Research on High-Performance Underwater-Curing Polymer Composites for Offshore Oil Riser Pipes

Area of Science:

• Materials Science
• Corrosion Engineering
• Offshore Engineering

Background:

• Riser pipes are critical for wellbore integrity and safety in offshore oil and gas extraction.
• Existing protective coatings face challenges like electrochemical corrosion and poor adhesion.
• Effective corrosion prevention is vital for extending the operational life of offshore infrastructure.

Purpose of the Study:

• To develop an advanced underwater-curing composite material for riser pipe protection.
• To overcome limitations of current coatings, focusing on corrosion resistance and adhesion.
• To enhance the reliability and efficiency of repair processes for offshore riser pipes.

Main Methods:

• Formulation of a composite material using a polyisobutylene (PIB) and butyl rubber (IIR) blend system.
• Development of a solvent-free, two-component epoxy system with nano-silica and latent curing agents.
• Systematic laboratory testing and field application experiments on offshore oil and gas well risers.

Main Results:

• The PIB/IIR blend achieved high peel strength, low water absorption, and wide temperature stability (-45 °C to 80 °C).
• The novel epoxy system demonstrated rapid underwater surface drying (30 min) and pull-off strength > 3.5 MPa.
• Field application on offshore risers showed a peel strength of 5 N/cm, significantly improving riser pipe service life.

Conclusions:

• The developed underwater-curing composite material effectively addresses corrosion and adhesion issues in riser pipes.
• The material provides a robust solution for enhancing offshore riser integrity and longevity.
• This research offers crucial technical support for improving offshore oil riser repair and maintenance.