Thermally insulated subsea production systems are becoming more common in deepwater completions for hydrate or wax control. Premature failures of the insulation materials for these systems have had signification operational impact. Syntactic foams or solid polymer insulation are currently the industry standard for subsea completion equipment. The types of insulation commonly used, their failure modes, and improved methods for selecting and qualifying these insulation systems are presented. For deepwater application, so-called "wet" insulation systems are preferred, because the insulation can be molded directly around the equipment without the need for an outer protective jacket. The insulation is exposed directly to the seawater on the outer surface, with the inner surface exposed to the high temperature operation. The critical parameters in design are the thermal conductivity, insulation thickness, and specific heat capacity. The material parameters of primary concern are resistance to degradation by seawater, high-temperature stability, and physical durability for both deployment and long-term service.

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