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The ShawCor Difference
STRONGFUNDAMENTALS
FUNDAMENTALSTRENGTHS
A Novel Wet Insulation Coating System for Deepwater and Extreme Conditions
By Dr. Shiwei William Guan, AOG, February 20, 2014
Content
Industry trends for flow assurance thermal insulation
Key design parameters
Design concept
Thermotite Ultra – line pipe system
Thermotite Ultra – field joint system
Qualification and validation tests
Project execution– Balboa Pipeline: Water depth = 1,124 meters in the Gulf of Mexico– Goliat Pipeline: the very first wet insulation installed in Arctic water
Summary
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Industry Trends for Flow Assurance Thermal Insulation
Longer design life
Longer tie-backs
Lower U (thermal transmittance) values
Deeper water, thicker wall pipe, more CRA/Clad pipes
Higher operating temperature (up to 150oC)
Tougher design, qualification and QC/HSE requirements for PQT, application process and installation
Corrosion resistance
Increased thermal performance
Improved mechanical performance
Longer period of storage in marine environments prior to deployment
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–Chevron Wheatstone - 110oC, 237 m, 30 yrs design life, tough spec
–Eni Norge Goliat - The 1st major development in the Arctic
–Statoil Åsgard - 140oC, 350 m
–Statoil Kristin - 155oC, 350 m
–BP Thunder Horse - 132oC, 2.200 m multi-layer on very heavy pipe
–Chevron Blind Faith - 150oC, 2.000 m, complex composite multi-layer
–Woodside Pluto - Complex composite multi-layer on heavy pipe
–Shell Kizomba B SHRs - Intricate PiP construction
–BP Block 31 - Extreme thickness on heavy wall pipe
–Total Pazflor - High thickness
–BP Skarv - Low U-value, multi-layer coating
Examples of Some Challenging Offshore Flow Assurance Projects
Current Flow Assurance Status Quo
Base insulation materials have changed little and are still focused on– Polyurethane, polypropylene and epoxy foams and syntactics
Limitations in existing materials High installation cost High thickness Hydrostatic pressure limitations Subsea stability Temperature limitations
Key Design Parameters for Deepwater and Extreme Conditions
The ability of the insulation to withstand the maximum hydrostatic pressure expected on the seabed as it is exposed to the maximum design/operation temperature:– Mechanical loads and thermal insulation requirements normally increase with
deeper waters– Compressive creep at the operating temperature during the service life
– Higher density: better mechanical but reduced thermal properties– Excessive coating thickness: reduced seabed stability for flowlines and
increased drag on a SCR
The change in the mechanical properties of the insulation after the application of the coating– Understand and validate the changes to ensure the insulated pipes can be
installed with no risk– Confirm the thermal insulation design can meet the expected performance
requirements
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Design Concept
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Implemented in 1-D FDA algorithms.
Easily ported to 2-D axio-symmetric / 3D models
Material relationships time, stress and temperature dependent
Accurate prediction of– Internal stresses– Densification– Dimensional change– Temperature profile– K-value profile– U-value and OHTC.
Thermotite Ultra – Line Pipe System
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1 2 354
1. Fusion Bonded Epoxy
2. ULTRABond adhesive
3. ULTRA Solid
4. ULTRA Foam / Solid
5. ULTRAShield
3-Layer Corrosion Protection System System buildup – Multilayer Insulation
Thermotite Ultra – Line Pipe System
Lower k factor than PP
Lower film thickness for same insulation value
No glass spheres
Infinite water depth
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Solids•Density 1030 kg/m3
•K-value 0.156 W/m.KFoams
•Density 740 – 850 kg/m3
•K-value 0,115 – 0,145 W/m.K
Comparative Chart of Bonded Subsea Pipe Thermal Insulation Systems
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Comparative Design Example
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Water Depth (meters) System Thickness (mm) Compression (%) Specific Gravity
< 300PPF 91 3.5 1.05
sPU 65 8.5 1.07
ULTRA foam 60 2.0 1.2
300 – 500 PPF 95 5 1.03
ULTRA foam 62 3.5 1.2
500 – 1500PPF 93 6.0 1.04
sPP 87 2.0 1.03
GsPU 75 2.5 1.1
ULTRA foam 65 3.2 1.2
> 1500sPP 90 2.8 1.02
GSPU 87 2.5 1.1
ULTRA 75 2.0 1.3
Thermotite Ultra – Line Pipe Qualification and Validation Testing
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Tests
CD Testing• 65C, -3.5V, 24 hours:
1.9 mm (S1) and 2.4 mm (S2) • 23C, -1.5V, 28 days:
6.6 mm (S1) and 2.4 mm (S2)
Hot Water Soak Test• 80oC, 7 days and 90oC,
28 days: Rating 1
Trawl Impact Test• 12.7 kJ
• DNV-RP-F111 • 50 mm diameter
impinger• 4 x impingements
• Testing at 0C
Clamping Test• Loads up to 500 kN
• Length 300 mm• Max. Load 25 MPa (60 mm
touchdown)• No damage to system
Resonant Fatigue• 500,000 cycles
• 10 Hz• 200 microstrains on steel
• Uncooled
Stinger Roller• 500 mm roller• 6 tons on one
wheel• No damage to
insulation/FJ
Axial Shear
Thermotite Ultra – Line Pipe Qualification and Validation Testing
Tests
SSV Testing• Temperature to 120oC• Pressure to 200 bar• Low compression• Validated U-value
Reeling Test• 10.75” x 14.3 pipe, 50 mm system
• Bend radius 7.5 m• Test temp. -10oC
• 4 cycles• No disruption of any kind
UV Ageing• Exposure Time Radiant
• Exposure at 340 nm• 800 hours 1036 kJ/m2
Thermal Cycling• 10 x 12 hour cycles
• -20C to +20C• No cracking or disbondment
Thermotite Ultra – Field Joint System
1. Fusion Bonded Epoxy
2. ULTRABond adhesive
3. ULTRAJoint
1 23
Thermotite Ultra – Field Joint Qualification and Validation Testing
Combined Thermal cycling and full scale bend testing
– No cracking or disbondment
SSV Testing, 1200 hours at 95oC– No significant change in any of the parameters (Gel
content, Swelling Index, Corrected Viscosity)
1 year at 95oC, 300 bar, SWIS JIP SSV test
– No signs of delamination or distress– No significant change in any of the parameters
(Stress/Elongation at Yield, Stress/Elongation at Break, Density)
– Water Absorption Test: Negligible water uptake
Trawl Board Impact Testing (12.7 kJ, DNV-RP-F111, 50 mm diameter impinger) – Remained intact
Stinger Roller Test (635 mm diameter roller, 6 tonnes) – No signs of distress or delamination
Thermotite Ultra Project Execution Winner of the Spotlight on New Technology Award at the
Offshore Technology Conference 2010
Balboa Subsea Tieback Project in GOM: Mariner Energy and Ocean Flow International (“OFI”), 2010– (5.563” (141 mm) pipe size x 12.7 mm WT, 48 mm foam system, 50°C
operation in 1124 m water depth, UID value 4.13 W/m2. K)– Insulation production completed in May 2010 by Bredero Shaw Pearland
coating facility in Texas, U.S.A.– Spooling of the insulated pipeline in late October 2010– Laid in November 2010 by Helix’s Express pipelay vessel– Balboa field began production on December 28, 2010
Thermotite Ultra Project Execution ENI Goliat: Technip, OD 12” and 40 mm Ultra Foam, 2011
– The very first installed wet insulated flowline in Arctic waters– 53 miles (85 km) off the Norwegian coast in the Barents Sea– 13.275” (338 mm) pipe x 14.6 mm WT , 40.5 mm foam system with DEH,
80°C operation in 400 m water depth, UID value 3.6 W/m2. K– Spooled on Technip’s Apache II reel-lay vessel
Benefits of Thermotite Ultra from a contractor’s perspective*• Enables less pipe – wall thickness to be proposed (where feasible), ie. Design can be optimised if
burst is not the limiting parameter• For reel vessels with very large reel size, eg. Technip new build Deep Energy, savings in steel cost
and weight can be significant• Gives competitive advantage on EPCI projects and reduced overall investment costs for end Client• Improves pipelay and trenching by increasing Specific Gravity• Reduced weight and volume could save additional round trips for reeling contractors and handling
costs • Allows reeling in low temperatures (an issue in Norway and Arctic region)
*Berstad, J, Boubli, M, and Crome, T (2013). “Installation of the Goliat Product Flowlines”, IBC’s 36th Annual Offshore Pipeline Technology Conference (OPT 2013), February 27 and 29, Amsterdam
A Novel Wet Insulation Coating System for Deepwater and Extreme Conditions
Anti-corrosion system same as for PP and PU, using FBE
Lower k-value of insulation gives improved thermal efficiency
As solid, lower k-value than sPP and GsPU
Superior low temperature performance
Design temperature to 120oC
Unlimited water depth
No glass microspheres
End to end solution
Two projects successfully executed
Approval underway with all major operators & EPCIs
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