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www.bhrgroup.co.uk 18th International Conference on PIPELINE PROTECTION Antwerp, Belgium; 4 - 6 November 2009 Long term experience with polypropylene thermal insulation on subsea pipelines

Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

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Page 1: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

www.bhrgroup.co.uk

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Long term experience withpolypropylene thermalinsulation on subsea pipelines

Page 2: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Contents•Introduction

• Why insulate

•Use of Polypropylene Foam Insulation

•Qualification

•Application

•Installation

•Operation

•Conclusions

Page 3: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Functional requirements for thermalinsulationProvide corrosion protection for thelifetime of the coated steel flowline

Provide the required thermal insulation(U-value) for the lifetime of the flowline

Flui

d te

mpe

ratu

re

Hydratetemp.

No insulation New insulation

Exposed insulation

Time to hydrate formation

Page 4: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Pipe steel types that have been insulated

Carbon steelSMSS (super martensittic stainless steel) 13 % CrCarbon steel with stainless steel liner (Bubi)Clad steel (carbon steel with metallurgicallybonded stainless steel liner)Duplex stainless steels

Page 5: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Field joint typesField joint type When used Parent coatingInjection mouldedpolypropylene

Reeling / S-lay /onshore / offshoretie-in

Polypropylene foam

Flame spray polypropylenewith polypropylene halfshells

Offshore tie-inand field joints

Polypropylene foam

Solid polyurethane S-lay / Stalk tie in(reeling)

Polypropylene (lowtemperatureapplications)Polyurethane

Page 6: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Anode attachement – for cathodic protectionand direct electric heating (DEH)

Page 7: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Five layer polypropylene foam system

Steel pipe: 228.6 mm OD x 11.6mm x 13% Cr

High temperature Fusion Bonded Epoxy

Polypropylene Outer Shield

Polypropylene Foam

Solid Polypropylene

Polypropylene high temperature Adhesive

Page 8: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Polypropylene foam insulated pipelines inStatoil

Feature Ranges

First installation 1991

Length installed 784 000 m

Diameters insulated 200 – 500 mm / 8-20 “

Water depths 82 - 390 m

Design temperatures 65 – 155 oC

U-values 3 – 8 (W/m2K)

Highest thickness 78.3 mm

Installation methods S-lay and reeling

Page 9: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Installed pipelines with polypropylene foaminsulation in Statoil

0

100000

200000

300000

400000

500000

600000

700000

800000

900000

1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010

Year

Insu

late

d pi

pe (m

)

Page 10: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Design temperatures for the subseaflowlines

0

20

40

60

80

100

120

140

160

180

1990 1995 2000 2005 2010

Year

Tem

pera

ture

( C

)Kristin

Page 11: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Water depth of installed pipelines

0

50

100

150

200

250

300

350

400

450

1990 1995 2000 2005 2010

Year

Wat

er d

epth

(m)

Page 12: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

U-values ( W/m2K) or coating thickness

0

10

20

30

40

50

60

70

80

90

1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010

Year

U-v

alue

(W/m

2K) /

Thi

ckne

ss (m

m)

Page 13: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

U-values for some of the flowlines

0

1

2

3

4

5

6

7

8

9

10

1990 1992 1994 1996 1998 2000 2002 2004 2006 2008 2010

Year

U-va

lue

(W/(m

2K)

Page 14: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Insulation application discrepancies

Density outside the required specificationEccentric placement of steel pipe in foamLack of bond between the three-layer coating andinsulationCracking of external weight coatingIrregular outer surface from unstable processconditionsCracking of factory coating due to less flexible FBECracking of factory coating and PP field jointCracking in coating at the spool base due to rollerboxing

Page 15: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

High temperature qualification – 155 C

-A temperature – time profile for theproduction from the reservoirs

-The flowlines were used as heat sinks tolower the well stream temperature toacceptable 132 oC for the risers andproduction facilities

-A close to solid PP insulation system

-Flow assurance based on direct electricheating (DEH)

-Special attention to anode connections tokeep water away from SMSS surface

Page 16: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Field joints and installation

Cracks in injection moulded polypropylenefield jointsCracks in tie-in joints both injection mouldedpolypropylene and polyurethaneCracks in the parent insulation materialBuckling of steel pipes in field joints due tostrain concentration associated with thecoatingCracks in connection with anode brackets

Page 17: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

In-service experience – hydrogen cracking

Page 18: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

In-service experience – polyurethane fieldjoints

Page 19: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Flame spray polypropylene

Page 20: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Key to successful projects

Direct involvement of own personnel with the pipecoater, i.e. increased internal knowledge baseQuality issues has been solved between pipecoaters and end userAll technical discussions has been solved betweenthe end user and pipe coaterHigh quality of the final deliveries

Page 21: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Conclusions

PP based foam has been the base case formost pipeline projects with insulationrequirements since the first installation in 1991

The system was further developed and qualifiedfor high temperature applications through anactive involvement with the coating systemsupplier

The in-service operational experience afterinstallation has been excellent.

Page 22: Long term experience with polypropylene thermal insulation ...( Presentations/Long Term... · Long term experience with polypropylene thermal insulation on subsea pipelines. ... Provide

18th International Conference onPIPELINE PROTECTION

Antwerp, Belgium; 4 - 6 November 2009

Long term experience withpolypropylene thermal insulation onsubsea pipelines

Bjørn Melve, Dana Ali, Harald Thon,Kristian Haraldsen

Statoil ASA, Norway www.statoil.com [email protected], [email protected],[email protected], [email protected]