Subsea Pipeline Thermal Insulation Using Segmented Hollow Elements
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Solution Overview
Problem
Current thermal management technologies for subsea pipelines, such as wet insulation and pipe-in-pipe systems, face limitations in deep water environments due to high pressures and costs, with a need for a more efficient and cost-effective solution that maintains hydrocarbon fluid temperature to prevent wax and hydrate formation.
Innovation Solution
A subsea pipeline thermal management system utilizing elongated hollow elements filled with insulation material, arranged in parallel layers around the pipeline, which can be wrapped and protected with a flexible layer to provide effective thermal insulation while reducing material and installation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet insulation is used for subsea pipeline thermal management, then installation simplicity and cost are improved, but thermal insulation performance deteriorates at depths greater than 12 miles due to high hydrostatic pressure
Solution Approach 1:
The insulation system is segmented into multiple discrete foam elements arranged in a matrix pattern around the pipeline. Each foam element is a separate insulating unit that collectively provides comprehensive thermal coverage. This segmentation allows the insulation to maintain structural integrity under hydrostatic pressure while achieving the required thermal performance through the combined effect of multiple elements.
Solution Approach 2:
The insulation system uses composite construction combining foam material elements with a protective outer layer. The foam elements provide thermal insulation while the protective layer shields against hydrostatic pressure and environmental factors. This composite approach achieves both thermal performance and pressure resistance without requiring thick single-layer insulation that would be vulnerable to damage during installation.
2Reliability
If pipe-in-pipe technology is used for thermal management, then thermal insulation performance is improved with U-value less than 2 W/(m2×K), but material costs, fabrication costs, and installation complexity increase significantly
Solution Approach 1:
The invention extracts the essential thermal insulation function from the complex pipe-in-pipe structure. Instead of requiring a complete outer steel pipe carrier system, the solution applies insulated foam elements directly to the pipeline surface. This extraction maintains the thermal performance benefit while eliminating the excessive material costs, fabrication complexity, and installation burden of the full pipe-in-pipe system.
Solution Approach 2:
The foam elements are designed as cost-effective, replaceable insulating units that can be applied directly to the pipeline without requiring expensive outer pipe structures. These elements provide sufficient thermal protection for the intended service life while being more economical than permanent pipe-in-pipe installations. The modular nature allows for easier replacement or maintenance if needed.
3Reliability
If thicker insulation coating is applied to increase tieback distance, then thermal insulation performance is improved, but installation damage risk increases during reel-lay installation
Solution Approach 1:
The insulation is divided into multiple discrete foam elements rather than a single thick continuous layer. This segmentation provides structural resilience during reel-lay installation, as the individual elements can flex and withstand handling stresses better than a monolithic thick coating. The segmented structure maintains thermal performance through collective coverage while improving resistance to installation damage.
Solution Approach 2:
The foam elements are designed with flexible characteristics that allow them to withstand the mechanical stresses of reel-lay installation. Rather than relying on thickness alone for protection, the elements have flexible properties that enable them to bend and flex during handling and installation without cracking or breaking, thereby maintaining both insulation performance and damage resistance.
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
This solution achieves thermal performance comparable to pipe-in-pipe systems while reducing weight and diameter, simplifying installation, and lowering costs by eliminating the need for an outer steel pipe, thus overcoming design and installation challenges in deep water environments.
Implementation Method 1
at least one insulating layer surrounding the pipeline. Each insulating layer includes a plurality of elongated hollow elements arranged side-by-side in a single layer in parallel with respect to one another. Each of the elongated hollow elements is sealed at its ends and contains an insulation material there within
Data Source
AI summary
Disclosed are apparatus, systems and methods for maintaining desired thermal properties of a flowing hydrocarbon fluid in a subsea pipeline. An insulating layer including a plurality of elongated hollow elements containing an insulation material can surround the pipeline. The apparatus can be located on a seabed and connected to a source of hydrocarbon fluid at one end and to a facility for processing hydrocarbon fluid at another end. One method includes spirally winding an elongated hollow element containing an insulation material around the subsea pipeline. One method includes wrapping the subsea pipeline with a connecting layer which includes surface protrusions protruding radially outwards. An insulating layer having surface features reversibly engageable with the surface protrusions of the connecting layer can be reversibly attached to the connecting layer by engaging the surface features of the at least one elongated hollow element with the surface protrusions of the connecting layer.