Rubber based systems have been used in subsea thermal insulation for many years and have proven themselves to be reliable and cost efficient. Formulations have been changed over the years, pressing the maximum usage temperature upwards and into the realm of 160 to180°C in a hot-wet environment. Until recently there was a need for high temperature along with pressure vessels (autoclaves) for vulcanisation. This has limited the widespread use of such systems. Recent changes have eliminated the need for autoclaves, however the high temperature vulcanisation hasstill been required.

A novel formulation has been developed to address these shortcomings, so that this class of materials could have wider use. This new material employs freely available materials in a unique blend. The material contains no hydrolysable groups and can operate from −40°C to 180°C continuously in air and in a hot-wet environment and retains its resilience and flexibility; and thus opening for use in both high and low temperature systems. The formulation does not include the use of hollow glass microspheres and is, correspondingly, without water depth limitations. A new, highly reliable vulcanisation chemistry allows for a stable latency time for application, with vulcanisation temperatures reduced to 50°C. This allows for rapid hand application and simultaneous vulcanisation on subsea trees, valves, manifolds, etc. The material is self-agglomerating, merging under gentle pressure, and can be applied at high thickness. As the base material has an intrinsically low thermal conductivity, glass-based fillers are not needed. The material adheres well to painted or primed surfaces and to many other materials typically used in the offshore thermal insulation industry.

The 2-component material is conveniently combined on site, reducing the need for refrigeration during transport and easing mobilisation logistics and is applied using simple hand tools. Extruded profiles can be used directly on complex structures or combined into sheets for ease of application on more regular shapes in order to optimise application rates. Moulds are not required for application, reducing engineering and fabrication cost, while also shortening mobilisation time.

The system has been extensively qualified according to ISO 12736 for continuous use at 180°C. This paper will detail important aspects of the development project along with the results of the qualification testing.

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