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Pipelines was selected as the best performing of the pro? le. Formulations showing a satisfac- the two-component XUR-760 ? eld joint three development formulations. tory cure pro? le and ? nal mechanical insulation material is mouldable onto properties were then screened for prop- anti-corrosion FBE coatings at tempera-

Phase one mission accomplished erty development using reactive rheom- tures up to 120°C. Finally, processing

Just one year after laboratory test- etry and transient compression testing. ratios were doubled from ±1% by weight ing started, machine-scale testing and The screening process narrowed our to ±2% using compact, mobile, standard lab-scale aging studies con? rmed that candidates down to ? ve formulations industry equipment. that showed the most promise. These XUR-07031977-760 is a two-component,

Ready for customer ev aluation formulations underwent further lab-scale non-mercury, catalyzed ? eld joint insula- tion material that matches or exceeds testing measure the rate of development Based on our machine-scale test results, the important properties of the legacy possible, up from the standard ±1% by of rheological and mechanical proper- XUR-07031977-760, now named

Hg-catalyzed product. Most importantly, weight, to make the formulation more ties. The three most promising formula- HYPERLAST FJ 760E, was invited to

XUR-07031977-760 cures rapidly after forgiving than all previous ? eld joint tions were selected for evaluation at the participate in pre-quali? cation testing on the ? eld-joint mold is ? lled, and it builds coatings. pilot scale, where a plural component a major project in the Gulf of Mexico.

Faster build of compressive strength polyurethane machine was used to compressive strength quickly – compa- • rable to the legacy Hg-catalyzed material – all parties wanted a faster build of injection mold and bond X760E to a two Amber Stephenson, (Figure 1). mechanical properties contributing to inch thick coating of Dow HYPERLAST is an R&D Manager

Final thermal and mechanical proper- more ef? cient onsite pipeline assembly. DW512/300E GSPU on a two inch diam- for polyurethanes • ties of XUR-07031977-760 also closely Strong adhesion to various substrates – eter pipe. R&D application match the Hg-catalyzed legacy material, primarily the fusion-bonded epoxy (FBE) development at The

Pilot-scale testing as shown in Figure 2. anti-corrosion coatings and the glass Dow Chemical

When compared to HYPERLAST syntactic polyurethane (GSPU) “parent” Pilot-scale testing was carried out at Company.

coatings on the pipe sections. Dow’s application center in Birch Vale, FJ589, XUR-07031977-760 shows excel- • Mechanical and aging performance UK. Full-sized, industry standard equip- lent mechanical integrity during hydro- thermal aging, shown in Figures 3 and equivalent to legacy Hg-catalyzed systems ment was used to produce, mix and apply Dave Parker is the 4. XUR-07031977-760 and HYPERLAST – subsea ? ow assurance coatings must the test materials, as would happen in offshore coatings

FJ589 were aged in simulated seawater at withstand thousands of hours of service. the ? eld. These larger samples were then specialist at Dow Oil, 85°C, dried, and tested at 23°C. XUR- subjected to the same series of tests per- Gas & Mining.

Laboratory screening and testing formed in the laboratory, including adhe- 07031977-760 demonstrated excellent

Dow’s research and development team sion, cure pro? le, compressive strength, adhesion to both GSPU parent coat- initiated an experimental program to hardness, and thermal conductivity. ings and FBE substrates. Furthermore, deliver against these customer require- Based on this testing, XUR-07031977-760 machine-scale testing con? rmed that ments. Starting in April of 2012, a series

Figure 2: Thermal property comparison of different catalysts, chain extenders, Mike Huspek is a polyols, and isocyanates were screened global account

HYPERLAST™

Property MeasureXUR-07031977-760 FJ589 at laboratory scale in Freeport, Texas, manager at Dow Oil, using a multi-variable design of experi- Gas & Mining.

Hardness Shore A 86 – 94 86 – 92 ments to ? nd formulations that matched

Tensile strength MPa =10 12 or exceeded the cure pro? le, property

Elongation at break % =100 220 build and ? nal performance characteris-

Nicked crescent tear strengthN/mm =30 45 tics of the legacy Hg-catalyzed ? eld joint

Density Kg/m31050 – 1165 1100 – 1150 coating.

Formulations were ? rst screened to Kamesh

Taber Abrasion mg loss =250 =250 ensure that the cured elastomer provided Vyakaranam,

Thermal conductivity W/m·K =0.195 =0.195 the requisite thermal and mechanical is a polyurethane

Speci? c heat capacity J / g·K 1.4 – 1.7 ~1.5 – ~1.9 properties. Cup calorimetry was then associate scientist at

NOTE: During customer Interviews, applicators requested minimal values on technical charts rather than used to optimize catalyst type and load- The Dow Chemical typical values. Values shown for HYPERLAST FJ589 are typical or average values. Values shown for XUR- ing, to provide the desired cure time and Company. For the 07031977-760 are minimum speci? cations.

past six years, he has been working in

Figure 1: Compressive strength

Figure 3: Tensile strength Figure 4: Elongation at break epoxy and polyurethanes product build over time comparison comparison after 4,000 hours comparison at 4000hrs research.