Dow Corning XTI-1003 RTV Silicone Rubber Insulation Advanced Technology for Subsea Wet Insulation Systems 1
Deepwater Flow Assurance More reliable, cost-efficient and lower-risk subsea wet insulation systems are needed for deepwater oil and gas operations. Robust materials and application quality are essential for structural and thermal integrity. 2
Deepwater Flow Assurance Key objectives: Reduce flowline blockages by maintaining production stream temperatures above HFT Provide specified no-touch times during shutdowns Reduce failures of insulation caused by joint separation, cracking, degradation, hydrostatic crushing or improper application 3
Solid Silicone Science Advanced technology for subsea flow assurance demands expertise, experience and collaboration. At Dow Corning, solid silicone science guarantees that not all silicones are created equal. Photo and application courtesy of Trelleborg Offshore Ltd 2012 4
Silicone Rubber Elastomers Based on Synthetic Polymers Silicon and oxygen Carbon Hydrogen Characteristics of "Plastic Glass" Flexibility and strength of plastics (carbon-based) Thermal stability and water resistance of glass (silica-based) 5
Silicone Rubber Elastomers Polydimethylsiloxane Silicones typically have a backbone that is inorganic like glass Side groups are organic in most cases, methyl 6
Silicone Elastomer Cure Chemistry Silicone polymers are networked through crosslinking (or curing) Cure is the conversion of molecules of any size into a large (insoluble) 3-dimensional network through the formation of covalent linkages Crosslinkers Material as supplied = Silicone polymer + filler + crosslinker 3-Dimensional Polymer Network Silicone Elastomer = Crosslinked linear silicone fluids or gums with a three-dimensional structure 7
Silicone Elastomer Cure Chemistry Crosslinking by addition-cure chemistry, uses a platinum catalyst to initiate curing and does not produce any by-products Once catalyzed, the cure will be completed, even in thick sections, with no exposure to atmosphere required Advantages Excellent deep section cure No cure reversal Cure accelerated with heat Low shrinkage No by-products CH 3 H CH 3 H 3 C SiO [SiO] n Si CH 3 CH 3 CH 3 CH 3 8
Solid Silicone Science Formulated for subsea insulation Non-syntactic, pure silicone Two-part silicone rubber system Designed to provide performance and ease of application 9
Not ALL Silicones Are Created Equal Dow Corning XTI-1003 RTV Silicone Rubber Insulation is a unique, high-strength, two-part, RTV liquid silicone rubber elastomer developed from a proven high-performance silicone polymer base and a platinum-catalyzed addition-cure system. Everything about this material from its thermal conductivity and resistance to degradation to its robust mix ratio and viscosity has been engineered to maximize its subsea insulation performance and to ensure that it is easy to mix and apply. 10
Silicone Comparison Study Not all silicones are created equal In high-temperature immersion testing against a syntactic silicone for subsea wet insulation, Dow Corning XTI-1003 RTV Silicone Rubber Insulation exhibits superior: Flexibility Joint bonding Tensile strength Elongation Resistance to water ingress FIGURE 1. Photograph of submerged tensile samples that have been immersed in simulated seawater at 135ºC for six months. 11
Dow Corning XTI-1003 RTV Silicone Rubber Insulation Translucent or yellow, two-part, addition-cure RTV silicone elastomer Non-syntactic silicone with: Increased joint strength High heat capacity Long-term flexibility Resistance to extreme pressures Extensive testing is validating its effectiveness in withstanding harsh subsea environments 12
Dow Corning XTI-1003 RTV Silicone Rubber Insulation Thermal stability across a wide temperature range Good insulating properties for specified no-touch times Excellent silicone-to-silicone bonding strength Good flexibility and resistance to cracking Especially compared to syntactic epoxies Reduced degradation with property retention Easy to apply in virtually any geometry and thickness Thermal image of pipe coated with Dow Corning XTI-1003 RTV Silicone Rubber Insulation. 13
Proving Performance Dow Corning XTI-1003 RTV Silicone Rubber Insulation does not utilize glass microspheres, emphasizing increased joint strength, high heat capacity, long-term flexibility and resistance to extreme pressures. Easily mixed and applied using standard cast-in-place equipment and processes, it cures to a translucent or yellow, high-strength silicone rubber. Extensive testing is validating its effectiveness in withstanding harsh subsea environments. 14
Heat-Aging Immersion Testing Test Conditions: Validated at third party testing facilities in conjunction with ExxonMobil GP65-08-61 Rev 3 standards 3% NaCl simulated seawater Testing conducted under pressure at 350 bar Continuous test-temperature exposure 115 C, 135 C, 150 C Vessels are removed from oven, allowed to cool before opening; samples for test are removed from the vessel Vessels are replaced under heated conditions to continue testing remaining specimens 15
Extended Heat-Aging Immersion Test Results TEST TEMPERATURE PROPERTY Bulk Tensile (MPa) Joint Tensile (MPa) Bulk Elongation (%) Joint Elongation (%) INITIAL 115 C (SwRI) 150 C (Element) 150 C (Element) 90 DAY 180 DAY 360 DAY INITIAL 90 DAY 180 DAY 360 DAY INITIAL 6.4 6.1 5.5 5.0 5.9 5.0 3.9 2.0 5.9 3.0 0.9 0.3 5.7 6.1 6.1 4.7 6.1 5.0 3.2 1.7 6.1 3.0 1.2 0.6 333 219 185 169 269 118 65 52 269 66 30 15 301 200 183 135 244 118 51 47 244 66 23 23 90 DAY 180 DAY 360 DAY Exposure of 2 mm thick ASTM tensile specimens which are subjected to wet heat aging at specified temperatures under pressure in a 3% NaCl seawater mixture to observe accelerated aging characteristics at external third-party labs. NOTE: Contact Dow Corning for information about ongoing temperature testing. 16
Heat-Aging Immersion Testing Extended Service Testing: Tensile Strength Exposure of 2 mm thick ASTM tensile specimens which are subjected to wet heat aging at specified temperatures under pressure in a 3% NaCl seawater mixture to observe accelerated aging characteristics at external third-party labs. NOTE: Contact Dow Corning for information about ongoing temperature testing. 17
Heat-Aging Immersion Testing Immersed Hardness Testing Exposure of 2 mm thick ASTM tensile specimens which are subjected to wet heat aging at specified temperatures under pressure in a 3% NaCl seawater mixture to observe accelerated aging characteristics at external third-party labs. NOTE: Contact Dow Corning for information about ongoing temperature testing. 18
Heat-Aging Immersion Testing Immersed Tensile Testing Exposure of compression cylinders 12.5 mm diameter x 25 mm length bulk specimens which are subjected to wet pressure heat aging. NOTE: Contact Dow Corning for information about ongoing temperature testing. 19
Simulated Service Test (SST) Results 115 C 135 C Thickness, inches 3 5 3 5 Safe operating temperature (SOT) 45 C 45 C Hydrate formation temperature (HFT) 22 C 22 C Lowest ambient seawater temperature (SWT) 4 C 4 C Test maximum operating temperature (TMxOT) 115 C 115 C Hydrostatic external pressure 228 bar 250 bar Seawater service depth (SSD) 2,050 m 2,480 m SOT to HFT at SSD, hours 4.71 6.96 6.18 11.05 TMxOT to HFT at SSD, hours 13.35 15.24 16.43 29.6 Simulated Service Test was completed at a test maximum operating temperature (TMxOT) of 115 C (239 F) and a hydrostatic external pressure of 228 bar (3350psig) for a seawater service depth of 2050 m (7500ft). Photo and application courtesy of PERMA-PIPE Oil and Gas 2015 20
Performance Properties PROPERTY UNIT RESULT Appearance Translucent or yellow Shelf life, stored in sealed containers Months 18 As Catalyzed 10:1 Ratio, by Weight Working time at 25 C (77 F) Minutes 90 Cure time at 25 C (77 F) Hours 12 As Cured Physical Properties Specific gravity 1.08 Durometer hardness, Shore A 40 Tensile strength MPa 5.5 Elongation % 325 Thermal conductivity (dry 0 C to 135 C) W/mK 0.17 Thermal conductivity (aged wet at 135 C) W/mK 0.17 Specific heat at 135 C J/g/ C 1.60 Tm C -46 Specification Writers: These values are not intended for use in preparing specifications. Please contact your local Dow Corning Sales Application Engineer before writing specifications on this product. 21
Ease of Application Easier processing for curved, straightline and flexible sections without special procedures Good joint integrity with strong siliconeto-silicone bonding Fast addition-reaction cure at ambient temperatures in unlimited thickness without requiring moisture Cure can be accelerated with heat No VOCs or exotherm Photo and application courtesy of Trelleborg Offshore Ltd 2012 22
Processing Information FACTOR Base Packaging Shelf life, stored in sealed containers Viscosity Curing Agent (Catalyst) Packaging Shelf life, stored in sealed containers Viscosity Mixed 10:1 by Weight Viscosity Working time at 23 C Cure time at ambient temperature RESULT 200 kg drums 18 months 55,000 mpa.s 20 kg pails 18 months 300 mpa.s 35,000 mpa.s 90 minutes 12 to 24 hours; can accelerate with heat 23
Joint Integrity Study 45 Bonding Study FIGURE 2. Representative photo (far right) of a cast tensile bar 45-degree bond joint of Dow Corning XTI-1003 RTV Silicone Rubber Insulation. Second cast was pigmented yellow for visual identification purposes of this photo. 24
Adhesion to Corrosion Coatings Dow Corning XTI-1003 RTV Silicone Rubber Insulation has excellent adhesion to itself contributing to joint integrity, but A primer should be applied to substrate corrosion coatings to ensure a good bond Dow Corning recommends applicators develop a proper adhesion procedure Application is CRITICAL to the success of any insulation system Application courtesy of Trelleborg Offshore Ltd 2012 25
Differentiating Characteristics Differentiating Characteristics High temperature Flexibility Application ease Joint strength Shelf life EHS profile Water absorption Cost in use Dow Corning XTI-1003 RTV Silicone Rubber Insulation Very good Excellent Very good Excellent Very good Very good Good Good 26
The information contained in this communication does not constitute an offer, does not give rise to binding obligations, and is subject to change without notice to you. The creation of binding obligations will occur only if an agreement is signed by authorized representatives of Dow Corning and your company. Any reference to competitor materials contained in this communication is not an endorsement of those materials by Dow Corning or an endorsement by the competitor of Dow Corning materials. To the fullest extent permitted by applicable law, Dow Corning disclaims any and all liability with respect to your use or reliance upon the information. DOW CORNING DOES NOT MAKE ANY WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, WITH RESPECT TO THE UTILITY OR COMPLETENESS OF THE INFORMATION AND DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. DOW CORNING DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES. 27