High-Temperature Field Joint Insulation for Offshore Pipelines
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Solution Overview
Problem
Conventional field joint materials, such as epoxy corrosion protection coatings and polyolefin insulation layers, are not suitable for high-temperature applications in offshore pipelines operating between 150°C to 200°C, necessitating a need for reliable field joint systems that can maintain insulation and protection at these elevated temperatures.
Innovation Solution
A method involving insulated pipe sections with a steel pipe, a corrosion protection coating, and a pipe insulation layer, where a first field joint insulation layer with heat resistance up to 205°C is applied, followed by a second layer with heat resistance up to 140°C, using polymer compositions like silicone elastomers and fluoroelastomers, and optionally including a protective layer and anti-corrosion coating to ensure continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional field joint materials (epoxy corrosion protection coatings and polyolefin insulation layers) are used, then the manufacturing process is simple and economical, but the materials cannot maintain insulation and protection at high temperatures (150°C to 200°C)
Solution Approach 1:
The patent applies composite materials by combining multiple insulation layers with different temperature resistance characteristics. The first insulation layer uses high-temperature resistant material (silicone elastomer or fluoroelastomer) capable of withstanding up to 205°C, while the second layer uses material resistant to 140°C. This composite structure ensures reliable thermal insulation and corrosion protection across the entire temperature range of 150°C to 200°C, resolving the contradiction between simple material application and high-temperature suitability.
2Reliability
If high temperature resistant materials are used, then the pipeline can operate reliably at 150°C to 200°C, but the field joint formation process becomes more complex
Solution Approach 1:
The patent segments the field joint insulation system into two distinct layers: a first insulation layer applied directly to the weld joint area made of high-temperature resistant material (silicone elastomer or fluoroelastomer), and a second insulation layer applied over the first layer made of material resistant to lower temperatures. This segmentation allows each layer to be optimized for its specific thermal environment, ensuring reliable continuous operation at 150°C to 200°C while maintaining a manageable application process through clear sequential steps.
3Reliability
If a multi-layer insulation system is applied, then thermal insulation and corrosion protection are maintained at high temperatures, but the application time and process duration increase
Solution Approach 1:
The patent implements preliminary action by applying the first high-temperature resistant insulation layer (silicone elastomer or fluoroelastomer) directly to the weld joint area before the pipeline is fully installed or before the second insulation layer is applied. This preliminary application ensures that the critical high-temperature zone is protected first, allowing subsequent layers to be applied more efficiently. The method maintains thermal insulation integrity at 150°C to 200°C while reducing total application time through this prioritized sequencing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The described method provides a reliable field joint system capable of maintaining thermal insulation and corrosion protection at high temperatures, ensuring the integrity and efficiency of offshore pipelines operating between 150°C to 200°C.
Implementation Method 1
a pipe insulation layer provided over the corrosion protection coating, wherein a terminal end of the pipe insulation layer is spaced from the end of the pipe, and wherein the pipe insulation layer comprises a polymer composition having thermal conductivity of less than about 0.40 W/mk, and/or heat resistance to continuous operating temperatures from about 150°C to above about 205°C
Data Source
Figure 1~2
Figure 3
Figure 3A
AI summary
A method for forming a high temperature field joint between two insulated pipe sections, and an insulated conduit having a low temperature field joint. The conduit comprises a steel pipe with a corrosion protection coating and a pipe insulation layer comprising a polymer composition having thermal conductivity of less than about 0.40 W/mk, and/or heat resistance to continuous operating temperatures from about 150°C to above about 205°C. After a circumferential weld joint is formed between the two pipes, a first field joint insulation layer is applied over the joint area, the first field joint insulation layer comprises a polymer composition having heat resistance to continuous operating temperatures from about 150°C to above about 205°C.