Materials systems for subsea “wet” insulation have been focused on polyurethane, polypropylene and epoxy foams and syntactics for many years. Although general improvements have been made in terms of performance and processing, no radically new systems have been released since 1998. These materials are widely used; however, they do have a range of limitations. These limitations are becoming increasingly apparent as the requirements for system performance continue to become more demanding.
Styrenic thermoplastics have been used as insulation materials for many years due to their intrinsically low thermal conductivity. Advanced blending technology provides materials with excellent foamability, good ductility, high impact tolerance and unique thermal properties. A programme to develop offshore pipe insulation systems based on styrenic alloys was started in 2007, considering thermal and mechanical performance along with global availability and scope for system adaptation. The challenge was to develop micro-balloon free systems with improved thermal properties, suitable for subsea deployment using all lay methods.
This programme included compatible field joint systems and is now at the point of completion having led to a radically new family of Bredero-Shaw proprietary styrenic formulations for subsea thermal insulation known as Thermotite® ULTRA™."