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www.bhrgroup.co.uk
18th International Conference onPIPELINE PROTECTION
Antwerp, Belgium; 4 - 6 November 2009
Long term experience withpolypropylene thermalinsulation on subsea pipelines
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
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
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
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
18th International Conference onPIPELINE PROTECTION
Antwerp, Belgium; 4 - 6 November 2009
Anode attachement – for cathodic protectionand direct electric heating (DEH)
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
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
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
)
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
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)
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)
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)
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
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
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
18th International Conference onPIPELINE PROTECTION
Antwerp, Belgium; 4 - 6 November 2009
In-service experience – hydrogen cracking
18th International Conference onPIPELINE PROTECTION
Antwerp, Belgium; 4 - 6 November 2009
In-service experience – polyurethane fieldjoints
18th International Conference onPIPELINE PROTECTION
Antwerp, Belgium; 4 - 6 November 2009
Flame spray polypropylene
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
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.
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]