insulation & linings

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Dr. Peter Singh, Bredero Shaw, Canada, discusses the
specics of high temperature insulated pipeline designed
for the particular demands of oil sands development.

ommercial exploitation of
the Alberta tar sands is
creating the need for high
temperature insulation coatings for bitumen pipelines.
In recent years, many large
energy companies have announced
major oil sands development projects.
Development plans include thermal
extraction methods to separate the
heavy oil from the sand and transporting it to markets via Edmonton using
large diameter transmission pipelines.
There are two options for transporting the bitumen by pipeline. The diluent
method uses lighter hydrocarbon fractions blended with the heavy bitumen
to lower the viscosity and allow it to be
economically pumped. After refining,
the light fractions are recovered and
reused. There are several drawbacks to this, one being the
larger pipeline capacity needed to transport a given amount
of bitumen, and a second being another pipeline is needed
for recycling the light fraction.
The second option, which is now being given stronger
consideration, is to heat the bitumen to a temperature
where the viscosity is sufficiently lowered to make pumping favourable. The temperatures being considered are in
the range of 110 - 150 C and even higher in some cases.
In the past, this option was discounted due to the lack of
economical coating and insulation solutions available for
the high temperature.

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The coating for a high temperature pipeline includes a corrosion coating, an insulation layer and a protective topcoat.

Figure 1. Cross section of

high temperature insulated
pipe system.

The corrosion coating provides an additional safety element

to protect the pipe in the event of topcoat and insulation
damage, which could allow the influx of corrosive media.
It is also a requirement of the Alberta Energy Utility Board
that oil and gas pipelines be built according to the CSA
Z662 standard, which requires both corrosion coating and
cathodic protection to be applied (Figure 1).
The typical design of the pipeline requires several heating stations to heat the bitumen, in order to compensate
for heat losses and maintain the temperature above a
critical flow temperature. The insulation should have very
low thermal conductivity in order to reduce the number
and proximity of required heating stations. Additionally,
the pipeline should maintain a reasonable temperature
long enough to allow remedial action such as pigging or
injection of condensate in the event of an uncontrolled
WORLD PIPELINES SEPTEMBER 2006 www.worldpipelines.com

29

insulation & linings

shutdown. Polyurethane foam insulation has been extensively used in oil and gas pipelines in the past. It has a very
low thermal conductivity and high compressive strength,
coupled with the ability to bond to the coated steel and
restrain the pipeline by transferring shear forces between
the steel and the soil.
The jacket system is required to protect the foam from
the elements, thereby preventing degradation of the foam
and reducing its insulation value. Typically, high density
polyethylene material has extensive experience in this role,
and has proven to be the material with the right mix of properties such as moisture permeation resistance, flexibility,
toughness and generally good handling characteristics.

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Some of the challenges of a high temperature pipeline
insulation system are very unique to the Canadian oil
sands environment:
l 110 C to 150 C temperature capability of the corrosion coating and insulation. The pipeline is normally
designed for a lifetime in excess of 30 years. The properties should remain above the minimum requirements
over this period.
l Joint lengths of 25 m (80 ft) are used to reduce the

l
l

high field labour costs of welding and joint coating during installation, as well as increase pipe laying speed.
High compressive strength greater than 480 kPa
(70 psi) to resist compressive forces from pipeline/
soil weight, thermal expansion as well as compensate
for reduction due to ageing at the high temperature.
Additionally, the long joints are normally transported
using pole trailers with a limited support area near the
ends. The foam must have high enough compressive
strength to prevent crushing.
Construction has to be carried out in winter and this
requires handling and installation in temperatures that
can reach -40 C for prolonged periods. Good flexibility
and handling characteristics are required to prevent
cracking and catastrophic failures of the polyethylene
jacket.
Compatible with available joint coating systems to
achieve desirable production speed in the environment.
Strong bond between foam and coated steel pipe to
restrain the pipeline from large thermal expansion.
Ability to bend the insulated pipe in the field to fit the
contours of the right of way, or ability to insulate induction heated pre-bend.

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Figure 2. Accelerated heat ageing apparatus.

Table 1. Summary of test results

30

Property

Bredero Shaw Type-1 HT Foam

Test pipe size x foam thickness

(mm)

114.3 x 50

Anticorrosion coating

FBE

Density (kg/m3)

84.2

Compressive strength
(MPa)

0.7

Water absorption (%)

6.1

Closed cell content (%)

90

Un-aged axial shear at

23 C (MPa)

0.205

Un-aged axial shear at

140 C (MPa)

0.118
@ 150 C

Un-aged tangential shear at

23 C (MPa)

0.445

Un-aged tangential shear at

140 C (MPa)

0.338
@ 150 C

WORLD PIPELINES SEPTEMBER 2006 www.worldpipelines.com

Historically, there has been little or no experience with

insulated oil transmission pipelines at these high temperatures. Long term testing was carried out to validate the
design and performance of the individual components, as
well as the whole insulated pipe system.
The first stage involved evaluating the anti-corrosion
coating. A high temperature fusion bonded epoxy material
(FBE) was selected from a number of potential candidates.
Standard coating tests referenced in CSA Z245.20 were
carried out. In addition, modified adhesion and cathodic
disbondment tests with higher temperature and longer
exposure duration were completed. The results show that
the high temperature FBE coatings performed very well and
were suitable for the intended application.
The polyurethane foam insulation was evaluated using
the EN 253 standard ASTM tests, as well as internal test
methods. Properties such as density, compressive strength,
thermal conductivity, water absorption and glass transition temperaEN 253:2003
ture were measured.
requirements
The complete insulated pipe
system was evaluated for mechani60.3 x 28 (typ.)
cal properties such as impact,
shear strength of the jacket and
None
insulation to the pipe, and flexibility
*60
at cold temperature. Full scale flex*0.3
ibility testing was carried out with
the insulated pipe system being
)10
bent up to 1.5 per pipe diameter
*88
at -25 C without cracking in the
foam or jacket.
*0.12
Accelerated heat ageing was
carried
out following the procedure
*0.08
outlined in the EN 253 standard on
pre-insulated bonded pipe systems.
*0.20
The test involves the ageing of pipes
at temperatures above the design
Not specified
temperature. This accelerates the
effects of ageing of the insulation,

insulation & linings

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Bredero Shaw has extensive experience with
sprayed and molded polyurethane foam used in
pre-insulated pipes. The pipe is coated in two
processes. The first is the application of anticorrosion FBE coating. Then, the pipe is taken to
the insulation plant where polyurethane foam is
spray applied and a polyethylene outer jacket is
extruded over the foam (Figures 3 and 4).
The foam insulation is produced by the mixing of two fast reacting liquid components along
with a cyclopentane blowing agent, to achieve
the required density and performance properties.

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Figure 3. Step 1 - FBE application.

Insulated pipe systems have been used for a

long time in oil and gas pipelines in Western
Canada. They are used to prevent hydrate formation in gas production and to prevent the build
up of waxes and asphaltenes in oil pipelines.
Considerable expertise exists in the designing and construction of long, buried insulated
pipelines. Innovative techniques and equipment
are being used in transportation, field bending,
field foaming and pre-stressing. In general, with
thousands of kilometers of buried insulated
pipelines, there is very good operating experience and high integrity of these pipelines.

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Figure 4. Step 2 - HT insulation application.

which can then be measured in shorter test durations. The

test results are then used to extrapolate to the estimated
maximum operating temperature for the design lifetime.
Initial, as well as thermally aged, performance results
indicate that the system has a maximum operating temperature of 150 C (Figure 2).

The field joint to be used is a Canusa Supercase

CSC. It provides a comparable level of insulation to complement the insulation coating
on the line pipe. The CSC is heat shrinkable and combines a cross-linked, high density
polyethylene casing with a high shear and peel
strength adhesive to provide a high quality, reliable system for protection and sealing of joints.
As a result of its design, the ends of the CSC
casing preferentially shrink. This innovation makes it perfect for foam-in-place applications.
l Specially designed to allow complete foam fill.
l Air-pressure testability ensures a quality installation.
l High performance, user friendly adhesive ensures longterm sealing protection.

Figure 5. PIpeline right of way.

Figure 6. Insulated coated pipe.

32

WORLD PIPELINES SEPTEMBER 2006 www.worldpipelines.com

insulation & linings

l Cross-linked backing results in excellent field handling
and does not pre-shrink in direct sunlight.
l Retains its shape and high stress resistance over the
lifetime of the pipeline.
l Non-cross-linked enhancements provide a conduit for
standard weldable plugs.
l Meets and exceeds the European Standard EN489 for
district heating joints.

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Shaw Pipe Protection Limited, part of Bredero Shaw, is
a premier provider of insulated pipes for the oil and gas
industry in western Canada. Pipeline operators, designers
and contractors have gained extensive experience with
the product and are affirmative in its implementation in
existing and new projects. With ongoing developments in
the oil sands of Alberta, Bredero Shaw has continuously
improved and developed new products to meet the rising
challenges.
The company has developed a high temperature insulation system for application in bitumen transportation.
Extensive validation testing shows that the system will
meet the requirements expected in the design of a high
temperature pipeline up to 150 C. The system uses a
spray-applied polyurethane foam, which has high temperature capability, and is superior in both performance and
economics compared to molded foam district heating insulation systems. The polyethylene jacket provides excellent
damage and moisture resistance and can be expected to
handle well during winter construction.

Figure 7. Insulated pipe being bent.

Figure 8. Heat shrinkable casing system for half-shell foamed

pre-insulated pipe joints.

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