Pipeline Technology Conference 2015

Topic:
Building the Fluid Highways of the future- Long Pipes Fluid Highway;
the development program so far.
Authors:
Neil Graham, Deryck Graham, Alexander Lapitsky
Presenter:
Neil Graham
Organisation:
Long Pipes Pty Ltd; Perth, Western Australia, Australia
Abstract:
The world needs a new lower cost more efficient means of fluid transportation for oil,
gas, water etc. Like almost all new technologies that we are working with today from
rockets, to fighter jets, to cars and now pipelines the answer appears to be
composites. These materials are many times stronger and lighter than steel. They
are inherently corrosion resistant or immune to corrosion. They can be made to
sense fell alert the operator or defend the pipe. Yet any one material on its own
cannot do the job so we are pioneering a new pipeline technology that combines
many composite materials and promises to produce a completely new technology in
pipelines that are made continuously in the field at high speed.
We call it the Fluid Highway .
This is the story of; the history, the development to date, the trials, the tribulations
and the successes on the development road, to produce the Long Pipes; Fluid
Highway .

Pipeline Technology Conference 2015

1.0 The History, the people, the project

To understand any development program you need to understand why and how it
was developed and the breakthroughs that enable it to work.

1.1 History; the Invention

The invention came from the need to solve the problem of leaking fiberglass screw
joints on our pipelines that we were installing in the oil/gas fields in Western Australia
for Chevron on the Gorgon project.

Figure 1 Barrow Island Nature Reserve

The GRE fiberglass pipe that we were the agent for was one of the best on the
market and our company Vortex was installing them on Barrow Island which is a
nature reserve and they could not leak, so any leaks had to be fixed immediately.
The problem was that our pipe joints leaked; 90-95% were OK but some leaked.
When they leaked the pipe had to be taken apart cleaned resealed and reinstalled.
This was costing a lot of money. In desperation our Managing Director, Trevor
Gossatti said that You have to make a pipe without joints that could run forever; a
Long Pipe without joints! So this is where the name of the company comes from.
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My response was That is impossible you cannot make a pipe without a joint there
are no mandrels long enough!
Finally one cool crisp morning in April 2008 I was driving to work and turning the
steering wheel in front of me and I worked out the basics of how to make a Long
Pipe without a joint.

Figure 2 Chevrons Gorgon Natural Gas Project on Barrow Island

1.2 The people and their history

This might sound too simple but my background and that of my father, was that we
had worked in the aerospace industry for 35 years and we were very familiar with
composite materials.
We had been building work boats and luxury boats in the 1970s and established our
first major aerospace composites company, Composite Industries Limited and listed
it on the Australian Stock Exchange (ASX) in 1987. This company was established to
build the Eagle X-TS 150 light carbon and Kevlar composites aircraft that we had
invented, designed, built, and put into production. This aircraft was probably the most
advanced light aircraft in the world at the time. It has unique flight characteristics and
its patented manufacturing technology was far in advance of even the fighter jets of
the 1980s.

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We had also built the 10,000 sq. meter production facility and the associated runway
and infrastructure and employed a staff of up to 200 people on the production of this
aircraft.

Figure 3 Flight of Eagle 150 X-TS for fire spotters and trainers

We sold this company to the Malaysian Government Consortium in 1992 and it has
subsequently become Asias largest aerospace company, CTRM.

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Quickstep Technologies Limited, ASX code: QHL
At the time of inventing the Long Pipe process in 2008 we had been working on the
development of the Quickstep Process for some 10 years.
We developed Quickstep as a rapid curing and melding process for aircraft and
space structures and automotive components from, floor pans for cars, to car panels.
See www.quickstep.com.au
This technology uses hot liquids not gas contained in two chambers one above the
part to be cured and one below the part to support and cure the part. The hot fluid is
pumped through the chambers to rapidly heat the part. The process is many times
faster than gas heating and in automotive applications which we are partnered with
Audi on for the European light weight car program can result in parts in 2 minutes
rather than hours using a conventional autoclave technology.

Figure 4 Patent drawing of the Quickstep Pressure chamber with vibrator at the top

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Figure 5 A large Quickstep curing plant, for an integrated space structure this demonstrates integrated
melded parts e.g. for full wings and spars and rocket casings

To achieve high speed production we were working on a new high speed resin
delivery system that produces space grade parts with AA auto finish for the rapid
manufacture of car and aerospace parts know as Resin Spray Transmission (RST).

Figure 6 Resin Spray Transmission Robotic Cell for automotive parts

This technology enables cars to be manufactured in composites at a competitive

price to metals saving up to 70% of the weight and making a much stiffer, safer
vehicle.

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One of our particular interests was to work with Lockheed to build the F-35 Joint
Strike Fighter (JSF)

Figure 7 JSF F-35 Lightning 11 VTOL

After 7 years of development work and demonstrations Quickstep won one of the
largest contracts in the world for the composite components on the JSF worth
approximately A$800M over the life of the JSF project.
We were also working on the Next Generation (NG) version of the JSF using our
Spar and Melding technology to bond/melt/weld the wings and spars together. This
is being done in the US and in Australia.
Quickstep is now Australias largest independent composite aerospace
manufacturer.
So with this background we had a good working knowledge and understanding of
advanced composites, resin flows and fibre systems for aerospace applications with
an expertise in design.
Composites are very different to steel as they require the loads to be carried by the
fibres not the mass of the structure. This means that the fibres must be aligned with
the load path or the matrix will be required to hold the load, or the part fails or
fatigues rapidly.
NO TECHNOLOGY FROM QUICKSTEP HAS BEEN USED IN THE PRODUCTION
OF THE LONG PIPES FLUID HIGHWAY
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1.3 The Project: Turning the concept of the Long Pipe joint free
continuous pipe into the Long Pipes Fluid Highway
Well you would think that with that background we could turn the concept into reality
quickly. I thought that it would just take a few weeks, to a few months to make the
first Long Pipe. The reality was very different; it took many years to even work out
how to make the first pipe. We had so many failures; we tried so many ways of
making a pipe and we gave up many times. We tried resin baths, resin injection, it
worked but only for a few meters and it was very slow. We tried using a pre-preg
plant as used by the re-lining industry it only worked for a few hundred meters and
the quality was poor with too many air bubbles trapped in the laminate. We were
almost convinced that a Long Pipe without a joint could not be made.
Then in October 2012, more than 4 years after the first simple thought; we worked
out how to make the first pipe and made it work in the factory!
Now in 2015 we have a production system that works in the field and this is the
result of the work and efforts of a whole team of people not just a few .but I am
jumping ahead of the
story.

Figure 8 Timeline taken to turn the concept into a production system to make the Fluid Highway

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1.4 The breakthroughs that enabled the production of the Long

Pipes Fluid Highway
We are driven by know-how protected by patents The patent presented below is
the first in a series of patents covering the method and the processes of pipe
production.
The Caterpillar Valve:
This linear; valve, brake, control system, stops the air leaking from the pressure side
to the resin wet -out side. While at the same time transporting resin and fibres from
the wet-out side to the inflation side; thus it stops the air leaking out of the sock and
ensures that the resin and fiberglass that is in the sock gets into the pipe being
produced at exactly the right ratio.
These drawings are from the PCT Patent Application PCT/AU2011/001401 and
depict the operation of the Caterpillar valve, and Resin Wave in detail.
The sock, as it is termed, wet with resin on the left side, is drawn through the
Caterpillar valve that traps the resin and glass between each cleat set, 171 depicts
the puddle of resin and glass being transported from the left side to the right side
where the valve releases it and the air pressure inside the pipe inflates it. The resin
then cures forming a solid pipe.

Figure 9 Caterpillar Valve Brake Controller as depicted in the Patent Application

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Resin Wave :
The key component of a composite is not the resin; it is the lack of air that makes a
good part; that is the key. If you can remove the air and wet the fiberglass with resin
you have a good part and using Resin Wave we get an almost perfect ratio of
glass to resin 70/30 and no air.
Resin Wave also means that there are almost no speed limits on the production of
the Fluid Highway as the wet out and cure process can take place over many
minutes and over a very long distance of hundreds of meters. Therefore high
speeds of 15 to 20 meters per minute are possible.
This drawing is from the patent as well and it shows the fiberglass being pulled
through on the left side and the resin 165 being pumped into the sock, the sock
being formed from the outer casing 156drawn around it and welded together at 151
to form a tube and then drawn through the caterpillar valve where it is inflated on the
right side. Once the caterpillar valve releases the sock then the inner liner inflates
forcing the resin around the pipe, forcing the air out through the top vent holes to wet
out and then cure the pipe to form a solid pipe.

Figure 10 Resin Wave wetting out the pipe as it is formed

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The Influsion process

Influsion is a new word to describe the unique new process of inflation and
infusion at the same time.
Not only does Resin Wave enable the pipe to be fully wet out on the run; it means
that the sock as it goes through the Caterpillar to form the pipe is pulled and inflated
at the same time. Thus stretching all the fibres in all directions within the sock and
pre-tensioning and aligning them at the same time as they are wet out. This
prestressing and locking them in to the resin matrix makes them just like prestressed
reinforced concrete. But there is more to it than just the Resin Wave and the prestressing of the fibre bundles; the fibres can also be printed and aligned to take the
loads that the pipe experiences in the field. This is just like the fibre alignment on the
wings of a fighter jet designed to take the loads at minimum weight and maximum
performance.

Figure 11 Drawing showing the loads on a pipe the fibres in a Long Pipe are 0/90/45/45 to hold
these loads

Figure 12 straight pre stressed fibre in resin matrix of a Long Pipe

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2.0 Making the Long Pipes Fluid Highway

2.1 Putting it all together
So with the combination of each of these breakthrough steps we have developed a
system of pipe manufacture that we use to produce the Fluid Highway.
Step 1 Sock Production

Figure 13 The Sock showing the inner liner with fiberglass layers encasing the inner liner

We produce a Sock comprising an inner liner of Thermoplastic Polyurethane or

other suitable thermoplastic around which we form layer, after layer of pre aligned
and stitched reinforcements that could be Kevlar, fibre glass or carbon fibre.
This is formed at up to 40 meters per minute; we call it printing. The sock is then laid
flat into a container. Each container holds 2-10 kms depending on the diameter and
pressure rating of the pipe, the bigger the diameter the shorter the distance, the
higher the pressure rating the shorter the distance that can be stored in the
container.

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Step 2: 1-4 steps for In Field Production
The containers are then brought to the field where the sock is pulled out, the resin is
added and it is put through the Caterpillar, inflated and it turns into a solid pipe once
the resin is cured.

Figure 14 Simplistic overview of the complete process

To make the pipe continuously to produce the Long Pipes Fluid Highway , without
a joint, the sock from one container is spliced, just like a continuous rope, or a
Hollywood movie, to the sock in the next container. In this way there is no full stop
and the splice is structurally no different to any other part of the pipe.

Pipe structure if the outer casing was removed

Fibre Orientation 0/90/45/45

Figure 15 Fibre alignment after Influsion and the resin has hardened

You can watch the video of the pipe being produced in the field at:
www.longpipes.com.au

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2.2 The Long Pipes Fluid Highway the product

This is the wall of the finished pipe once cured

Figure 16 Finished pipe showing: outer casing/reinforcement in the middle/felt/TPU Inner liner

This shows the multilayered product that we produce in field. In this way we produce
a composite of a number of different materials each doing its own specific task; the
inner liner protects the reinforcements from attack from the fluids being transported;
the reinforcement is the strongest that can be achieved for the weight and materials
used to hold the loads and the outer casing protects the reinforcements from attack
from the outside world.
It is just like a hydraulic hose but rigid with an inner liner, a layer of reinforcement
and an outer casing to protect the reinforcements from the environment.
The first thing to recognise about a Long Pipe Fluid Highway is that:
A LONG PIPE FLUID HIGHWAY IS NOT A FIBERGLASS PIPE
The fiberglass and resin never come in contact with the fluids being transported!
The fiberglass never comes in contact with the outside environment.

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The Long Pipe has similarities to the high quality, high pressure spoolable pipe on
the market today that have inner liners/reinforcements/outer casings.
However we consider that we will have some advantages in comparison to a
spoolable pipe as we are not size/diameter limited to 150-200mm or to the length of
a pipe that can be transported on a roll, on rail and road transport.
We consider that we can in theory produce a pipe to any size or length.
We have demonstrated 80mm to 600mm so far but we consider a pipe up to 3m
diameter appears possible but may not be practical.
Pipes to 2 meters appear practical but are not planned immediately.
The most practical sizes appear to be between 150mm to 1.5m and between 200 bar
operating for the smaller pipes to 60 bar for the larger pipes.
However this is all still in the future and we must prove it.

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2.3 We have produced pipes in the factory and in the field:

Figure 17 Pipe made in Factory September 2014 gentle curves are possible

Figure 18 Pipe in the field December 2014 long distances are possible

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However this means we are new, so new, that we are doing all the tests that we can,
to prove verify and support the findings and benefits that we have demonstrated or
think that we have demonstrated so far.
We need to develop the data to support our conclusions and we are working at that
by hoop, hydraulic and laminate testing as well as raw materials data as supplied by
our suppliers and in field testing.
Based on the provisos above we have found many successes/benefits using these
materials in these unique ways to make a unique composite the Long Pipes Fluid
Highway
With the unique methods and materials that we use we can now tailor the pipe to suit
the materials to be transported down to the molecular layer.

2.4 The major successes/benefits of the Long Pipes Fluid Highway:

No Joints: for 1km or 1,000kms -No metal welders required
Fast construction: 5-20m/min, in field continuous, could be run 24/7; saving months
to years in constructing a pipeline
Cost competitive with existing technologies: Steel, HDPE, Fiberglass jointed
pipe, Spoolable pipe
Onshore and off shore: the demonstration of onshore production has been
achieved; in time we expect to be able to produce off shore as well
Corrosion and erosion resistance= long life = low maintenance
The fiberglass/Kevlar/carbon fibre reinforcement never comes in contact with the
fluids being transported.
Multi Layered (7-9 layer) BASF, Thermoplastic Poly Urethane TPU, or EVOH or
Polyethylene, so we can tailor the corrosion resistance to suit the fluids being
transported; for H2S for oil field, CH4 for gas, chemical, CO2 and drinking water
transportation or for the hydro-transportation of coal and iron ore OR the many things
yet to come that we have not thought of yet?
The inner liner and the outer casing are part of the laminate and cured with the
laminate so they are part of the pipe this provides exceptional long term corrosion
resistance.
The inner liner is backed with 2.5mm of resin rich laminate that may provide many
decades of corrosion resistance even if the inner liner is breached.
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Estimates of life expectancy in extremely aggressive sour oil, H2S or CO2
environments, suggests 35years+, versus 2-6 years for uncoated steel
Gas Impermeable: The inner liner can be made with EVOH (Ethylene vinyl alcohol)
resin in one of the layers of the inner liner to provide superior gas CH4 barrier
properties for high pressure gas pipeline projects.
Go around corners: Gentle bends can be accommodated in field
Low labour cost: estimated 32:1 reduction versus steel pipe
Operates in extreme temperature: No brittle fracture, explosive failure; fracture
does not run along pipe; operations to minus -60C or up to +90C
Transport and storage cost reduction: As the sock is laid flat and compressed into
containers and the resin is in liquid form we do not transport air. Therefore there is a
massive reduction in the volume and parts being transported to site estimates of
80% savings in volume, 75% reduction in weight and 200 times less logistics
movements are predicted in comparison to steel pipe. No storage yards required
materials are delivered directly to the production machine in the field.
Low friction; energy efficient: No joints and a smooth inner liner mean significant
pumping energy reduction; estimates of 40% in comparison with a nominal steel pipe
Low Friction; reduces build-up of contaminants on pipe wall even at low speed and
temperature, no joints easier to clean with a soft pig
Strong, High Pressure: Fibres are aligned to take the hoop and axial loads thus
making it stronger than filament wound fiberglass to hold pressure loads:-our lowest
pressure pipe is 4 layers 300mm ID and 100 bar burst. A 20 layer 300mm ID pipe
we estimate to have a 400 bar burst with Max Operating pressure of potentially 200
bar. We anticipate higher long term pressure resistance with better fatigue life than
other pipes because the fibre bundles, not the resin takes the loads1. This will be
demonstrated as our development program progresses and we enter and complete
certification and conduct regression pressure testing on the pipes in the coming year.
Tough: The quadraxial glass fabric that a Fluid Highway is made from is unlike any
conventional wound Fiberglass Pipe, as the fibre bundles axis follow the loads in the
pipe; and the multi axial structure under tension is locked layer to layer thus making
it fracture resistant and much tougher than a conventional filament wrapped
laminate.

Based on Saertex finite element analysis

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Tough/encased: a further protective layer of concrete or polymer can be
formed/added to the pipe as it is produced to provide added protection or crush
resistance
Impact damage: leading to micro fractures within the reinforcement does not
produce a leak unless the inner liner is punctured.
Intelligent: Being linear continuous and fiberglass we can imbed optical fibre
sensors directly into the pipe as part of the pipe that are able to react and sense the
movements of the pipe to warn of any potential threat or disturbance or failure of or
to the pipe. With the sensors in and part of the pipe, the pipe can warn the operator
of any intrusions, blockages or flow restrictions, wear or damage to the pipe.
Defensive: Systems can be embedded into the pipe to protect the pipe from
intrusion and interference and provide appropriate actions to defend the pipe or
render the intrusion ineffective.
Non Conductive: The materials of construction are non-conductive and have high
electrical resistance thus enabling them to be used under high voltage power lines.
No Interference with surrounding infrastructure: Being non-conductive and fully
encased there is no opportunity for electrolysis between incompatible materials and
no electrical or cathodic protection is required

3.0 With these successes/ benefits; where do we take the

first steps on the roll out that leads to the adoption of the
Fluid Highway ?
We do not expect to replace all pipes or even have a significant impact for years to
come and there will be many areas where steel, fiberglass, spoolable and HDPE will
always be dominant.
However we do expect to have specific performance and cost advantages in some
small areas that we call sweet spots where we consider that the Long Pipes Fluid
Highway benefits may have advantages. In these areas we hope to start the
process of demonstrating these benefits in the real world.
The bar chart below sets out areas where we see that we might provide benefits in
comparison to the existing technologies of today.

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4.0 The year ahead; the first little steps onto the Fluid
Highway
We expect to complete the first long runs being 4 kms shortly. Then multiple runs of
process water and hydro-transportation lines for a mining company of up to a total of
90kms. Then if this is successful and certification completed up to 50kms of brine
line for a gas project in Queensland; after this entry to the US market; then we will
see what happens next.
There is a long way to go to get to the world using the Fluid Highway but we are
clearly taking the first steps and we will keep the PTC Berlin 2015 informed with the
latest information as we present the talk to the conference in Session 2, Design and
Construction, June 8th.

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