A Novel Thermal Insulation System for Bonded Subsea · PDF fileA Novel Thermal Insulation System for Bonded Subsea Single ... fusion bonded epoxy, ... The Thermotite® ULTRA field

Jackson et. Al. BHR Conference, Antwerp, 2009 Page 1 of 14

A Novel Thermal Insulation System for Bonded Subsea Single Pipe Wet

Insulation Applications

18th BHR Conference on Pipeline Protection, Antwerp, Belgium, 4th to 6th November 2009

Jackson, Ai. Jackson, Pii. Wan, Eii. and Hegdal J.Piii

ABSTRACT

Insulating pipes and subsea structures is essential to avoid the possibility of wax and hydrate formation. The

materials used for insulation have been around for a few decades and include polypropylenes, polyurethanes,

epoxies and rubbers. As in many areas of commercial activity over this period, there have been considerable

developments with regards to these materials, which have enhanced and improved their performance. More

recently there have been market requirements for the development of low thermal conductivity yet high

compressive strength insulation solutions. This paper will present details on a new family of subsea insulation

materials with unique properties which offer alternatives to the traditional polypropylenes and polyurethanes

solutions and yet cater for high temperature, unlimited water depth applications.

INTRODUCTION

Bonded single pipe subsea thermal insulation has been established as a reliable tool for passive flow

assurance since the 1980siv. Recent developmentsv have added an active component to the design of

subsea pipeline and tie-back systems through inductive and conductive power input. This type of

system is referred to as “thermally managed”. The development of materials has generally focused on

four material groups; rubbers, epoxies, polyurethanes and polypropylenes, with the introduction into

the market being in that chronological order. Variants of these materials; solids, foams and syntactics

have provided a range of candidate materials with differing properties for use in the manufacture of

commercial insulation systems to meet a wide range of operational requirements (see Table 1).

Although these materials are established in the market they do not by any means represent an

exhaustive list of potential materials that can be used in thermal insulation applications.


Material K-value (W/m.K) Max. temp. (oC) Max depth (m)

Rubber (Neoprene / HNBR) 0.26 – 0.28 90 / 140 Unlimited

Filled (Neoprene / HNBR) 0.12 – 0.14 90 / 140 Unlimited

Syntactic epoxies 0.12-0.17 110 2800

Polyurethane 0.19-0.20 90 wet /115 dry Unlimited

Syntatcic polyurethane* 0.13 90 wet /115 dry 300

Syntatcic polyurethane** 0.14 – 0.17 90 wet /115 dry 2800

Polypropylene 0.21 – 0.26 145 Unlimited

Polypropylene foams 0.13 – 0.2 145 2000m***

Syntactic polypropylene** 0.17 145 2800m Table 1: Typical parameters for subsea thermal insulation materials

* polymeric microspheres ** glass microspheres ***specific formulations The majority of thermally insulated subsea lines are either in-field lines, gathering lines or tie-backs.

Over the past years the trend has been toward extending the usable range of tie-backs in order to

maximise the number of potential satellite fields that can be successfully tied back to a given host, or to

encompass sufficient reserves for a reservoir cluster to be viable. At the same time the thermal

performance requirements have become ever more demanding. The need for maintaining the flow of

well fluid within a given steady state window for optimal processing and minimum operational risk has

led to requirements for low U-values for insulation systems. Risks associated with inhibition of

hydrates and waxes over many kilometers has led to extended cool down requirements to enable

decisions to be made and corrective actions to be taken in the case of a production shut-in. The advent

of extended tie-backs has enabled cost effective capacity augmentation for many existing production

assets; some of them nearing the end of their otherwise useful life. In addition the development of

processing hubs has become increasingly popular, particularly in so called “green field” areas where

other infrastructure is limited or non-existent, allowing for rational exploitation of oil and gas reserves

which would otherwise be economically non-feasible.

TRADITIONAL MATERIALS

The most commonly used materials in subsea thermal insulation are polyurethanes and polypropylenes;

due to their suitability for large scale production, availability of raw materials and system cost. The

need for vulcanization in autoclaves has generally limited the use of rubber based systems to manifolds,

jumpers and bends, whilst the need for pre-casting of shapes and long cure times have limited the use

of syntactic epoxies in general to strap-on modules and single components.


Since the mid 1990s the average length of tie-backs has steadily increased, and line burialvi and

electrically heated systems have become more commonvii to further stretch the limits for single pipe

systems. In these cases the main workhorse has been polypropylenes as heightened complexity in the

use of polyurethanes and epoxies, brought about by water absorption and property change, has led to

condensation polymers being used less widely. Other than using lower density foams and syntactic

materials the material choices have changed little.

Recent work performed in Bredero Shaw’s laboratories and plants have demonstrated the ability of

styrenic alloys and blends to provide highly robust thermal insulation systems through extrusion and

injection moulding.

NEW FAMILY OF MATERIALS

The newly developed Thermotite® ULTRA family of products utilises foamed, flexibilised and solid

styrenic based thermoplastic materials to provide highly robust, lay friendly and highly efficient

bonded subsea thermal insulation systems capable of low U-value and great ocean depth. This paper

will present the qualification and verification work performed in advance of the release of these

products to the market.

Styrenic materials have been established in commercial markets since the 1930s, when BASF

developed the first process to isolate the resin. The material was also released into the US market in

1937 by Dow Chemical. Polystyrene was the first stable engineering polymer, having a high modulus,

high dimensional stability and low distortion. Styrofoam was released onto the commercial market by

Dow Chemical in 1954. At that time this was however a brittle material and needed to be further

developed. Since this cautious beginning, advances in the development of the technology have made

the material highly impact resistant by the addition of butadiene to the polymerisate, alternatively

compounding with ABS, or increasing rigidity through the incorporation of, for example, SMA. The

result is a wide range of material property envelopes from stretchy rubbers to bearing grade materials.

In all cases this is a non-biodegradable material which, as it does not contain cleavable groups, is not

affected by water exposure. Styrenics are also widely miscible or compatible with many high quality

engineering thermoplastics, giving great flexibility in mechanical and thermal design of systems.


Styrenic materials in general and in the case of the Thermotite® ULTRA family styrenic blends and

alloys, are materials that can be processed at high output rates using current extrusion and injection

moulding processes. This is a significant operational advantage since these are the two most common

methods of manufacture of subsea thermal insulation. These materials are also readily foamed,

providing low creep foams with low k-value and low water take-up. Styrenic materials have inherently

low thermal conductivity even as solids, favourable modulus values compared to polypropylenes in

general, and have good low temperature properties with a Tg below -30oC.

SYSTEM BUILD

The Thermotite® ULTRA line pipe coating system comprises a styrenic 3-layer structure including

fusion bonded epoxy, a specially designed adhesive using a blend of materials and finally a styrenic

based top-coat.

The insulation system is then extruded onto this base structure in the normal manner, either as solid,

foam or combination of the two to the required thickness. Finally the wear coat is applied by wrap

extrusion or co-extrusion to build the final system.

The Thermotite® ULTRA field joint system is applied according to standard practices for injection

moulded polypropylene (IMPP) field joints; using modified pre-treatment values and a specific high

ductility styrenic infill material.

In the event of repairs, a highly robust thermoplastic repair material has been developed and

extensively tested.

Visually the system looks identical to any polypropylene based thermal insulation system. Bredero

Shaw’s development philosophy is to build on existing skill sets and adapt existing practices to bring

forth a new and exciting range of thermal insulation products with a minimum of risk.


SYSTEM BENEFITS

The Thermotite® ULTRA system is conveniently mobilised in existing 3-layer factories with some

minor equipment and process modifications. The manufacturing process does not require twin screw or

compounding extruders to blend in glass microspheres to achieve low thermal conductivity. Even as a

solid, the natural thermal conductivity of the resin as a solid is lower than that of syntactic PP. At the

same time however if a twin screw extruder is available at the plant of choice, it can be used for the

application of the solid. This manufacturing flexibility means that Thermotite ULTRA will be available

in plants worldwide using existing production practices.

Thermotite ULTRA’s naturally low k-value leads to a thinner insulation layer than is generally the case

for polypropylene or polyurethane based systems. The ability to foam the system results in low k-

values that are not readily achievable for subsea foams that must also withstand high hydrostatic

pressure.

This higher density system combined with its lower thermal conductivity extends cool down

performance, assists in optimizing hydrodynamic response in risers and improves sea bed stability in

flowlines. The insulation can store more energy with less heat loss to maintain fluid temperatures for

longer periods of time. (refer to Table 3 for relative thermal diffusivity).

The Thermotite® ULTRA system does not contain glass microspheres, since these are not required to

give high thermal performance. As a result the solid systems have unrivaled deep water performance

with unlimited capability.

The excellent low temperature performance of the styrenic material systems used in the Thermotite®

ULTRA family give benefits for cold climate reeling, while the matched flexibility of the field joint

provides mechanically continuous systems with little stiffness mismatch.

The low water absorption of the system and lack of cleavable groups in the resin make this materials

family ideally suited to subsea operation as an exposed system, buried system and potentially as a

highly performing insulant in DEH systems.


TESTING PERFORMED

The Thermotite® ULTRA system has been tested extensively in the lab, on pilot scale production lines

and with coated pipe produced during 5 full scale trials in three different production facilities around

the world. In total, in excess of 120 pipes have been processed and tested and over 80 field joints have

been applied. The results of the rigorous performance tests are presented below.

Materials testing:

Mechanical

Mechanical testing was performed on all components of the Thermotite® ULTRA system in

accordance with ASTM D638 at 50 mm/min. These materials are formulated for good low temperature

ductility and impact performance. As can be seen in Table 3, the ductility of the components does not

show the degree of change seen with polypropylene materials, remaining high down to -10°C. This is

particularly important with a view to reeling activities in cold climates, where temperatures as low as

-5°C are not uncommon when pipe is collected from the spool base.

Temperature (oC)

Material Property Unit -10 0 20 Solid insulation Strain @ yield % 6 8 8

Strain @ break % 33 35 35 Stress @ yield MPa 23 23 22 Stress @ break MPa 26 25 24

Foamed insulation Strain @ yield % 4 4 6 Strain @ break % 18 18 20 Stress @ yield MPa 15 14 9 Stress @ break MPa 15 15 10

Field Joint Material Strain @ yield % 8 10 10 Strain @ break % 70 80 100 Stress @ yield MPa 18 14 14 Stress @ break MPa 25 20 20

Outer shield Strain @ yield % 7 7 9 Strain @ break % 40 50 50 Stress @ yield MPa 25 23 18 Stress @ break MPa 22 20 12

Repair material Strain @ yield % 8 10 10 Strain @ break % 70 80 100 Stress @ yield MPa 18 14 14 Stress @ break MPa 25 20 20

Table 2: Mechanical properties for ULTRA component materials


Thermal

The following thermal properties have been measured on material taken from pipe (Table 3). 50 mm

discs were used for thermal conductivity measurements, using PMMA as the calibration standard.

Specific heat capacity was measured using DSC at a heat rate of 10oC/min. on 20 mg samples. As can

be seen the values are generally low relative to corresponding polypropylene foams with similar

modulus.

Density

(kg/m3) K-value (W/m.K)

Specific Heat (J/kg.K)

Relative Diffusivity*

Material 30oC 60oC 30oC 60oC 30oC

Solid Insulation 1040 0.152 0.158 1250 1630 0.667811

Foamed Insulation @ 18% foaming 850 0.121 0.13 1250 1630 0.650443

Foamed Insulation @ 23% foaming 800 0.110 0.118 1250 1630 0.628269

Field Joint Infill Material 1010 0.146 0.152 1380 1700 0.598281

Outer Shield 1028 0.168 0.171 1350 1680 0.69141

Repair Material 1010 0.146 0.152 1380 1700 0.598281

Reference high mod. PP 900 0.26 0.258 1650 2200 1

Table 3: Thermal properties for ULTRA component materials

* Normalised on PP Testing of the corrosion protection system The 3-layer corrosion protection system comprises a standard FBE coating, onto which the specially

formulated ULTRABond adhesive is applied. A thicker layer of ULTRA solid is then applied onto the

ULTRABond surface in the same way that the familiar 3-layer PE and PP products are produced.

The resulting structure has been tested in accordance with those standards applicable for 3-Layer PP

and PE with respect to CD and hot water soak.

CD testing

CD testing was performed at 65oC for 48 hours at a test voltage of -1.5V and at 23°C for 28 days. The

results are shown below pictorially. The system showed an average disbondment of FBE to steel of 2

mm during this test for 48 hours and 3.8 mm after 28 days. No signs of disruption of the FBE-


ULTRABond adhesion were seen. The FBE used in this trial was Scotchkote 226N from 3M, applied at

a thickness of 300 microns, and the ULTRABond system was applied at a thickness of 300 microns.

Figure 1: Sample after CD testing at 654oC, 48 hours, -1.5V

Hot water soak testing Hot water soak testing was performed at 80oC for 7 days. No delamination or detachment from the steel

substrate was seen during the test. The FBE used in this trial was Scotchkote 226N from 3M, applied at

a thickness of 300 microns, and the ULTRABond system was applied at a thickness of 300 microns

.

Figure 2: Sample after hot water soak testing.


Systems testing The ULTRA product has been subjected to extensive system testing in order to demonstrate and to

document the performance envelope of the product. All generally accepted installation and operation

tests are complete from the point of view of the product release, however project specific requirements

and product improvements will undoubtedly require re-visiting these tests from time to time.

Trawl board impact testing

The complete system, both solid foamed and field joint was subjected to trawl board impact testing

using a pendulum impinger at an energy of 12.7 kJ in accordance with the DnV trawl gear interference

code “DNV-RP-F111 Interference Between Trawl Gear and Pipelines”. A 50 mm diameter

hemispherical impinger head was used and four impingements were made, of which two coincided.

Testing was performed at 4oC.

Subsequent sectioning was performed in order to determine the nature and extent of potential damage

and delamination. The results of this testing are shown graphically in Figure 3. No signs of damage

were seen in any of the samples, and no delamination was seen either within the insulation system or to

steel.

Figure 3a - c: Trawl board impact testing on (a) field joint (b) line pipe and (c) cross section after impact.

Resonant fatigue testing

Resonant fatigue testing has been performed at TWI on a 6 m long section of 10.75” OD pipe coated

with 50 mm of Thermotite® ULTRA including a field joint (300 mm cutback, 8 mm overbuild, 50 mm

overlap). The test, carried out for 500,000 cycles at 0.2% strain was conducted at a frequency of 20 Hz.


The temperature of the system rose by 2 – 3oC, however the test was completed without evidence of

damage or deterioration.

Figure 4: Fatigue test set-up at TWI.

Stinger roller testing

In order to address the effect of roller contact (in the case of roller boxing stinger loads) a section of

pipe was subjected to a stinger roller test during which a section of pipe including a field joint was

pulled beneath a 350 mm dia. roller, onto which a load of 4 tons was applied. The pull speed was ca. 2

m/min. The roller passed over the coating and field joint without sign of indentation or cracking.

Subsequent dissection of the sample showed no signs of distress and no indication of delamination.

Figure 5: Stinger roller test.


Tensioner clamp

The ULTRA 95 system was subjected to increasing squeeze loads between two parallel thrust surfaces,

mounted in an instrumented hydraulic press. Squeeze loads of up to 500 kN were applied to a 300 mm

long section. The length of the touch-down onto the anvils was measured and plotted against the load

applied. The sample was also inspected for any internal cracking or delamination during the test. The

test set-up is shown in Figure 6. No indications of crack initiation or delamination of the sample were

seen.

Figure 6: Clamp arrangement for compression testing

Simulated service Samples of solid and foamed systems have been subjected to simulated service testing in order to verify

the k-value and creep model for system design. A sample of the solid system was subjected to

simulated service testing at a variety of temperatures over a period of 49 days and at a variety of

hydrostatic loadings. The sample, 50 mm of system applied to a 10.75” x 15.9 mm X65 steel pipe, was

instrumented with LVDT probes to record thickness change, in addition to six heat flux cells with

integrated thermocouples. The results are shown below (Table 4).


Pressure Operating

Temperature (oC) Duration

(Days) Compressive Creep (%)

System k-value (W/mK)

50 bar 77.40 6 0.35 0.159 100 bar 77.37 1 0.74 0.160 120 bar 77.36 9 0.91 0.161 200 bar 79.17 11 1.71 0.165 280 bar 79.12 11 2.30 0.167 280 bar 91.80 11 2.36 0.170

Table 4: Results of SSV testing on the solid system

As can be seen, the compressive response of the system having gained equilibrium was very small and

well within the expectations for existing materials when used under similar conditions.

Full scale bend test

The Thermotite® ULTRA system has been extensively tested for reel deployment; eight 12.2 m long

10.75” x 14.3 mm pipes with 50 mm of insulation systems have been reel tested at 4oC on a 7.5m bend

former. This applies for solid, foamed and flexibilised systems. No signs of distress within or in the

vicinity of the field joint were observed during the test, including no signs of localized or general over-

stressing. The field joint was in each case subsequently dissected and it was determined that no internal

delamination or damage had been induced during the test.

Figure 7: ULTRA system at full bend (outer fibre strain 2.4%).


Axial shear testing Axial shear testing has been performed on all major interfaces within the ULTRA systems at relevant

temperatures reflecting operation. The values returned show a high level of cohesion between

successive application steps, and also within the material itself. This is of course important for system

integrity during lay and operation of the line. Testing of the innermost interface at 95oC shows the

robustness of the system at higher temperature

Shear strength

(Mpa) FBE - ULTRAbond (23C) 14 FBE - ULTRAbond (95oC) 7 3-Layer - Insulation 12 Insulation - Insulation 12 Within insulation 15 Insulation - outer shield 12

DESIGN EXAMPLES The following design examples illustrate the advantages of the ULTRA system for a range of

applications relative to market incumbents:

Designs are based on a 10.75” x 14.3 mm steel pipe, requiring a U-value of 3 W/m2K on the OD of the

pipe, and assuming a production fluid with Cp=2,300 J/kg.K, density 140 kg/m3 and a k-value 0f 0.04

W/m.K, cooling from 50°C to 20°C in a 4oC environment. Field life 20 years. Field operating at 95oC.

For shallow water to 200 m:

System FBE

(mm) Adhesive

(mm) Inner solid (mm)

Insulant (mm)

Outer shield (mm)

Total (mm)

Compression (%)

SG Tcool (Hours)

PPF 0.3 0.3 5.4 82 3 91 3.5 1.05 12 sPU 0.3 - - 64.7 - 65 8.5 1.07 8.5 ULTRA foam

0.3 0.3 - 56.4 3 60 2 1.2 10

Table 5: Axial shear results for ULTRA


For shallow water from 300 - 500 m: System FBE

(mm) Adhesive


Insulant (mm)

Outer shield (mm)

Total (mm)

Compression (%)

SG Tcool (Hours)

PPF 0.3 0.3 5.4 80 3 89 7 1.05 11 ULTRA* 0.3 0.3 5.4 53 3 62 3.5 1.2 10.5 * foam solid composite For shallow water from 500 m - 1000 m: System FBE

(mm) Adhesive


Insulant (mm)

Outer shield (mm)

Total (mm)

Compression (%)

SG Tcool (Hours)

PPF 0.3 0.3 5.4 84 3 93 6 1.04 11 sPP 0.3 0.3 5.4 78 3 87 2 1.03 10.5 GsPU 0.3 - - 74.4 - 75 2.5 1.1 10 ULTRA* 0.3 0.3 19.4 42 3 65 3.2 1.2 11 * foam solid composite For water depths >1000 m: System FBE

(mm) Adhesive


Insulant (mm)

Outer shield (mm)

Total (mm)

Compression (%)

SG Tcool (Hours)

sPP 0.3 0.3 5.4 81 3 90 2.8 1.02 11 GSPU 0.3 - - 86.4 - 87 2.5 1.1 10.5 ULTRA 0.3 0.3 5.4 66 3 75 2 1.3 12 FINAL COMMENTS Thermotite® ULTRA is a new family of highly robust thermal insulation systems which has been

developed and tested. The testing detailed in this paper adequately demonstrates that this system is

suitable for use as a reliable thermal insulation system for subsea use, and is friendly toward pipe lay

with the compatible field joint system. The improved thermal performance relative to market

incumbents provides high thermal efficiency at reduced coating thickness.

i Bredero Shaw Norway a.s. ii ShawCor LLC iii Norewgian Technical University iv Solheim, A., Aker Vetco A/S, Norway; Prichard, M., Vetco Gray Inc, USA; Newcombe, R., Vetco Gray Ltd, UK.

Offshore Europe, 5 – 8 September 1989. v Direct Impedence Heating of Deepwater Flowlines, Hansen, A.B., Clasen, T.L. and Bass, R.M. OTC proceedings 1999 vi Auk pipeline, 12 km 8 inch line, buried to a depth of 1 m in 1986 vii DEH projects – Statoil Åsgard, Statoil Kristin, Statoil Huldra, BP Skarv, Woodside Pluto

brederoshaw.comthe GLOBAL LEADER in pipe coating solutions.

PRO

DU

CT D

ATA

SHEET

FLOWASSURANCE

Featu

res & Ben

efits

Superior Insulation Properties• Lower thermal conductivity of both solid and foamed systems

results in lower achievable U values

• Reduced thermal diffusivity extends cool-down time

• Compatibility with direct electrical heating systems (DEH) extends system utilization

Unmatched Mechanical Performance• Superior low temperature ductility enables lower temperature

reeling and increased flexibility in installation schedule.

• Incompressibility of solid system allows unlimited water depth installation

• Higher insulation density coupled with reduced thickness improves seabed stability of flowlines and assists in optimizing hydrodynamic response of risers

Thinner Insulation• Lower thermal conductivity translates to reduced insulation

thickness and potential savings in transportation and installation costs

• Thinner insulation and reduced pipe profile results in lower lay strains and improved hydrodynamic response

No Glass Microspheres• Zero risk of compromised thermal performance due to glass

breakage or degradation during service

• Superior insulation performance without glass enables unlimited depth installation

Proven Field Joint Technology• Compatible injection-moulded field joint material

guarantees insulation integrity and system performance

• Lower field-joint application temperature facilitates cooling and reduces moulding cycle time

Application Using Conventional Equipment• Streamlined delivery schedules, product standardisation and

quality assurance practices due to simplified processing operations

• Universally and readily available project management and logistics support from multiple existing plant locations

Thermotite® ULTRA™Superior Subsea Insulation

Product Description

Thermotite® ULTRA™ is an innovative subsea insulation system with unlimited water depth capability, comprising a specially engineered blend of polymeric materials having unique mechanical and thermal properties. The superior performance of Thermotite® ULTRA™ assures complete system integrity during service, and reduced energy loss in steady state and transient conditions.

23

45

1

1. Fusion Bonded Epoxy2. ULTRABond Adhesive3. ULTRA Solid4. ULTRA Foam5. ULTRAShield

Applications

Oil & GasPipelines

Subsea Pipelines

Small DiameterPipelines

PDS - Flow Assurance Pages.indd 20 4/19/2011 9:18:26 AM

Regio

nal O

ffices

brederoshaw.comthe GLOBAL LEADER in pipe coating solutions.

The information contained herein is indicative of the types of coatings provided by Bredero Shaw, and is not intended to be a guarantee that a particular coating will be suitable for a given application. Since many unique environmental, operating, and design conditions must be considered, the user shall determine the suitability of the coating for the intended use and assume all the risks and liabilities in connection therewith. Bredero Shaw’s liability is stated in our standard conditions of sale.

About Bredero ShawBredero Shaw is the global leader in pipe coating solutions. With more than 80 years of experience, the largest team of dedicated pipe coating professionals, the most extensive network of strategically located plants worldwide and with proven innovative coating technologies, the company has protected more pipelines in virtually every environment and operating condition than anyone in the industry.

Bredero Shaw offers technologically advanced solutions for anti-corrosion coatings, protective and weight coatings, thermal flow assurance coatings, internal coatings, custom coatings and field joints for both onshore and offshore applications. This broad range of products and services provides Bredero Shaw with the unique capability to service the full spectrum of pipeline protection and flow assurance requirements. Consult your Bredero Shaw representative for your unique project requirements.

HEAD OFFICEBredero Shaw

3838 N. Sam Houston Pkwy E.Suite 300

Houston, Texas 77032-3400, USA

Phone: [email protected]

NORTH AMERICABredero Shaw

Two Executive Place,200, 1824 Crowchild Trail, N.W.

Calgary, Alberta T2M 3Y7, Canada


LATIN AMERICABredero Shaw

3838 N. Sam Houston Pkwy E.Suite 300

Houston, Texas 77032-3400, USA


EUROPE, MIDDLE EAST, AFRICA & RUSSIA

Bredero ShawLakeside House

1 Furzeground Way Stockley Park, Uxbridge

UB11 1BDPhone: +44 (0) 208 622 3071

[email protected]

ASIA PACIFICBredero Shaw

101 Thomson Road#17-01/02 United Square

Singapore 307591Phone: +65-6732-2355

[email protected]

Thermotite® ULTRA™Superior Subsea Insulation

PlantsNorth America Latin America EMAR Asia Pacific

Pearland, Texas Veracruz, Mexico Leith, ScotlandOrkanger, Norway

Kuantan, MalaysiaKabil, Batam Island, Malaysia

Product Application Process

SurfaceInspection

Grind SurfaceDefects

Blast CleanPreheat

Preheat

Preheat

FBEApplication

3-LayerTopcoat

ExtrudedAdhesive

InductionHeat

Stockpile

ElectricalInspection

ProductInspection

ProductInspection

ProductInspection

ExtrudedULTRA Shield

Extruded* Solid orFoam ULTRA

Quench

Quench

Quench

Thermotite® ULTRA™_rev021

Typical Plant Capabilities and Product Properties

Capability/Property Thermotite® ULTRA™

Diameter Range .................................................................................................................................................4” - 30”

Maximum Water Depth..................................................................................................................... Unlimited as solid

Density ............................................................................................................................................... 800 - 1040 kg/m3

Heat Capacity (Cp)...................................................................................................................................... 1220 J/kg K

Thermal Conductivity (k) .................................................................................................................0.11 - 0.16 W/m K

Axial Shear Strength ....................................................................................................................................... >10 Mpa

Simulated Service .......................................................................................................... (tested up to) 280 bar at 95°C

Outer Fiber Strain (Reel Lay) ........................................................................................................2.6% strain at -10°C

Values shown are typical and may vary from plant to plant. Consult Bredero Shaw for special requirements.Note: As density and composition are design variables with Thermotite® ULTRA™ the above figures are given as general guidelines. Where there is a range specified, the interval is related also to the density range for the particular component. In addition, it should be noted that Thermotite® ULTRA™ has passed tests for Resonant Fatigue, Trawl Board Impact, Stinger Roller and Tensioner Clamp.

* Insulation and outer shield layers may also be extruded by the crosshead method.

PDS - Flow Assurance Pages.indd 21 4/19/2011 9:18:28 AM

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A Novel Thermal Insulation System for Bonded Subsea · PDF fileA Novel Thermal Insulation System for Bonded Subsea Single ... fusion bonded epoxy, ... The Thermotite® ULTRA field