Subsea Products & Services - Advanced · PDF fileSubsea Products & Services Thermal...
Transcript of Subsea Products & Services - Advanced · PDF fileSubsea Products & Services Thermal...
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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
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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.
Introduction
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 2014.
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 Equity-
backed Management Team of
the Year Award and International
Impact Award from the British
Private Equity and Venture Capital
Association (BVCA).
Furnace control roomAdvanced Insulation Ltd - 2015 EEF Smart
Product Award Joint Winner Testing Laboratory
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Advanced Insulation manufactures a wide range of products for the Subsea industry.
Subsea Systems and Products
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.
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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.
ContraTherm®
Innovative Insulation Technology
ContraTherm®
Insulation Solutions
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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
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.
C55 Syntactic Phenolics
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.
C25 Syntactic Silicones
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.
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
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D2204 Phenolic Composite Laminate
Epoxy Flow Coat
C55 Phenolic Insulation Foam
Tie Coat
Substrate Coated with Corrosion Coating
C25 Syntactic Silicone Foam
C25 Primer
Substrate Coated with Corrosion Coating
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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.
ContraTherm®
C55 Subsea Insulation System
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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 MicrospheresThe 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.
ContraTherm® C55 ambient curing makes it ideal for direct application to equipment
on construction or manufacturing sites globally.
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
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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.
ContraTherm®
C55 Direct Application Method
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.
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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 pre-
packaged 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 straight-
forward should it be required.
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.
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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.
ContraTherm®
C55 Pre-moulded Engineered Components
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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.
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.
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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.
ContraTherm®
C25 Subsea Insulation System
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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.
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.
Once cured ContraTherm® is sufficiently robust to allow transportation without the need for further protection beyond that typically required for the equipment itself.
Micrograph of C25
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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.
C25 Direct Application Method
ContraTherm®
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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.
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.
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.
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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
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.
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.
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.
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C25 Series Syntactic Silicone
C55 Series Syntactic Phenolic
D2004 Series Phenolic Outer Skin
Density [kgs/m3] 780-820 600-850 1300-1350
Thermal Conductivity (Dry) [W/mK]
0.15-0.16 0.14-0.17 0.18-0.22
Thermal Conductivity (Aged) [W/mK]*
0.16-0.18 0.19-0.22 0.22-0.24
Specific Heat Capacity [J/KgK]
1300-1700 1700-2200 -
Maximum Service Temperature [ºC]
150 185 200
Maximum Operating Depth [msw]
3000 3000 3000
Hardness 70 Shore A 50 Shore D -
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.
*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.
ContraTherm® Mechanical and Thermal Properties
Property
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JumpersJumpers are used to connect subsea
structures. They can be flexible or
fabricated from rigid pipe.
ContraTherm® Applications
ContraTherm® can be applied to a wide variety of subsea applications including:
Risers Risers are fabricated rigid or flexible
pipes providing vertical transportation
of oil & gas from the seabed to surface
production / drilling facilities.
Tie-in spoolsTie-in spools are short lengths of rigid
pipes and bends used to connect
pipelines to structures.
ManifoldsA manifold is a junction
or centre for connecting
a number of wells and
selectively routing the flow.
Xmas treesXmas trees are a set of valves, spools
and fittings used to control the flow
of oil or gas from a well.
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ValvesSubsea valves are used to
control the flow of oil & gas
through a subsea pipeline.
PLETSA PLET is a subsea
pipeline end termination.
Metering protection
Subsea metering is a
system for monitoring oil
well production.
Goose necksGoose necks are a series of
bends at the end of horizontal
or vertical pipe.
Dog housesDog houses are insulation units which are
designed to sustain the thermal integrity of
a system at the connection point.
Flange coversFlanges are used to provide a bolted connection
between pipes, to form a complete piping system.
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Subsea Buoyancy & Moulded Products
OverviewAdvanced 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 SummaryInstallation 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.
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ROV in Operation. Photo Courtesy of JFD.
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OverviewAdvanced 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.
Features: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
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Modsyn Subsurface Floats.
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.
All optional metalwork hot-dip galvanised.
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Modular Buoyancy
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OverviewModular 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 - 1750mm x 1750mm Cross-section.
- MID - 2350mm x 2350mm Cross-section.
- MAX – 3000mm x 3000mm Cross-section.
Can be supplied with a variety of
handling options
ApplicationsSuspended moorings.
Equipment Installation.
General offshore operations.
Mini Modular Buoy
Mid Modular Buoy
Max Modular Buoy
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ConstructionThe 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.
FeaturesModular 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.
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Modular Buoys
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Pipe Laying Floats
OverviewPipe 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.
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.
ApplicationsSurface pipeline installation.
Deepwater pipeline installation.
FeaturesStandardised 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.
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Modular Pipe Laying Floats
Single Piece Custom Pipe Laying Floats
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ConstructionModular 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.
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.
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PUSAD Pipe Laying Float Complete with Banding.
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Subsea Installation Buoys
OverviewAdvanced 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.
FeaturesRopes
Various through hole arrangements.
Rotary moulded polyethylene outer shell.
Cast syntactic foam core with a specification to suit the water depth
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Top image:500kg Subsea Installation Float.
Right image:100kg Subsea Installation Float.
Subsea Installation Floats
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Umbilical Floats
OverviewAdvanced 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.
ApplicationsROV Cable.
General umbilical, cable or hose buoyancy.
ConstructionThe 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.
FeaturesTwo 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.
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Subsea Umbilcal Float
Subsea Umbilical Floats with Integral Clamps and Banding
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OverviewAdvanced Insulation offer a range of composite foam ROV buoyancy blocks for
use in operating depths down to 6000MSW.
ApplicationsManned, Autonomous and Remote Operated Vehicles.
ConstructionPVC 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.
FeaturesLightweight 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.
ROV Buoyancy
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ROV in Operation. Photo Courtesy of JFD
CNC Machining of ROV Buoyancy Block
CNC Machined ROV Buoyancy Block
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OverviewAdvanced Insulation design and manufacture a range of bespoke piggyback saddles for use in spacing and securing
additional lines to existing pipelines.
ApplicationsSurface pipeline installation.
Deepwater pipeline installation.
ConstructionManufactured in high performance polyurethane elastomer.
A range of hardnesses to suit any requirements.
High heat resistant formulas available.
FeaturesRange of high visibility colours.
Non-marking material.
Tough, impact and abrasion resistant.
In-house CNC mould making facility.
Customer specific detail / graphics.
One piece or multiple section designs.
Piggyback Saddles, Clamps & Guides
Single or multiple hole configurations are available.
Strapping location grooves incorporated.
Low density for lightweight designs.
Neutrally buoyant in seawater.
Axial load testing capability.
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Piggyback Saddle
Saddles
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OverviewAdvanced Insulation offer a modular interlocking
tubular cable protection product designed to protect
cables or pipelines from abrasion and impact.
ApplicationsSubsea Flow-lines.
Power cables.
Fiber optic cables.
Umbilicals.
ConstructionInterlocking 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.
FeaturesTough, 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.
Subsea Cable Protection
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Subsea Cable Protection Sub Tector - 4 Piece Modular.
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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.
Banding
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HCL Smart® Band. Courtesy of HCL Fasteners Ltd.
Smart® Band is registered as a trademark of HCL Fasteners Ltd.
CONTACT INFORMATION
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.
www.aisplc.com
Angola:
+244 923 364 273
Brazil:
+55 19 41417117
Kazakhstan:
+7 707 600 4452
Korea:
+82 51 921 6367
Malaysia:
+60 3 5121 3886
United Arab Emirates:
+971 4 8813567
United Kingdom:
+44 (0)1452 880880
United States:
+1 (281) 600 0022