TX 75083-3836, U.S.A., fax 01-972-952-9435. AbstractExternal coating systems of flowlines and risers ensure both structural and thermal insulation functions which should be efficient throughout the design life in-service, typically 25 years. In that context, the long term behaviour of thermal insulation materials is difficult to predict due to the coupled effects of three factors: hydrostatic pressure up to 300 bar, thermal gradient over 120°C between internal effluents and external sea water and the water absorption of constitutive materials. In addition, laboratory data collected on small size specimens of insulation materials are normally used to predict the thermo-mechanical behaviour of full scale systems, but laboratory testing simply do not properly simulate the service conditions, in particular the complex loading existing through the coating thickness. This paper covers the background to the development of both test facilities and models to study the thermo-mechanical behaviour of production coated steel pipe in ultra deep water conditions. This original work was launched to provide both experimental and computed data to better understand and predict the thermo-mechanical behaviour of insulation materials whilst considered as a full scale system. On the one hand, experimental data obtained on instrumented insulated pipes immersed in large scale facilities simulating ultra deep water are presented in both steady and transient states. On the other hand, a finite element model dedicated to the abovementioned insulated pipes was developed to predict their thermo-mechanical behaviour. Correlation between full scale experimental data and related model predictions are discussed to validate the predictive model taking into account the coupling between hydrostatic pressure and temperature gradient. Additional modelling developments to include the water absorption are planned to reach a suitable prediction of the whole service life.
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