Development and characterization of composite materials for production of composite risers by filament winding

Abstract

Industry has been challenged to provide riser systems which are more cost effective and which can fill the technology gaps with respect to water depth, riser diameter and high temperatures left open by flexibles, steel catenary risers (SCRs) and hybrid risers. Composite materials present advantages over conventional steel risers because composite materials are lighter, more fatigue and corrosion resistant, better thermal insulators and can be designed for improving the structural and mechanical response. This paper contains a study of the toughening mechanism of an epoxy resin under rubber addition by means of fractographic analysis and its relation with the fracture process and increase of strength of a composite riser employing this polymeric matrix. Initially, an epoxy resin system was toughened by rubber CTBN addition (10 wt. (%)) as a way of improving the flexibility of future risers. Mechanical and thermal analyses were carried out for characterizing the polymeric systems. Later, composite tubes were prepared and mechanically characterized. The influence of matrix toughening on the mechanical behavior of the tubes was also studied. Split-disk tests were used to determine the hoop tensile strength of these specimens. The results indicate that the matrix plays an important role in composite fracture processes. The adding rubber to the polymeric matrix promoted a simultaneous increase of stress and elongation at fracture of the tubes manufactured herein, which is not often reported. These results, probably, is function of better adhesion between fibers and polymeric matrix observed in the CTBN-modified composite rings, which was evidenced in the fractografic analysis by SEM after the split-disk tests.

A review on design, manufacture and mechanics of composite risers

“…Sobrinho et al Sobrinho et al, 2011) reported an experimental effort to enhance the toughness of the composite risers by introducing a toughening agent, rubber, into the epoxy resin which increases the elongation of the composite material but results in a compromised tensile strength and a reduced elastic modulus. For riser components and their connections, DNV-RP-F202 (Det Norske Veritas, 2009) suggests test requirements of the MCI on the design phase and after fabrication including axial, bending fatigue tests, stress rupture and external pressure tests of both the MCI and end fittings.…”

Reprocessability of poly(ethylene terephthalate) nanocomposites

“…On account of that, it is established that the incorporation of clay often improves the thermal stability of polymer due to the high heat resistance of clay layers as well as the formation of mass transport barrier toward volatile products. 2,23 On the other hand, the T 5 of PET/OMMT/5S has reduced to 392.5 C. Sobrinho et al 24 reported that the thermal stability of epoxy blends decreased by the addition of rubber content. As discussed in our earlier work, 25 adding SEBS-g-MAH could induce embedment of clays inside the SEBS phase and this might be responsible for the poorer thermal stability.…”

A novel high performance bismaleimide/diallyl bisphenol A (BMI/DBA)–epoxy interpenetrating network resin for rigid riser application

“…2 Other works also have shown the feasibility of composite risers. 2 In order to realize the full potential of composite materials, suitable matrix resins have to be developed, as the majority of the degradative process that eventually causes the composite failures 6 occur either in the resin or the resin-bre interface. 2 In order to realize the full potential of composite materials, suitable matrix resins have to be developed, as the majority of the degradative process that eventually causes the composite failures 6 occur either in the resin or the resin-bre interface.…”

“…2,3 Initially, the Institut Français du Pétrole (IFP) and Aerospatiale developed and manufactured multi-layered high performance composite pipes for offshore applications, and demonstrated that these composite risers that were made with carbon bres and glass bers, and epoxy resin, could be successfully used as production risers. 2,3 Initially, the Institut Français du Pétrole (IFP) and Aerospatiale developed and manufactured multi-layered high performance composite pipes for offshore applications, and demonstrated that these composite risers that were made with carbon bres and glass bers, and epoxy resin, could be successfully used as production risers.…”

“…2,3 Initially, the Institut Français du Pétrole (IFP) and Aerospatiale developed and manufactured multi-layered high performance composite pipes for offshore applications, and demonstrated that these composite risers that were made with carbon bres and glass bers, and epoxy resin, could be successfully used as production risers. 4,5 Ledjane Lima Sobrinho et al 2 also studied the development of resin matrix materials (T g ¼ 141 C) for the production of composite risers by lament winding. 4,5 Ledjane Lima Sobrinho et al 2 also studied the development of resin matrix materials (T g ¼ 141 C) for the production of composite risers by lament winding.…”