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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

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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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