Development of novel technology for connections in high pressure flexible polymer piping systems

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In order to increase market share in a competitive global environment, Flexpipe Systems, a division of ShawCor Ltd., recently launched a new product called FlexFlow Linepipe, which is a larger diameter fiber-reinforced thermoplastic composite linepipe that will be made available in 6" and 8" inside diameters, with 750 psi and 1500 psi pressure ratings. Flexpipe's product line is currently limited to pipe solutions with diameters of less than 4". An engineering team consisting of Shawcor experts in Ontario and Alberta has made substantial progress in the development of the new product, and prototype development and production of large diameter composite linepipe is well underway. Pipe segments will be limited in length since, due to the larger diameter, the new product cannot be spooled and transported like as Flexpipe's small-diameter legacy products. This in turn requires a pipe assembly using suitable reinforced connector fittings. For the 750 psi rated linepipe, reinforced electrofusion fittings have been developed for the reliable joining of pipe segments. However, fittings capable of more efficiently sustaining the loadings that occur in the high-pressure 8" linepipe are required. In this case, the stress distribution in the pipe joint caused by sustained axial loading and 60°C must be managed to remain for 20 years or more within material limits including a safety margin. Developing a suitable fitting for the given material system is a considerable technological challenge, and Shawcor/Flexpipe is seeking the expertise from the Ontario and Alberta university researchers to address these challenges and develop a fundamental understanding for a novel pipe joint design that meets performance requirements and is reliable, cost-effective, long-lasting even in adverse environmental conditions. The goal of the project is to establish an advanced knowledgebase and develop a novel solution for a high-pressure fitting/coupling for the linepipe that provides required strength and a high degree of durability and safety. The development of a novel pipe joint offers the opportunity to integrate sensing functionalities and functionally graded material systems for exceptional reliability, which would further advance Shawcor's technology leadership in the industry.