Influence of foam morphology on end of life U-value
for subsea foamed polypropylene pipeline insulation
June 7 2017
AMIrsquos Oil amp Gas Polymer Engineering Texas 2017
Foam Morphology and End of Life U-value
2
Contents
bull Shawcor at a glance
bull Hydrostatic compression
bull Triaxial compression test
bull Simulated Service Test
bull U-value case study
bull Foam morphology
bull Triaxial test results
bull SST results
bull Thermal design process
bull Hypothetical designs
bull Summary
Shawcor at glance
3
Global Energy Services Company
~ 5000Employees worldwide
80+ Global locations
25Countries across the globe
236 Issued Patents 86 Proprietary Formulations Solutions ndash Driven by Innovative Technology
~ $18 (CAD)
Billion revenues
Provides technology-based solutions for the pipeline and pipe services market and the petrochemical and industrial markets Shawcor focuses on five core competencies pipeline coating welding inspections composite pipe oilfield asset management and cables and connectors
4
ShawcorProducts and Services Offering
sPP(U gt 3 W msup2 K)
120 150 18080
100
500
1000
1500
2000
2500
3000
200
GsPU(U gt 3 W
msup2 K)UltraFoam
(U gt 2 W msup2 K)
UltraSolid(U gt 3 W msup2 K)
XtremeTemp(U gt 3 W msup2 K)
Wat
er D
epth
[m
]
Design Temperature [degC]
PPFoam(U gt 3 W msup2 K)
5
Shawcor ndash Wet flowline insulation solutions
bull PPFoam
bull 150 degC and 500 m
bull High density foam Nominal density 740 kgm3
Hydrostatic Compression
6
Hydrostatic pressure according to water depth bull
from 1 MPa to 30 MPa
Constant over the pipelinersquos lifetime (bull 30 years)
Initial compression componentbull
Upon installationbull
Considered instantaneousbull
Recoverablebull
Creep compression componentbull
Over entire lifetimebull
Limited recoverybull
ISO bull 12736 calls for determination of
ldquohydrostatic compressive behaviorrdquo of each
layer of insulation
At bull 23 degC and max rated temperature
Shall be determined for each insulation layerbull
Standard for Petroleum and natural gas industries mdash
Wet thermal insulation coatings for pipelines flow lines equipment and subsea structures
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Foam Morphology and End of Life U-value
2
Contents
bull Shawcor at a glance
bull Hydrostatic compression
bull Triaxial compression test
bull Simulated Service Test
bull U-value case study
bull Foam morphology
bull Triaxial test results
bull SST results
bull Thermal design process
bull Hypothetical designs
bull Summary
Shawcor at glance
3
Global Energy Services Company
~ 5000Employees worldwide
80+ Global locations
25Countries across the globe
236 Issued Patents 86 Proprietary Formulations Solutions ndash Driven by Innovative Technology
~ $18 (CAD)
Billion revenues
Provides technology-based solutions for the pipeline and pipe services market and the petrochemical and industrial markets Shawcor focuses on five core competencies pipeline coating welding inspections composite pipe oilfield asset management and cables and connectors
4
ShawcorProducts and Services Offering
sPP(U gt 3 W msup2 K)
120 150 18080
100
500
1000
1500
2000
2500
3000
200
GsPU(U gt 3 W
msup2 K)UltraFoam
(U gt 2 W msup2 K)
UltraSolid(U gt 3 W msup2 K)
XtremeTemp(U gt 3 W msup2 K)
Wat
er D
epth
[m
]
Design Temperature [degC]
PPFoam(U gt 3 W msup2 K)
5
Shawcor ndash Wet flowline insulation solutions
bull PPFoam
bull 150 degC and 500 m
bull High density foam Nominal density 740 kgm3
Hydrostatic Compression
6
Hydrostatic pressure according to water depth bull
from 1 MPa to 30 MPa
Constant over the pipelinersquos lifetime (bull 30 years)
Initial compression componentbull
Upon installationbull
Considered instantaneousbull
Recoverablebull
Creep compression componentbull
Over entire lifetimebull
Limited recoverybull
ISO bull 12736 calls for determination of
ldquohydrostatic compressive behaviorrdquo of each
layer of insulation
At bull 23 degC and max rated temperature
Shall be determined for each insulation layerbull
Standard for Petroleum and natural gas industries mdash
Wet thermal insulation coatings for pipelines flow lines equipment and subsea structures
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Shawcor at glance
3
Global Energy Services Company
~ 5000Employees worldwide
80+ Global locations
25Countries across the globe
236 Issued Patents 86 Proprietary Formulations Solutions ndash Driven by Innovative Technology
~ $18 (CAD)
Billion revenues
Provides technology-based solutions for the pipeline and pipe services market and the petrochemical and industrial markets Shawcor focuses on five core competencies pipeline coating welding inspections composite pipe oilfield asset management and cables and connectors
4
ShawcorProducts and Services Offering
sPP(U gt 3 W msup2 K)
120 150 18080
100
500
1000
1500
2000
2500
3000
200
GsPU(U gt 3 W
msup2 K)UltraFoam
(U gt 2 W msup2 K)
UltraSolid(U gt 3 W msup2 K)
XtremeTemp(U gt 3 W msup2 K)
Wat
er D
epth
[m
]
Design Temperature [degC]
PPFoam(U gt 3 W msup2 K)
5
Shawcor ndash Wet flowline insulation solutions
bull PPFoam
bull 150 degC and 500 m
bull High density foam Nominal density 740 kgm3
Hydrostatic Compression
6
Hydrostatic pressure according to water depth bull
from 1 MPa to 30 MPa
Constant over the pipelinersquos lifetime (bull 30 years)
Initial compression componentbull
Upon installationbull
Considered instantaneousbull
Recoverablebull
Creep compression componentbull
Over entire lifetimebull
Limited recoverybull
ISO bull 12736 calls for determination of
ldquohydrostatic compressive behaviorrdquo of each
layer of insulation
At bull 23 degC and max rated temperature
Shall be determined for each insulation layerbull
Standard for Petroleum and natural gas industries mdash
Wet thermal insulation coatings for pipelines flow lines equipment and subsea structures
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
4
ShawcorProducts and Services Offering
sPP(U gt 3 W msup2 K)
120 150 18080
100
500
1000
1500
2000
2500
3000
200
GsPU(U gt 3 W
msup2 K)UltraFoam
(U gt 2 W msup2 K)
UltraSolid(U gt 3 W msup2 K)
XtremeTemp(U gt 3 W msup2 K)
Wat
er D
epth
[m
]
Design Temperature [degC]
PPFoam(U gt 3 W msup2 K)
5
Shawcor ndash Wet flowline insulation solutions
bull PPFoam
bull 150 degC and 500 m
bull High density foam Nominal density 740 kgm3
Hydrostatic Compression
6
Hydrostatic pressure according to water depth bull
from 1 MPa to 30 MPa
Constant over the pipelinersquos lifetime (bull 30 years)
Initial compression componentbull
Upon installationbull
Considered instantaneousbull
Recoverablebull
Creep compression componentbull
Over entire lifetimebull
Limited recoverybull
ISO bull 12736 calls for determination of
ldquohydrostatic compressive behaviorrdquo of each
layer of insulation
At bull 23 degC and max rated temperature
Shall be determined for each insulation layerbull
Standard for Petroleum and natural gas industries mdash
Wet thermal insulation coatings for pipelines flow lines equipment and subsea structures
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
sPP(U gt 3 W msup2 K)
120 150 18080
100
500
1000
1500
2000
2500
3000
200
GsPU(U gt 3 W
msup2 K)UltraFoam
(U gt 2 W msup2 K)
UltraSolid(U gt 3 W msup2 K)
XtremeTemp(U gt 3 W msup2 K)
Wat
er D
epth
[m
]
Design Temperature [degC]
PPFoam(U gt 3 W msup2 K)
5
Shawcor ndash Wet flowline insulation solutions
bull PPFoam
bull 150 degC and 500 m
bull High density foam Nominal density 740 kgm3
Hydrostatic Compression
6
Hydrostatic pressure according to water depth bull
from 1 MPa to 30 MPa
Constant over the pipelinersquos lifetime (bull 30 years)
Initial compression componentbull
Upon installationbull
Considered instantaneousbull
Recoverablebull
Creep compression componentbull
Over entire lifetimebull
Limited recoverybull
ISO bull 12736 calls for determination of
ldquohydrostatic compressive behaviorrdquo of each
layer of insulation
At bull 23 degC and max rated temperature
Shall be determined for each insulation layerbull
Standard for Petroleum and natural gas industries mdash
Wet thermal insulation coatings for pipelines flow lines equipment and subsea structures
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Hydrostatic Compression
6
Hydrostatic pressure according to water depth bull
from 1 MPa to 30 MPa
Constant over the pipelinersquos lifetime (bull 30 years)
Initial compression componentbull
Upon installationbull
Considered instantaneousbull
Recoverablebull
Creep compression componentbull
Over entire lifetimebull
Limited recoverybull
ISO bull 12736 calls for determination of
ldquohydrostatic compressive behaviorrdquo of each
layer of insulation
At bull 23 degC and max rated temperature
Shall be determined for each insulation layerbull
Standard for Petroleum and natural gas industries mdash
Wet thermal insulation coatings for pipelines flow lines equipment and subsea structures
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
MEASUREMENT OF HYDROSTATIC COMPRESSIONTriaxial Compression Test and Simulated Service Test
7
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Triaxial Compression Test
8
Method
bull Cylindrical test specimen
bull Contained in cylindrical steel autoclave
bull Piston pressing down on top of sample
bull Produces a tri-axial stress state
bull Mimics the stresses in pipe coating
bull Temperature and pressure constant
bull Compression recorded over time
bull Measures initial compression
bull Measures creep compression
bull Common test on foamed insulation at Shawcor
bull Described in ISO 12736 Annex AEssential test for design of thermal insulation
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
9
bull Creep rates increase with temperature
bull Thick insulation is split into test
sections (L1 L2 L3 hellip)
bull Average temperature is calculated
for each section
bull Cylindrical test specimen
bull Typically Oslash32 mm x 55 mm
bull Machined to 003 mm tolerance
bull Radial orientation
bull One specimen can be made from
several plugs
bull Diameter is compensated for
thermal expansion - allows a snug
fit in the autoclave
L1
L1
L1
Triaxial Compression Test
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
10
Triaxial Compression Test
End of Life (typically 30 years) compression is extrapolated
Compression is dependent on pressure temperature foam density and foam morphology
20 years = 175200 h25 years = 219000 h30 years = 262800 h
bull Compression of PPFoam follows a logarithmic trend
bull Typical test duration is 100 h
bull Short duration is verified by long term testing
bull Large library of historical data
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
11
bull A 28 day test of the pipe at operational conditions
bull Internal operation temperature
bull External water temperature and hydrostatic water pressure
bull Measures heat loss and radial compression
bull Primarily used to verify the U-value (next slide) of the pipe
bull In some cases the SST is used to verify cool-down or thermalcycling performance
bull The SST is not an ageing test
Shawcor CRampD test vessel
bull Heat loss measured through surface of insulated pipe
bull Displacement of pipe surface measured using LVDTs
SST description
Simulated Service Test
bull Shawcor CRampD vesselbull le 6 m pipe specimenbull 7 electrically heated
temperature zonesbull 20 pipe surface heat
flux sensors in 7 zonesbull 12 high resolution
LVDTs in 4 zones
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
12
LVDT sensitivity
Simulated Service Test
-10
-05
00
05
10
15
20
0 500 1000 1500 2000
Co
mp
ress
ion
[
]
Time [minutes]
Internal heatersturned on
Start pressurization
Thermalexpansion
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
13
bull The U-value is an engineering concept
bull Convenient for calculating a heat loss rate for a given temperature differential
119880 119877ref =| ሶ119902 119877ref |
|119879o minus 119879i|119877ref - radius of a cylindrical reference surface
ሶ119902 119877ref - heat flux through the referencesurface ie heat loss rate per unit area
|119879o minus 119879i| - the temperature difference driving theheat loss
bull 119879o and 119879i are kept constant during the test
bull Shawcor will measure the heat flux ሶ119902 119877o through theouter surface of the pipe (at 119877o) and calculate ሶ119902 119877ref
ሶ119902 119877ref =119877o119877ref
ሶ119902 119877o
bull 2119877ref is defined by the Client It is always the inner or outer diameter of the steel pipe
bull Shawcor will design an isulation that meets theClientrsquos U-value requirement at 2119877ref
bull Shawcor measure U-value at an accuracy of approx 3
SST U-value
Simulated Service Test
Ro
Ri
Ti
To
Rref
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
14
SST bull compression is reported as an average over the 28 day test duration
PPFoambull creep compression occurs on a time scale longer than the 28 day test duration
For bull PPFoam less than 50 of the total compression over the lifetime of the pipe may
occur during the test duration
High bull compaction will increase the density of the insulation in turn increasing the U-
value
Operationbull temperature typically drops with time in service and lowers the minimum
downstream temperature where hydrate formation is critical =gt EOL is important
Verybull limited SST compression data is available Must cover a wide range of
temperatures and pressures (and pipelayer geometries and foam densities)
SST compression
Simulated Service Test
Caution required for highcompression materials
bull PPFoam at high pressure and high temperature
bull Other foams with a long term creep trend
OK for low compression materials
bull Glass syntactic PP
bull Solid materials
bull PPFoam at low pressure and
low temperature
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
15
U-value as function of compression
The bull insulation should meet the U-value criteria at the end of the life(EOL) of the pipeline
Coatingbull compression as function oftime is determined with low uncertaintyand can be extrapolated to EOL
Typicallybull no significant trend to determine EOL U-value
Accurancybull of U-value measurementis 3
Shawcorbull will design insulations thatmeets the U-value at the end of life ofthe pipeline based on EOL compression data
Requiresbull knowledge about the creepcompression rate of the coating
Simulated Service Test
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
DESIGN CASE STUDYU-value for poor vs improved foam morphology
16
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
bull SST and triaxial compression measurements taken from full scale pipes
bull Pipes produced with poor foam morphology High compression
bull Pipes with improved foam morphology due to process improvements
bull Test results are directly comparable
bull Same pipe OD
bull Same foam density (740 kgm3)
bull Same test pressure (56 MPa)
bull Same test temperature
bull Similar thicknesses
bull Hypotetical thermal designs were made to illustrate
bull Impact on material consumption
bull Impact on U-value
17
DESIGN CASE STUDY
Poor foam morphologyvs
Improved foam morphology
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Image Segmentation
bull Identify each foam cell
bull Find the centroid of the cell
bull Measure cell size cell orientation and
aspect ratio
bull Calculate the number density of cells
ie number of foam cells per mm3
bull If applicable Calculate foam transport
properties or mechanical properties
18
Foam Morphology Identification
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Usebull different foaming agent
Pellet bull size and distribution
Foamingbull agent powder size and
distribution
Nucleationbull mechanism
Fine tune bull loading of foaming agent Too
much will cause course foam structure with
much cell coalescence
Set moderate melt bull temperature High end
temperature will increase foam cell size
and reduce number density
Reducebull mechanical distortion of foam cells
Elongated foam cells have low
compressive strength
Improvement of Morphology
19
Foam Morphology Improvements
Deformation Improved
Low dosage Coalescence
Micrographs have the same scale
bull Same densitybull Cell size down 35 bull Aspect radio down 40
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
20
Triaxial Test Results 56 MPa
bull Poor foam morphology 81 compression end of test and 12 extrapolated to EOL at 73 degC
bull Improved foam morphology 43 compression end of test and 64 extrapolated to EOL at 73 degC
bull Excellent fit to logarithmic function for all temperatures R2 ge 095
bull Same density plusmn 2
0
1
2
3
4
5
6
7
8
9
001 01 1 10 100 1000
Co
mp
ress
ion
[
]
Time [h]
Poor morphology 30 degC
Poor morphology 50 degC
Poor morphology 73 degC
Improved morphology 30 degC
Improved morphology 50 degC
Improved morphology 73 degC
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
SST compression data EOL extrapolation
21
SST Compression Test Results 56 MPa
00
05
10
15
20
25
30
35
0 200 400 600
Co
mp
ress
ion
[
]
Time [h]
Before improvement After improvement 1
After improvement 2
y = 01560ln(x) + 02774Rsup2 = 09983
y = 01650ln(x) + 04070Rsup2 = 09997
y = 02713ln(x) + 12126Rsup2 = 09985
00
05
10
15
20
25
30
35
40
45
50
1 10 100 1000 10000 100000C
om
pre
ssio
n[
]Time [h]
30 years Log (After improvement 2)
Log (After improvement 1) Log (Before improvement)
Low compression critical for strapped on units requiring pretension
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
LayerThickness
[mm]
EOL triaxial compression []
Before opt After opt
FBE 03 00 00
Adhesive 03 00 00
3L 54 10 10
Foam layer 1 30 128 64
Solid intermediate 3 10 10
Foam layer 2 30 102 51
Solid intermediate 3 10 10
Foam layer 3 30 54 34
Solid topcoat 4 10 10
Thickness weighed compr [] 82 44
Tri-axial compression
Before improvement
30 end of test compression
47 EOL compression
After improvement
13 end of test compression
22 EOL compression
Shawcor SST have high accuracy on
compression LVDTs Measurement can
be considered the actual compression of
the pipeline
SST compression
22
Triaxial vs SST Compression 56 MPa
Triaxialbull compression results are conservative compared to SST compression resultsBetter bull models are needed for the relationshipbetween triaxial tests and actual compression (SST)
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Thermal Insulation Design Process
23
Requirements and Conditions
bull U-value
bull Cool-down time
bull Max compression
bull Max thickness
bull Buoyancy
bull Design temperature
bull Water depth
bull Lifetime
bull Installation type
bull Other input
Design
bull Select insulation system
bull Foam density
bull Compression
bull Thermal properties
bull Proven capability
=gtbull Layer thicknesses
bull U-value
bull Cost
bull Etc
Verification
bull Triaxial compression
bull Other material tests
bull Installation tests
bull Simulated Service Test
bull Other system tests
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
bull A thermal design defines the thickness of
insulation required to reach an insulation
requirement
bull The most common requirement is U-value
bull Insulation coatings consists of several layers
bull Each layer in the thermal insulation is defined
at start of life (SOL) and end of life (EOL)
bull Thickness
bull Density 120588
bull Thermal conductivity 119896
bull Foam density increases with compression
bull Thermal conductivity increases with
increasing foam density
bull For small changes in density
119896EOL = 119896SOL120588EOL120588SOL
bull U-value increases with increasing thermal
conductivity
U-value
119880 119877ref = 119877ref
119895=1
119899ln(119877119895+1119877119895)
119896119895
minus1
24
Thermal Insulation Design Process
Rj Rj+1
Rref
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Poor foam morphology U = 236 Wm2K Improved foam morphology U = 236 Wm2K
25
Cost Impact SST compression
5 reduction in thickness and PP consumption with improved foam
12119Coating mass [kgm] 11550Coating mass [kgm]
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 280 0173 740
PP Solid 30 0229 920
PP Foam Mid 280 0174 740
PP Solid 30 0233 920
PP Foam Outer 286 0174 740
PP Solid 40 0236 920
Total 1006
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 270 0180 769
PP Solid 30 0230 925
PP Foam Mid 274 0178 759
PP Solid 30 0234 925
PP Foam Outer 282 0178 755
PP Solid 40 0237 925
Total 984
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Poor foam morhology Thickness 106 mm Improved foam morphology Thickness 106 mm
26
U-value Impact SST compression
Coating compression 22
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0229 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 289 0180 769
PP Solid 30 0230 925
PP Foam Mid 293 0178 759
PP Solid 30 0234 925
PP Foam Outer 295 0178 755
PP Solid 40 0237 925
Total 1036
236 W(m2K)U-value of LP on OD U-value of LP on OD 225 W(m2K)
Layer Build Start of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0300 1300
Adhesive 03 0219 900
PP Solid 54 0223 920
PP Foam Inner 300 0173 740
PP Solid 30 0228 920
PP Foam Mid 300 0174 740
PP Solid 30 0233 920
PP Foam Outer 300 0174 740
PP Solid 40 0236 920
Total 1060
Layer Build End of Life
Material Thickn [mm] k [W(mK)] Dens [kgm3]
FBE 03 0301 1304
Adhesive 03 0220 903
PP Solid 54 0224 925
PP Foam Inner 273 0190 812
PP Solid 30 0230 925
PP Foam Mid 286 0183 778
PP Solid 30 0234 925
PP Foam Outer 292 0180 762
PP Solid 40 0237 925
Total 1010
Coating compression 47
Matching the SST
compression
5 reduction in U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
U = 236 Wm2K
47 =gt 22 compression
106 mm =gt 101 mm thickness
1212 kgm PP =gt 1155 kgm PP (5
down)
Thickness 106 mm
47 =gt 22 compression
236 Wm2K =gt 225 Wm2K (5 down)
Compression data
- Only known after test (PQT stage)
+ Actual compression
SST compression data
U = 236 Wm2K
82 =gt 44 compression
116 mm =gt 105 mm thickness
1345 kgm PP =gt 1202 kgm PP (11
down)
Thickness 116 mm
82 =gt 44 compression
236 Wm2K =gt 218 Wm2K (8 down)
Compression data
- Overly conservative
+ Wide range of historical data available
Triaxial compression data
27
What compression data to use in design
In general historical triaxial compression data is used in designHowever 82 would be considered unrealistically high
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
bull ISO12736 calls for determination of rdquohydrostatic compressive behaviorrdquo
bull Triaxial compression test is a good method for measuring creep compression but
conservative
bull Detailed knowledge of foam compression is essential for accurate thermal designs
bull Triaxial compression data is primary source of compression data for design
bull Future work Better models are needed for the relationship between triaxial test results
and actual compression (SST)
bull U-value EOL can not generally be determined in SST test
bull Poor PPFoam morphology can double foam compression
bull Foam morphology (aspect ratio cell size cell number density) can be quantified using
image segmentation to show foam improvement
bull Foam compressibility can be improved by process improvements
bull Improved foam morphology reduces project cost
28
Summary
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value
Thank you for your attention
QUESTIONSJAN PEDER HEGDAL
Research Manager ndash Global Flow Assurance
Pipeline Performance
Shawcor Norway AS
PO Box 214 N-7301 Orkanger Norway
m +44 (0) 794 966 2302
m +47 902 19 913
e jphegdalshawcorcom
shawcorcom
29
Foam Morphology and End of Life U-value