Subsea Products & Services

Transcription

1 Subsea Products & Services Thermal Insulation Buoyancy & Moulded Products

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3 Contents Introduction Subsea Systems and Products ContraTherm Innovative Insulation Technology ContraTherm Insulation Solutions C55 Subsea Insulation System C55 Direct Application Method C55 Pre-Moulded Engineered Components C25 Subsea Insulation System C25 Direct Application Method ContraTherm Material & Technical Properties ContraTherm Applications Subsea Buoyancy and Moulded Products Modsyn Subsurface Floats Modular Buoyancy Pipe Laying Floats Subsea Installation Buoys Umbilical Floats ROV Buoyancy Piggyback Saddles Subsea Cable Protection Banding

4 Introduction Since its formation in 2007, Advanced Insulation has become a single source provider for insulation and fire protection systems to the offshore oil and gas industry, and represents one of the most respected and progressive names in topside and subsea insulation worldwide. Advanced Insulation offers a wide range of products to meet the growing demand for fire protection and thermal insulation systems adaptable for elevated service temperatures and pressures. Advanced Insulation also provide a range of subsea buoyancy and SURF (subsea, umbilicals, risers and flowlines) products along with Marine specific fendering and buoyancy systems. The company s products are qualified and used worldwide by major oil and gas companies including: Total, ConocoPhilips, Chevron, Samsung, BP, Statoil, ONGC, ENI Woodside, Talisman and ExxonMobil as well as by their engineering and fabrication contractors. Furnace control room Advanced Insulation Ltd EEF Smart Product Award Joint Winner Testing Laboratory Advanced Insulation ISO9001:2008, OHSAS18001 and ISO14001:2004 accreditations reflect the company s commitment to quality and sustainability in the manufacture, supply and application of insulation and fire proofing products and services. The company is registered with First Point Assessment (FPAL and FPK), the oil and gas supply chain database for the UK, KZ and The Netherlands, a division of Achilles Information Limited. Advanced Insulation has achieved exceptional growth since the company started both in the UK and overseas through growing demand, increasing turnover from 3m in 2008 to 44m in In recognition to this, Advanced Insulation has recently been ranked 58th in The Sunday Times HSBC International Track 200 which lists Britain s mid-market private companies with the fastest-growing international sales. With a number of facilities in the United Kingdom and further facilities located in Angola, Brazil, Kazakhstan, Korea, United Arab Emirates and the United States, Advanced Insulation is well positioned to offer support throughout the world, wherever the project is. Advanced Insulation has twice been awarded The Queen s Award for Enterprise under the category of International Trade (2012) and Innovation (2013). These are highly prestigious awards for outstanding achievement by UK businesses in the categories of Innovation, International Trade and Sustainable Development. Further recent awards for Advanced Insulation include the 2015 EEF Smart Product award for the innovative ContraFlame MS400 lightweight under-deck protection system for offshore oil platforms, Insider South West International Trade Awards - International Company of the Year award (2015) in 16m - 50m turnover category and the Mid-Market Private Equitybacked Management Team of the Year Award and International Impact Award from the British Private Equity and Venture Capital Association (BVCA). 4

5 Subsea Systems and Products Advanced Insulation manufactures a wide range of products for the Subsea industry. Advanced Insulation s ContraTherm range of phenolic and silicone based resin systems have been engineered for high temperature environments. ContraTherm C55 and C25 meet the most technically demanding subsea insulation challenges, developed to meet the need for resilient insulation capable of tolerating the temperature and pressure extremes required for high temperature developments. For Subsea Buoyancy, Advanced Insulation offer a range of installation buoys and engineered buoyancy for flowlines, manufactured from lightweight syntactic foams which can perform in depths in excess of 3000MSW. Advanced Insulation also produce subsea, umbilicals, risers and flowlines (SURF) protection for bend limiting, fatigue prevention, impact and abrasion prevention as well as a range of piggyback saddles and clamps, banding and banding tools. 5

6 ContraTherm Innovative Insulation Technology Advanced Insulation specialises in the manufacture and supply of unique syntactic foam insulation systems designed for upstream oil and gas infrastructures. Focusing on phenolic and silicone based resin systems for high temperature environments, Advanced Insulation offers solutions to the most technically demanding subsea insulation challenges. The effective use of insulation materials on subsea pipelines and equipment assists flow assurance by maintaining flow rates which in turn optimises productivity and therefore lowers processing costs. Insulating subsea equipment reduces the cooling of reservoir fluids and maintains them above temperatures at which waxes and hydrates may form, thereby minimising the risk of diminished flow rates and blockages. Insulation may be applied to subsea equipment including but not limited to pipelines, Xmas trees, manifolds, jumper spools, pipe line end terminations and flange connections. As oil and gas production extracts fluids of ever increasing temperatures from deeper waters and at longer tie-back distances from the host structure, the benefit of insulating subsea equipment becomes increasingly apparent. With fluid temperatures approaching 180ºC (356ºF) and at water depths approaching 3,000 msw (10,000 fsw) the need for a high temperature, high pressure insulation material capable of withstanding such environmental extremes becomes a consideration of paramount importance. 6

7 ContraTherm Insulation Solutions Advanced Insulation has developed its ContraTherm solutions specifically to meet the need for resilient insulation materials capable of tolerating the temperature and pressure extremes required for high temperature developments. The ContraTherm systems are engineered to withstand the particular service requirements demanded by offshore oil and gas production and come into their own where high temperature, high pressure field developments are concerned. ContraTherm Subsea Systems C25 Syntactic Silicones Silicone resins offer a highly flexible, high temperature insulation system that is fast becoming the recognised solution for dynamic application service. Advanced Insulation recommends the C25 Series for service on dynamic applications such as production jumpers, tie in spools and steel risers. C55 Syntactic Phenolics Phenolic resins are widely used in high temperature applications and are the acknowledged choice for elevated service temperatures. Advanced Insulation recommends the C55 Series for service on less dynamic applications such as Xmas trees, manifolds, supported jumpers and pipeline end terminations. Epoxy Flow Coat C25 Syntactic Silicone Foam D2204 Phenolic Composite Laminate C55 Phenolic Insulation Foam C25 Primer Substrate Coated with Corrosion Coating Tie Coat Substrate Coated with Corrosion Coating Benefits to industry Excellent thermal insulation properties Excellent resistance to water ingress Excellent stability in water depths to 3000 msw Excellent resistance to compression loads Excellent resistance to impact loads Long term high temperature stability Long term structural stability Ease of application, modification and repair The use of ContraTherm on subsea pipelines and equipment assists flow assurance by maintaining flow rates, which will in turn optimise productivity and lower processing costs. ContraTherm can be applied to subsea equipment such as Xmas trees, manifolds, jumper spools, pipeline end terminations and flange connections. 7

8 ContraTherm C55 Subsea Insulation System ContraTherm C55 is a multi-layer syntactic phenolic composite system with properties that can be tailored to meet specific project requirements. Syntactic foams have been used in the offshore industry for more than 30 years and have become one of the key materials used in ever more demanding subsea applications. The low thermal conductivity and robust mechanical structure of ContraTherm C55 are ideally suited for subsea thermal insulation applications. The individual elements of the multi-layer system provide their own particular benefit and combine to provide a value for money solution. The D2004 phenolic composite top coat provides an extremely robust, impact resistant, hard wearing outer skin with a surface finish tailored to suit project requirements. The composite consists of multiple glass fibre layers impregnated with phenolic resin to form a tough outer skin of nominal 4mm thickness. This composite also provides a barrier to water ingress limiting water absorption in the insulation foam. ContraTherm insulation foam consists of an optimised fill of glass microspheres dispersed and supported within a phenolic resin matrix which provides the necessary integrity and strength. The thickness of the core material is determined by the insulation performance requirements of the specific project. There are several ContraTherm material grades individually developed for differing water depth requirements. ContraTherm Tie Coat provides a tacky interlayer which bonds the syntactic foam core material and gives good bond integrity to the substrate. Tie Coat may be applied directly to shot blasted steel coated with the standard high performance anti-corrosion coatings widely used by the subsea equipment manufacturers. C55 ambient curing properties make the system ideal for direct application to equipment on construction or manufacturing sites globally. The hand applied application methodology combined with the minimum requirement for complex application equipment, and the absence of mould tooling, ensures C55 is a very flexible material to apply from a scheduling perspective; a benefit where complex equipment build programmes are involved. The final layer of the GRP top skin is a resin flow coat to finish the laminating process. The standard colour for the flow coat is yellow however other standard RAL colours may be used to suit the client s requirements. The yellow flow coat ensures the insulation is visible to ROVs on subsea operations. The C55 Subsea System is equally comfortable in hot/wet or hot/ dry conditions and is therefore ideal for use in a retrofitted insulation system for flange protection covers or doghouses. Advanced Insulation reports both new and aged thermal conductivities for the bare C55 foam. Advanced Insulation recommends that the aged values are used in all thermal calculations providing a more conservative coating thickness. 8

9 ContraTherm C55 ambient curing makes it ideal for direct application to equipment on construction or manufacturing sites globally. The C55 insulation foam thickness will be determined by calculation from the thermal conductivity or specific heat capacity to meet the required overall heat transfer coefficient or cool down criteria. C55 is applied in layers until the required thickness is achieved. There is no practical limitation to the thickness of insulation that may be applied. ContraTherm C55 will perform as an integrated system fully bonded at all interfaces under the anticipated exposure conditions. Glass Microspheres The excellent thermal performance and high hydrostatic pressure capability of C55 insulation foam is provided by the presence of specially developed glass microspheres supported in the phenolic resin. The microspheres are microscopic closed cells of borosilicate glass which exhibit very stable insulation properties over long term environmental exposure. The phenolic binder does not absorb water and any voids between the microspheres and the resin represent an almost insignificant volume into which water can ingress. Advanced Insulation has tested for and established the maximum water absorption of the C55 insulation foam which occurs when the bare foam is exposed to highly pressurised water. The Tie Coat may be applied directly to shot blasted steel coated with the standard high performance anti-corrosion coatings widely used by subsea equipment manufacturers. There are several C55 material grades individually developed for different water depth requirements. Micrograph of C55 foam 9

10 ContraTherm C55 Direct Application Method ContraTherm C55 is supplied either as a wet coating applied directly to the corrosion coated substrate in the field or as a pre-moulded engineered component. A combination of both methodologies may provide the best solution in certain applications. The process of direct application involves mobilising materials, equipment and personnel to construction sites worldwide and applying the ContraTherm C55 system directly to the equipment substrate. The ContraTherm C55 Subsea System s cold curing properties make it an ideal material for direct application at any stage in the build programme of the subsea equipment, including finished assembled packages such as Xmas trees and manifolds. This allows the EPC contractor to fit the application of thermal insulation into the overall delivery programme with a great degree of flexibility. This application methodology, not requiring the construction of any mould tooling or formers, makes it possible to apply ContraTherm in areas which would normally prove difficult to access. In its wet state, the core material has a bread dough consistency and is designed to be easily applied to equipment and pipe work in layers of up to 20mm thickness at a time without sagging. The material does not experience shrinkage during curing enabling accurate thickness control. The application process guarantees joints will become homogenous ensuring there are no weak points in the system. The process is relatively simple and makes any modification or adjustments to the insulation thickness and coverage during application quick and simple. The composite outer skin will be applied to the ContraTherm core once the curing process is sufficiently advanced. The individual glass fibre layers are wrapped onto the core material and impregnated with resin between each individual layer. 10

11 The ContraTherm C55 Subsea System s ambient curing properties make it an ideal material for direct application at any stage in the build programme of subsea equipment, including finished assembled packages such as Xmas trees and manifolds. The ContraTherm C55 System does not require the fabrication of mould tooling nor does it require complex pumping equipment. The ContraTherm C55 System utilises simple mixing and application equipment which is readily available and does not require extensive maintenance or spares in the field. The relative simplicity of the application process makes the ContraTherm C55 System an ideal material for application using local labour with suitable training and under the supervision of Advanced Insulation technicians. The ContraTherm C55 System is supplied in pre-measured and prepackaged kits to ensure correct usage. Where the ContraTherm C55 System is directly applied, the insulation foam may be shaped to suit detailed interface requirements prior to curing. The post cured composition and texture of C55 insulation foam ContraTherm is ideally suited for machining using standard woodworking type equipment. This means that the removal of the ContraTherm C55 System is straightforward should it be required. 11

12 ContraTherm C55 Pre-moulded Engineered Components ContraTherm C55 can be moulded into pre-designed shapes to suit the equipment to be insulated. Such mouldings may be required to reduce application times and/or to provide for articulation or removable solutions where later access may be required. Pre-moulded components require some pre-engineering but their use can increase operational flexibility by reducing the on-site insulation schedule and may shorten the overall equipment lead-time and critical path. C55 components are produced by compression moulding. The material properties allow intricate single piece mouldings to be manufactured. This is advantageous as large or complex mouldings need not be manufactured in smaller subassemblies and subsequently bonded together risking potential weak spots at the joint interfaces. Pre-moulded components come in a range of shapes and sizes from relatively simple moulded panels, blocks or half-shell C-sections, up to the most complex connector cover arrangements such as ROV installed doghouse mouldings. Each design is engineered to match the dimensions of the component to be insulated and produced in highly accurate compression moulds. The shapes are subsequently fastened to the structure by the most suitable means, from simple strap banding arrangements to complex ROV operated closure systems, and sealed as appropriate to minimise water flow and retain insulation performance. Whilst Advanced Insulation will mould very complex components individually, the bonding of subordinate pieces can be achieved by the use of proven subsea epoxy adhesives. These adhesives also allow the bonding of panels directly to the substrate when necessary. A simple pre-moulded solution, such as a panel for subsequent bonding to a flow meter or valve body or a pair of C-section half shells for a pipe field joint arrangement, would be delivered to site in a kit form consisting of the insulation pieces, the epoxy adhesive and the strap banding or other form of mechanical fastening. The design of even simple components is engineered to suit specific demands, from jigsaw arrangement removable pieces to application time driven fast field joint covers for offshore pipe-lay operations. 12

13 Pre-moulded components come in a range of shapes and sizes from relatively simple moulded panels, blocks or half-shell C-sections up to the most complex connector cover arrangements such as ROV installed doghouse mouldings. More complex components are delivered in their final assembled condition in advance of final installation. This may involve the fixing into position of painted steel handling and closure frames and sealing arrangements to minimise the flow of water through the cover. Advanced Insulation supplies all associated bespoke steel fixtures, seals and other accompaniments required for specific insulation component designs whether surface or subsea, diver or ROV installed. The design of connector covers is complex and usually individual to each application. Advanced Insulation engineers work closely with clients to develop the most suitable solution, taking a holistic approach from manufacturing capability through to ease of installation whilst maintaining a specific focus on the project requirements. 13

14 ContraTherm C25 Subsea Insulation System Contratherm C25 is a specially formulated two part syntactic silicone system tailored to meet stringent subsea requirements. Syntactic silicone foams have been used in the offshore industry for 10 years and syntactic foams in general for over 30 years. The low thermal conductivity and flexible nature of Contratherm C25 make it an ideal product for subsea thermal insulation on dynamic structures. C25 insulation foam consists of an optimised fill of glass microspheres dispersed and supported within a silicone resin matrix which provides the necessary integrity and strength. The thickness of material is determined by the insulation performance requirements of the specific project. C25 is applied by direct casting to shot blasted steel coated with the high performance anti-corrosion coatings widely used by the subsea equipment manufacturers. Contratherm Primer is first applied to the substrate to provide an interlayer to the syntactic foam core material and to give good bond integrity to the substrate. C25 products are applied at room temperature so there is no need to heat the substrate being insulated. C25 s ambient curing properties make the system ideal for direct application to equipment on construction or manufacturing sites globally. The pump in situ application methodology, combined with non complex standardised equipment, ensures that C25 is a very flexible material to apply from a scheduling perspective; a benefit where complex equipment build programmes are involved. The application strategy is to use multiple low capacity pumps to maximise flexibility, increase ease of handling and provide redundancy at the operating site. Multiple pumps provide the option of filling moulds in parallel. C25 is applied by pumping the material into moulds fitted to the substrate to provide the required insulation thickness and profile. The silicone resin has a greater open time than other pumped materials which allows a slower and more considered pumping strategy. The rheology of the material requires a slower pump speed which allows the operator sufficient time to manage the pumping process. C25 is a flexible insulation material that is capable of absorbing the stresses applied through structure movements in service. Stresses are caused by the movement of the pipe structures through thermal expansion at elevated operating temperatures, pipe deflections and natural movement. The material will absorb such stresses without cracking or buckling. The standard colour for C25 is yellow, however, other standard RAL colours may be used to suit the client s purpose. The yellow colour provides high visibility to the insulation to ensure it is visible to ROVs on subsea operations. C25 is equally comfortable in hot/wet or hot/dry conditions and is therefore ideal for use in a retrofitted insulation system where ease of subsequent removal is important. 14

15 The ContraTherm C25 Subsea System s ambient curing properties makes the system ideal for direct application to equipment on construction or manufacturing sites globally. The primer may be applied directly to shot blasted steel coated with the standard high anti-corrosion coatings widely used by subsea equipment manufacturers. The C25 insulation foam thickness will be determined by calculation from the thermal conductivity or specific heat capacity to meet the required overall heat transfer coefficient or cool down criteria. The C25 system is applied by filling moulds to the required thickness in a single pour. There is no practical limitation to the thickness of insulation that may be applied. The system will perform as an integrated system fully bonded at all interfaces under the anticipated exposure conditions. During mould tool design Advanced Insulation will be able to manipulate client CAD models to optimise mould design. The mould tools are designed to be robust and reusable yet simple to aid ease of installation and removal. Glass Microspheres The excellent thermal performance and high hydrostatic pressure capability of C25 is provided by the presence of specially developed glass microspheres supported in the silicone resin. The microspheres are microscopic closed cells of borosilicate glass which exhibit very stable insulation properties over long term environmental exposure. The silicone binder does not absorb water and any voids between the microspheres and the resin represent an almost insignificant volume into which water can ingress. Advanced Insulation has tested for and established the maximum water absorption of the C25 insulation foam which occurs when the C25 is exposed to highly pressurised water. Micrograph of C25 Once cured ContraTherm is sufficiently robust to allow transportation without the need for further protection beyond that typically required for the equipment itself. 15

16 ContraTherm C25 Direct Application Method ContraTherm C25 is supplied as a wet coating applied directly to the primed substrate in the field. Engineered components can be moulded to provide removable insulation solutions for certain applications. The process of direct application involves mobilising materials, equipment and personnel to construction sites worldwide and applying the ContraTherm C25 system directly to the equipment substrate. The ContraTherm C25 system s ambient curing properties make it an ideal material for direct application at any stage in the build programme of the subsea equipment, including finished assembled packages such as jumpers and manifolds. This allows the EPC contractor to fit the application of thermal insulation into the overall delivery programme with a great degree of flexibility. The application methodology requires the construction of mould tooling which is engineered to suit any areas that are more difficult to access. This is not an issue with jumpers and tie-in spools which are the key service application for C25. The material does not experience shrinkage during curing enabling accurate thickness control. The application process guarantees joints become homogenous ensuring there are no weak points in the system The C25 product is a two part high viscosity liquid material applied by using a plural component pump. Application is by means of pumping the mixed material into moulds constructed around the structure being insulated. The material is poured into the cavity between the substrate and the mould tools guaranteeing the thickness and position of the insulation. Tools are generally reusable to provide a cost efficient system of application. 16

17 The ContraTherm C25 Subsea System s ambient curing properties make it an ideal material for direct application at any stage in the build programme of subsea equipment, including finished assembled packages such as jumpers and manifolds. Once cured, ContraTherm C25 is sufficiently robust to allow transportation without the need for further protection beyond that typically required for the equipment itself. The mould tools dictate the dimension and profile of the insulation moulding. Each moulding is profiled to accept the adjacent moulding to ensure correct bonding. Contratherm primers are used at all interfaces to ensure good bonding between insulation mouldings and the substrate. The primers are pigmented to highlight coverage during the application process. The bond strength created by the primer is greater than the strength of the bulk material. C25 can be cast to any thickness subject to any practical limitation within the subsea structure s dimensions. C25 is applied in ambient conditions and does not require the substrate to be preheated. The material is ambient curing and does not create internal stresses or impose stresses on the substate. This process ensures long term security of the insulation system as the risk of future separation of individual mouldings is negated. C25 material is easily removeable with the correct tools and is easily repaired using the same application process. Whilst closed moulds are normally used, open moulds can be used, when required by the application. 17

18 ContraTherm Material & Technical Properties ContraTherm has been developed thanks to continuing investment in research and development within Advanced Insulation s own laboratories and through qualification programmes often involving third party facilities. In developing the materials, a constant focus was maintained on the critical parameters required of high temperature, high pressure insulation materials. The material evaluation process can be split into two main categories, material definition and full scale performance testing. Material Definition Extensive laboratory scale testing is completed to determine material properties in new and aged conditions. Such testing enables material performance to be defined according to: Temperature Capability Hydrostatic Pressure Capability Thermal Performance Material Density Mechanical Performance Water Absorption Resistance Full Scale Testing Service capabilities of the materials are also determined by laboratory testing. However, it is essential to verify the materials performance at the full scale to demonstrate fitness for purpose. Advanced Insulation have tested their products predicted service performance through: Simulated Service Testing Thermal Cycling Testing Cool Down Testing Cathodic Disbondment Testing Chemical Resistance ContraTherm shows exceptional chemical resistance, not only to seawater, oils and solvents, but also acids and other aggressive chemicals. This is advantageous in that ContraTherm will not be affected by accidental exposure to materials and liquids typically used in the production and installation phases of a project. Mechanical Stability ContraTherm provides excellent mechanical stability. The insulation properties of ContraTherm will not significantly change with time which is important considering extended duration field design lives. Water absorption into the material initially affects mechanical and thermal properties, however once the system reaches equilibrium in service these properties will remain constant. ContraTherm insulation foam is a closed cell structure which is highly resistant to water permeation in the event of any accidental damage or exposure to water. Advanced Insulation has successfully tested its products to major oil company qualification programmes, further full scale testing can be undertaken to meet individual project requirements. 18

19 ContraTherm Mechanical and Thermal Properties Property C25 Series Syntactic Silicone C55 Series Syntactic Phenolic D2004 Series Phenolic Outer Skin Density [kgs/m 3 ] Thermal Conductivity (Dry) [W/mK] Thermal Conductivity (Aged) [W/mK]* Specific Heat Capacity [J/KgK] Maximum Service Temperature [ºC] Maximum Operating Depth [msw] Hardness 70 Shore A 50 Shore D - *Aged data is based upon long term exposure testing of un-faced foam having been exposed on all sides and represents the worst case scenario. Please note this information is based on our present state of knowledge and is intended to provide general notes on our products and their properties. It should not therefore be construed as guaranteeing specific properties of the products described or their suitability for a particular application. The values are subject to changes without notice, please consult with us prior to the application. For more detailed product datasheets please contact Advanced Insulation. 19

20 ContraTherm Applications ContraTherm can be applied to a wide variety of subsea applications including: Jumpers Jumpers are used to connect subsea structures. They can be flexible or fabricated from rigid pipe. Risers Risers are fabricated rigid or flexible pipes providing vertical transportation of oil & gas from the seabed to surface production / drilling facilities. Tie-in spools Tie-in spools are short lengths of rigid pipes and bends used to connect pipelines to structures. Xmas trees Xmas trees are a set of valves, spools and fittings used to control the flow of oil or gas from a well. Manifolds A manifold is a junction or centre for connecting a number of wells and selectively routing the flow. 20

21 PLETS A PLET is a subsea pipeline end termination. Metering protection Subsea metering is a system for monitoring oil well production. Goose necks Goose necks are a series of bends at the end of horizontal or vertical pipe. Dog houses Dog houses are insulation units which are designed to sustain the thermal integrity of a system at the connection point. Flange covers Flanges are used to provide a bolted connection between pipes, to form a complete piping system. Valves Subsea valves are used to control the flow of oil & gas through a subsea pipeline. 21

22 Subsea Buoyancy & Moulded Products Overview Advanced Insulation offer a range of market leading subsea buoyancy solutions alongside moulded polyurethane products for subsea impact and abrasion protection. Buoyancy and protection products can be offered as a full package along with ContraTherm where required. Advanced Insulation has the capability to manufacture subsea buoyancy products from syntactic lightweight materials that can be used in depths in excess of 3000MSW. Product Summary Installation Buoyancy: installation buoys, modsyn floats, umbilical flotation, modular buoys and pipe laying floats Engineered Buoyancy: distributed buoyancy modules incorporating proprietary engineered clamp technology, ROV buoyancy, ROV umbilical flotation, and bespoke subsea buoyancy. Protection Products: Cable and flowline protection. Clamping Solutions: Piggyback saddles and clamps, umbilical clamps, banding and banding tools. In-house Testing Facilities Macrosphere testing cells rated to 700 Bar. Deep water hydrostatic test chamber rated to 300 Bar. Shallow water hydrostatic test chamber rated to 100 Bar. ROV in Operation. Photo Courtesy of JFD. 22

23 Pipe Laying Floats Piggyback Saddles 23

24 Modsyn Subsurface Floats Overview Advanced Insulation manufactures a range of moulded floats where small amounts of tethered buoyancy are required. 3 sizes are available as standard. Configured with either a central through hole or with fixed eye top and bottom. Range of depth ratings available from surface to 6000MSW. Applications: Umbilical/cable support. Installation aids. Trimming Buoyancy. Construction: Tough impact/abrasion resistant rotationally moulded polyethylene shell, 6mm wall thickness. High performance composite syntactic foam core. Internal Through Hole Ø40mm Central Rod Ø20mm. Features: All optional metalwork hot-dip galvanised. Durable high quality construction. Versatile. Rotary moulded polyethylene skin formulated to provide UV resistance. Simple to attach through central hole either using steelwork or ties. Cost effective buoyancy solution for a wide variety of subsea operations. Colour coding available for depth identification. Optional in-moulded customer graphics. Recessed lifting slots. Flat surface to assist on-board stability and handling. Modsyn Subsurface Floats. 24

25 Modsyn Subsurface Float 29 Modsyn Subsurface Float 59 Modsyn Subsurface Float

26 Modular Buoyancy Overview Modular buoyancy is a customisable product providing support for mooring systems from surface to 3000MSW. Individual buoyancy elements or complete buoys including central structural steelwork assemblies are available. 3 standard sizes are available in multiple configurations: - MINI mm x 1750mm Cross-section. - MID mm x 2350mm Cross-section. - MAX 3000mm x 3000mm Cross-section. Can be supplied with a variety of handling options Mini Modular Buoy Applications Suspended moorings. Equipment Installation. General offshore operations. Mid Modular Buoy Max Modular Buoy 26

27 Construction The flotation core component maybe syntactic foam for deepwater deployment or more lightweight expanded polymer foams to maximise buoyancy yield in shallow waters, and are cast with a robust impact resistant rotationally moulded external shell. Surface and Syntactic foam core versions can be easily repaired on site or by return to Advanced Insulation. Additional impact protection for extreme service environments is additionally available. Features Modular design, 1-40T of nett buoyancy. MINI, MID and MAX industry standard sizes. Compartmentalised design for greater protection. Flat sides to facilitate stable storage and tight operational configurations. Easily adjustable to meet specific buoyancy requirement. Interlocking design to eliminate rotation during operation. Modular design allows easy buoyancy element change-out in damage events. Ease of repair. Central structural steelwork. Lightweight foam flotation cores. Modular Buoys 27

28 Pipe Laying Floats Overview Pipe Laying Floats are primarily used as temporary buoyancy modules strapped to a pipeline to reduce the tension and weight in the pipeline during the installation process. Advanced Insulation can offer a number of solutions tailored to fit a customer s specific requirements. Advanced Insulation manufacture the floats in the following configurations: Single piece unit configured with either an open through hole or with a through chain and shackles to assist with handling operations. Modular float configuration consisting of multiple individual units secured together with a central through pipe complete with pad eyes each end. Modular Pipe Laying Floats Both configurations have strap/band recess built into the buoyancy units to locate bands used to secure the buoys to the pipeline. A range of depth ratings are available from surface to 3000MSW. Applications Surface pipeline installation. Deepwater pipeline installation. Single Piece Custom Pipe Laying Floats Features Standardised modular design rotationally moulded external shell. Modular configurations enable the number of modules to be adjusted to suit project requirements. Damaged modules easily replaced at minimal cost and intervention. Designed to accommodate all subsea pipeline diameters. Integral strap grooves and ease of access for quick release. Robust and impact resistant external shell. Lightweight foam flotation core. Easy to release by divers or ROVs. Interlocking spigot and cuff designs available. 28

29 Construction Modular Floats This configuration consists of multiple individual units secured together with a central through rigid bar complete with pad eyes each end. PUSAD: Rotary Moulded Polyethylene (PE) Shell, Polyurethane (PU Foam FIlled Core) Cost effective. Modular configuration enabling adjustment to suit project. Easily replaceable if damaged. Shallow depths down to 3000MSW. SYNSAD: Rotary Moulded Polyethylene (PE) Shell, Syntactic Foam Core High performance. Range of densities available to suit required depth rating. Deep water installation from 250MSW 3000MSW. Visuals showing PUSAD and SYNSAD Standard Widths. EPSAD: Closed Cell Expanded Polymer (EP) Saddles c/w PU Elastomer Sprayed Skin Lightweight & consistent foam. Low water absorption. Sprayed with durable polyurethane elastomer skin - impact/abrasion resistant. Variety of lengths available to suit buoyancy needs. Density can be varied to suit the required depth rating. Cross-section dimensions sized to best suit shipping by container. Configuration options include open through hole, chain through and rigid bar. Chamfered ends available. Single Piece Custom Floats Depending on preferred handling methods, single piece units can be configured with an open through hole, a through chain and shackle assembly or a rigid central pipe with pad eyes each end. In the event of a low volume or bespoke requirement alternative materials are available. Banding Options: Carbon Steel. Inconel Stainless Steel. SMART bands. PUSAD Pipe Laying Float Complete with Banding. 29

30 Subsea Installation Buoys Overview Advanced Insulations range of subsea installation buoys are designed to provide a general purpose solution to subsea buoyancy. Available in 2 standard sizes: 100kg and 500kg. Water depth ratings available between 250MSW and 3000MSW. Can be configured with a variety of through hole arrangements or alternatively with pad eyes top and bottom. Advanced Insulation are able to offer bespoke sizes and dimensions upon request. Features Ropes Various through hole arrangements. Top image: 500kg Subsea Installation Float. Right image: 100kg Subsea Installation Float. Rotary moulded polyethylene outer shell. Cast syntactic foam core with a specification to suit the water depth Subsea Installation Floats 30

31 Umbilical Floats Overview Advanced Insulation offer 2-piece wrap around floatation modules for cables and control umbilicals. They can be used in combination with ROVs to maintain the necessary length of umbilical buoyancy below the surface. The floats are in two halves with an integral elastomer clamp assembly, configured to the OD of the cable / umbilical. Water depth ratings available between 250MSW and 3000MSW. The flotation modules can be rated for operating depths from surface down to 6000MSW. Applications ROV Cable. General umbilical, cable or hose buoyancy. Construction The flotation core component may be high performance syntactic foam for deepwater deployment or more light weight expanded polymer foams to maximise buoyancy yield in shallower waters, and may be cast within a rotationally moulded outer skin or a tough and durable sprayed elastomer. Features Two piece purpose built flotation modules. Strapping location grooves incorporated. Overcentre latch fastening option for ease of assembly / installation. Polyurethane elastomer / steel clamp construction. Lightweight foam flotation core. Optional customer graphics. Axial load testing capability. Subsea Umbilcal Float Subsea Umbilical Floats with Integral Clamps and Banding 31

32 ROV Buoyancy Overview Advanced Insulation offer a range of composite foam ROV buoyancy blocks for use in operating depths down to 6000MSW. Applications Manned, Autonomous and Remote Operated Vehicles. Construction PVC based copolymer foams are traditionally used for shallow water (<600MSW) deployment, where as pure syntactic foams available in Low density and Ultra-low density variants are used for depths down to 6000MSW. Composite syntactic foam core comprising injection moulded macrospheres encapsulated within a polyurethane based syntactic foam matrix. The buoyancy blocks are laminated and then machined into customised complex shapes as required using in-house CNC machining facilities, enabling a fast turnaround from bespoke design to delivery. A light stable and wear resistant polyurethane based elastomer external coating is then applied to the client colour and surface finish specifications. Alternatively pure syntactic foam blocks manufactured using high strength thermosetting resin incorporating hollow glass microspheres. ROV in Operation. Photo Courtesy of JFD Features CNC Machining of ROV Buoyancy Block Lightweight Low-density and Ultra-low density syntactic foam cores provide exceptional buoyancy and enable reliable operational performance at deeper depths. Bespoke design and build. In-house CNC machining facilities. High performance polyurethane elastomer coating. Range of surface finishes available. Light stable topcoat. Optional customer graphics. CNC Machined ROV Buoyancy Block 32

33 Piggyback Saddles, Clamps & Guides Overview Advanced Insulation design and manufacture a range of bespoke piggyback saddles for use in spacing and securing additional lines to existing pipelines. Applications Surface pipeline installation. Deepwater pipeline installation. Construction Manufactured in high performance polyurethane elastomer. A range of hardnesses to suit any requirements. High heat resistant formulas available. Features Range of high visibility colours. Piggyback Saddle Single or multiple hole configurations are available. Non-marking material. Strapping location grooves incorporated. Tough, impact and abrasion resistant. Low density for lightweight designs. In-house CNC mould making facility. Neutrally buoyant in seawater. Customer specific detail / graphics. Axial load testing capability. One piece or multiple section designs. Saddles 33

34 Subsea Cable Protection Overview Advanced Insulation offer a modular interlocking tubular cable protection product designed to protect cables or pipelines from abrasion and impact. Applications Subsea Flow-lines. Power cables. Fiber optic cables. Umbilicals. Subsea Cable Protection Sub Tector - 4 Piece Modular. Construction Interlocking modules are moulded in a high performance polyurethane elastomer. In-house CNC machining facility enables fast production of prototype and production tooling to reduce lead times and ensure the quickest response. Integral strap grooves are incorporated to house all types of metallic or polymeric strapping solutions. Additionally Advanced Insulation can assist in the supply and specifications of the strapping most appropriate for the conditions of installation and service. Features Tough, impact and abrasion resistant. In-house CNC mould making facility. Interlocking moulding design assists in ease of installation. Strapping location grooves incorporated. Low density for lightweight designs. Neutrally buoyant in seawater. Range of high visibility colours. Non-marking material. 34

35 Banding Advanced Insulation offer a range of metal banding options which are all cost effective, have a high corrosive resistance and a high tensile strength: Carbon Steel. Grade 316 Stainless Steel. Monel. Inconel. Advanced Insulation is also able to offer an alternative polymeric strapping system which incorporates a single buckle, is fully non corrosive resistant and very easy to install: HCL Smartband. Advanced Insulation also offer fully comprehensive installation advice and support and can provide installation tooling. HCL Smart Band. Courtesy of HCL Fasteners Ltd. Smart Band is registered as a trademark of HCL Fasteners Ltd. 35

36 CONTACT INFORMATION Angola: Brazil: Kazakhstan: Korea: Malaysia: United Arab Emirates: United Kingdom: 44 (0) United States: 1 (281) Advanced Insulation Limited offers a full technical support service for all our products, regardless of location or application. For further details, please contact your nearest management office and let us know how we can help. info@aisplc.com