/m D.i. mm 350 21.2 203.2 4.6 231.2 510 17.9 243.2 5.6 263.2 Th. mm 14.0 10.0 0.75 17.7 0.6 6.9 275.2 291.2 292.7 Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Imperial units 8.00 in 12.07 in 0.349 cf/ft 0.795 cf/ft 49.8 Ib/ft 72.1 Ib/ft -1.1 lb/ft 21.2 lb/ft Metric units 203.20 mm 306.70 mm 32.43 1/m 73.88 1/m 74.1 kg/m 107.4 kg/m -1.6 kg/m 31.6 kg/m 0.98 I J i ii- 1 li i 1."

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36 Bursting pressure Collapse pressure 188 bars Damage limit in traction Theoretical laying depth 5413 psi 427,166 lbs 373 bars 2724 psi 190,038 daN 6013 m It has been confirmed that, by comparison with the flexible hose of Example No. 10, the collapse pressure has been sharply increased from 122 to 188 bars and by comparison with the flexible hose of Example No. 1, the decrease in weight is 60.2% and the theoretical laying depth is 6013 metres.

Example No. 12 A flexible hose is fabricated similar to that in Example No. 11, but the "Zeta" filaments 14 millimetres in thickness in layer No. 1 are replaced by "Zeta" filaments 16 millimetres in thickness.

The flexible hose obtained under these conditions possesses the following characteristics: 1 2 3 4 Description Carcase in aluminium Nylon internal sheath "Zeta" aluminium Nylon inner sheath Reinforcements at 350 aluminium 4.0 mm thick Ribbon Nylon outer sheath Rm MPa kg/m 350 24.8 4.7 510 18.2 5.4 D.i. mm 203.2 235.7 247.2 267.6 279.2 295.2 296.7 Th. mm 16.0 10.0 0.75 17.9 0.6 6.9 Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full ;f sea water in air Empty weight in sea water S Wt. full of sea water in sea water Imperial units 8.00 in 12.23 in 0.349 cf/ft 0.816 cf/ft 52.8 lb/ft 75.1 Ib/ft 0.5 lb/ft 22.9 Ib/ft Metric units 203.20 mm 310.70 mm 32.43 1/m 75.82 1/m 78.5 kg/m 111.7 kg/m 0.8 kg/m 34.0 kg/m d 1 4 i.7.

T'-"dx 37 Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth 5365 psi 3974 psi 427,483 lbs 1.01 370 bars 274 bars 190,180 daN 5593 m It has been confirmed that, by comparison with the flexible hose of Example No. 11, the collapse pressure has been sharply increased from 188 to 274 bars and, compared with the hose of Example No. 1, from 108 to 274 bars. By comparison with the flexible hose of Example No. 1, the decrease in weight is 57.2% and the theoretical laying depth is 5593 metres.

Example No. 13 A flexible hose is fabricated similar to that in Example No. 1, but the FM 15 steel "Zeta" filaments 6.2 millimetres in thickness in layer No. 3 are replaced by 2017 aluminium alloy "Zeta" filaments 10 millimetres in thickness, with mechanical characteristics Rm 500 MPa and A 9%.

20 The FM 15 steel reinforcements have also been replaced by armourings of a composite organic matrix 6 millimetres in thickness reinforced with glass fibres, with mechanical characteristic Rm 2500 MPa.

The flexible hose obtained under these conditions possesses the following characteristics: Description 1 Carcase in stainless steel 304 80 x 2 millimetres 2 Nylon internal sheath 3 "Zeta" aluminium 4 Nylon inner sheath Reinforcements at 350 composite 6 Ribbon 7 Nylon outer sheath RAjy

/T^

s Rm MPa kg/m D.i. mm Th. mm 540 31.0 203.2 10.0 4.9 223.2 500 17.4 235.2 10.0 5.1 255.2 2500 15.8 267.2 12.0 0.6 291.2 0.75 6.9 292.7 1 r r: Ebb lixl i i i 1~ 38 Characteristics Internal diameter External diameter Internal volume External volume Empty weight in air Weight full of sea water in air Empty weight in sea water Wt. full of sea water in sea water Floatability factor when empty in sea water Bursting pressure Collapse pressure Damage limit in traction Theoretical laying depth Imperial units 8.00 in 12.07 in 0.379 cf/ft 0.795 cf/ft 52.8 Ib/ft 79.1 Ib/ft 3.9 Ib/ft 22.9 Ib/ft 5365 psi 1570 psi 1,061,829 Ibs Metric units 203.20 mm 306.70 mm 35.18 1/m 73.88 1/m 81.6 kg/m 117.6 kg/m 5.9 kg/m 34.0 kg/m 1.08 370 bars 108 bars 472,301 daN 11,272 m By comparison with the flexible hose of Example No. 1, for identical bursting and collapse pressures, there is a decrease in weight of 47% and the theoretical laying depth is greater than 10,000 metres.

From the foregoing Examples it emerges that, in the case of Example No. 1, it is possible, as an approximation, and specifically, with the object of making a comparison with the other examples at approximately 713 metres, to evaluate the order of magnitude of the possible depth of water, this 25 value being the smaller of the two limitations which are able to be estimated directly by starting from summarised indications appearing in the Tables "theoretical limit of depth of laying" 2140 metres divided by 3, or 713 metres, and "collapse pressure" 1115 metres divided by 1.5, or 30 743 metres.

Attention is drawn to the fact that the limitation by the weight of the flexible hose as a function of its axial resistance, in particular, may vary, in actuality, at least from single to double, depending upon the circumstances.

If the same evaluation is applied to Example 12, the depth C reached is greater than 18,000 metres.

T 0 1 M 39 In Examples 2 to 10 inclusive and Example 13, the foregoing evaluation leads to an under-estimation of the layin9 depth. Actually, in these Examples, the internal carcase was not dimensioned to correspond to the laying pressure, this being done for the purpose of comparing the flexible hose among themselves.

It should be noted that the "collapse" does not occur unless the outer sheath, which is generally leak-proof, is pierced and, furthermore, unless the inner sheath 4 is not leak-proof or is defective in this regard.

Thus, if the flexible hose is not defective in any way, it is possible to evaluate the laying depth, taking into account the theoretical laying depth and not taking into consideration the limitation given in the Example.

The present invention also relates to flexible hose having structures different from those shown in Fig. 1.

The present invention may be applied, in particular, to flexible hose containing an inner tube made from elastomeric or synthetic plastics material, with or without an internal carcase.

Fig. 2 shows a cross-section through a layer of interlocking strips 8. This layer is generally used as the I internal carcase.

Fig. 3 depicts "Zeta" profiled elements 9. This shape allows for the presence of a lobe or rounded portion which fits into a groove 11 of the adjacent spiral element.

Thus, an interlocking of adjacent spiral elements is obtained.

The "Zeta" profiled elements generally serve for fabrication of the pressure-resistant armouring, but may also be used for the internal carcase 1.

40 The use of other shapes than "Zeta" for the profiles does not fall outside the scope of the present invention, especially the simple shapes such as those with a rectangular cross-section or with a shape.

In Fig. 3, rectangular cross-section profiles 12 have been placed on top of the "Zeta" profiles, as indicated by the dashed lines, to complete the double-layered pressureresistant reinforecement. Thus, in this example, the pressure-resistant reinforcement combines a "Zeta" profile layer with a rectangular profile layer, with the latter preferably forming the outer layer in relation to the interior of the flexible hose.

Fig. 4 depicts another example of the pressure-resistant reinforcement which consists of two filaments or profiles 13 and 14 with a flattened shaped cross-section, wound helicoidally.

SO.One of these profiles 14 has the arms 15 of the opening towards the outside in relation to the axis 16 of the :flexible hose and the other profile 13 has the arms 17 of

A

the 1"U" opening inwards towards the axis of the flexible hose.

*''The arm 17 of the profile 13 fits into the centre space in *the of the profile 14 and inversely the arm 15 of the profile 14 fits into the centre space 19 of the of the profile 13.

It does not fall outside the scope of the present invention if some of the elements are embedded in a flexible elastomeric resin, in particular if the elements of the tensile-resistance reinforcement are embedded in a rubberised sheath.

Among the different structures of flexible hose to which the teachings of the present invention may be applied, there should be noted, in particular, those which are L: 41 discussed in the Examples, such as the following: a) a flexible hose as shown in Fig. 1, but without sheath 4, but with a tensile-resistant reinforcement 5 and a pressure-resistant armouring 3 in aluminium of the series 2000, 5000, 6000 or 7000, b) a flexible hose as shown in Fig. 1, but without the pressure-resistant reinforcement 3 or the sheath 4 and with at least one of the remaining elongated elements in the structure consisting of aluminium in the series 2000, 5000, 6000 or 7000, c) a flexible hose as shown in Fig. 1, but also including a "Zeta" shaped reinforcing element 3 resistant to pressure, a collar or elongated element with a simple cross-section, especially of rectangular cross-section, with or without sheath 4, one at least of the remaining :i elongated elements in the structure consisting of aluminium in the series 2000, 5000, 6000 or 7000, d) all the Examples given in the present Application "include an internal carcase 1 and a sheath 2, but they may be replaced with a leak-proof tube sufficiently flexible to allow the final product to be flexible, but i 54 sufficiently rigid to prevent if being crushed during fabrication of the flexible hose.

In accordance with the present invention, when two layers 25 of different metals follow one another, for example aluminium and then steel or, in certain cases, two different types of aluminium alloys, it may be preferable to interpose an insulating sheath.

Furthermore, it does not fall outside the scope of the present invention to interpose a sheath or layer of antifriction material between the different layers making up one of the components in accordance with the present t invention and, in particular, in the case of the tensile- 4 42 resistant armouring when this is made of steel.

In the present invention, the components containing aluminium alloys of the series 2000, 5000, 6000 or 7000 should preferably be constituted entirely of these particular aluminium alloys.

It will be understood that, in the present invention, when the designations used are for the aluminium alloys of the series 2000, 5000, 6000 or 7000, then this will apply, unless specifically stated otherwise, to all the grades of alloys belonging to any one of these series.

The flexible hose in accordance with the present invention may, in particular, include composite materials in organic matrices.

*0 In the Examples given previously, (Examples 2 to 12 15 inclusive), the states referred to for the different aluminium alloys correspond to the preferred states.

The grades and states referred to in Examples 2 to 6 and eo Examples 9 to 12 for the elongated elements included in the armourings resistant to pressure or saddling, could be used 20 for the elongated elements in aluminium alloys included in the traction-resistant armourings.

Furthermore, it does not fall outside the scope of the present invention if one of the aluminium alloys of the series of the grades and/or states referred to in the present invention is replaced by another equivalent aluminium alloy.

NT 0 ;Si/i;

Claims

1. A reinforced hose including at least one of a pressure-resistance reinforcement, a tensile-strength reinforcement, and an inner carcass, wherein at least one of the pressure-resistance reinforcement, the tensile- strength reinforcement and the inner carcass includes at least one elongated element and wherein said at least one elongated element has undergone a work hardening operation and is composed of an aluminium alloy.

2. The flexible hose according to Claim 1, characterised in that said aluminium alloy is an aluminium alloy of the series 2000, 5000, 6000 or 7000.

3. The flexible hose according to Claim 2 includes a pressure-resistant reinforcement and/or a tensile- resistant reinforcement characterised in that one at :least of said reinforcements comprises at least one 5 elongated element of an aluminium alloy of one of the series 2000, 5000, 6000 or 7000 and, for preference in one of the following grades: 2014, 2017, 2024, 2117, 2618, 5050, 5052, 5056, 5082, 5086, 5154, 5183, 5754, 6005, 6060, 6061, 603, 6066, 6070, 6082, 6351, 7001, 7020, 7049, 7050, 10 7075, 7175, 7178 or 7475.

4. The flexible hose according to any one of Claims 1 to 3, characterised in that said elongated aluminium alloy has a resistance to rupture under tensile (Rm) at least equal to 300 MPa and, for preference, at least equal to 350 MPa. The flexible hose according to Claim 1, including an internal carcase characterised in that said carcase comprises at least one elongated element composed of an aluminium alloy of one of the series: 1000, 2000, 3000, 4000, 5000, 6000, 7000 and, for preference in one of the following grades: 1100, 1180, 3103, 5050, 5052, 5056, 5083, 5456, 6060, 6061, 6082, 6083 or 6106. 'i -i I. -44

6. The flexible hose according to either Claim 1 or including an internal carcase characterised in that said carcase contains of least one elongated element comprising an aluminium alloy having a resistance to rupture under tensile (Rm) at least equal to 200 MPa and, for preference, at least equal to 250 MPa and an elastic limit at 0.2% Re 02 at least equal to 150 MPa and, for preference, at least equal to 190 MPa.

7. The flexible hose according to any one of the preceding Claims, characterised in that it includes an internal carcase containing at least one elongated element comprising an aluminium alloy, this elongated element being a profile or a binding or interlocking filament.

8. The flexible hose according to Claim 7, characterised in that said elongated element is of the 'Z' shaped cross section.

9. The flexible hose according to Claim 2, characterised in that said aluminium alloy is subjected to a dissolution heat treatment.

10. The flexible hose according to Claim 9, characterised in that said elongated element is subjected to a final work-hardening treatment preceded and/or followed by tempering.

11. The flexible hose according to Claim characterised in that said work-hardening is a cold hardening having a rate of 3% at least in the case of utilisation of an aluminium alloy of the series 2000, 6000, 7000, or a rate of 20% at least in the case of utilisation of an aluminium alloy of the series 5000.

12. The flexible hose according to Claim 1i, characterised in that said work-hardening is a cold harden- S SRA ing having a rate between 3% and 40% and, for preference, between 5% and 25% in the case of utilisation of an L VT VT 0< 4 *,p 45 aluminium alloy of the series 2000, 6000 or 7000.

13. The flexible hose according to Claim 11, characterised in that said work-hardening is a cold harden- ing having a rate between 20% and 90% and, for preference, between 40% and 70% in the case of utilisation of an aluminium alloy of the series 5000.

14. The flexible hose according to any one of the preceding claims, characterised in that said elongated element has been subjected to rolling or stretching. The flexible hose according to Claim 14, characterised in that said elongated element has been subjected to a partial or total tempering or to a hardening and tempering of which the characteristic parameters are a :function of said rate of hardening and/or of the nature of the alloy.

16. The flexible hose according to any one of Claims 1 to 15, characterised in that said aluminium component is coated with an alloy which protects it against corrosion.

17. The flexible hose according to any one of Claims u 1 to 16, characterised in that said aluminium component is coated with a thermoplastic film, especially a polyethylene, a polyamide, a polyvinylidene fluoride or a polypropylene, or an elastomer or a rubber.

18. The flexible hose according to any one of the preceding Claims, characterised in that said aluminium component has a ductility at least equal to 3%.

19. The flexible hose according to Claim 18, characterised in that said aluminium component is in the series 2000 or 7000 and the ductility of said component is between 6% and 20% and, for preference, between 10% and ©Ti iL S, VT, 1 l T i, 46 The flexible hose according to Claim 18, characterised in that said aluminium component is in the series 5000 or 6000 and the ductility of said component is at least equal to 6%.

21. The flexible hose according to any one of the preceding claims wherein said hose includes a carcase, a sheath and reinforcement, said carcase comprising a binding strip or a binding filament, especially of the type, and said reinforcement includes an element which is a profile, a cable or a filament, and wherein said binding strip or filament of the carcase comprises an aluminium alloy of the series 2000, 3000, 4000, 5000, 6000 or 7000, and/or said elongated element of said reinforcement should consist of an aluminium alloy of the series 2000, 5000, 6000 or 7000.

22. The flexible hose according to Claim 21, characterised in that the carcase constituted of a steel binding strip or filament.

23. The flexible hose according to Claim 21, characterised in that said reinforcement comprises steel. S: 24. The flexible hose according to Claim 3, characterised in that said tensile-resistant reinforcement comprises essentially of steel and said pressure resistant reinforcement consists essentially of an aluminium alloy. The flexible hose according to Claim 24, characterised in that the hose includes an anti-friction sheath which is, for preference, leak-proof and electrically insulating, this sheath being disposed between the pressure resistant reinforcement and the tensile- resistant reinforcement.

26. The flexible hose according to either Claims 24 or 25, character.ised in that it includes a tensile- i resistant reinforcement comprising at least two layers of ti 'iC -47- filaments, cables or profiles and, in addition, a layer or sheath of anti-friction material interposed at least between said two layers.

27. The flexible hose according to Claim 3, characterised in that said tensile-resistant reinforcement and said pressure resistant reinforcement consists essentially of an aluminium alloy of the series 2000, 5000, 6000 or 7000.

28. The flexible hose according to any one of the preceding Claims, characterised in that the hose includes an external strip or external binding filaments.

29. The flexible hose according to any one of the preceding Claims, characterised in that the hose includes at least one internal sheath of a plastics material, such as a polyamide, a polyvinylidene fluoride, or an elastic material such as rubber or a synthetic elastomer.

30. The flexible hose according to any one of the preceding Claims, characterised in that the hose includes a pressure-resistant reinforcement containing at least one t layer formed from a profile optionally having a cross- section of interlocking shape, such as a or a fabricated from an aluminium alloy of the series 2000, 5000, 6000 or 7000.

31. The flexible hose according to any one of the preceding Claims, characterised in that the hose includes a composite material with an organic matrix.

32. A reinforcement hose substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings. DATED this 7th day of May 1992. 4C2 INSTITUT FRANCAIS DU PETROLE and COFLEXIP s By Their Patent Attorneys GRIFFITH HACK CO Fellows Institute of Patent SAttorneys of Australia f