Abstract: A flotation device comprises three-dimensional cellular structure comprising a plurality of lengthwise adjacent and radially adjacent hollow cylindrical tubes, wherein interstices between the plurality of cylinders are filled with a composite matrix of macrospheres and syntactic foam.

Abstract: A length of buoyant, flexible insulating material for lengthwise encasing a length of pipe comprises syntactic foam that includes a thermoset resin binder and microspheres, wherein the syntactic foam encases a plurality of substantially parallel longitudinal fibrous strands. The thermoset resin may comprise an epoxy resin that includes Bisphenol-A, a curing agent, and a flexibilizer.

Abstract: A macrosphere comprises a multilayered spherical wall that includes (i) a first wall that includes a first epoxy and first fibers (ii) a second wall that includes a second epoxy and second fibers and (iii) a third wall that includes a third epoxy and glass micro spheres, wherein the third wall is located between the first and second walls and the multilayered spherical wall forms a hollow chamber. The fibers may be carbon fibers. However, it is contemplated that glass fibers may also be used rather than carbon fibers. In addition, it is contemplated that the first layer may be formed using glass fibers, while the second layer is formed using carbon fibers.

Abstract: A method of manufacturing syntactic foam comprises mixing a non-liquid amine adduct and a liquid epoxy to form a matrix. Hollow microspheres are added to the mixture and mixed together to form a mixture, which may then be poured into a mold and heated to form a molded syntactic foam component.

Abstract: Precast thermal insulation for flowlines and risers includes an outer protective shell that has an exterior surface and an interior surface that together define a volume within the outer protective shell. High elongation syntactic foam insulation is located within the volume, and comprises microsphere and a semi-rigid epoxy plastic resin binder. The precast thermal insulation permits advanced materials to be used for risers and flowlines, including highly flexible systems for installation by reeling.

Abstract: A streamlined annular buoy for marine pipelines includes a first annular buoy half comprising syntactic foam, where the first buoy half includes a substantially planar exterior first mating surface that includes an axial first channel formed therein and a first domed exterior surface radial to the axial first channel. Buoy also includes a second annular buoy half comprising syntactic foam, where the second buoy half includes a substantially planar exterior second mating surface that includes an axial second channel formed therein and a second domed exterior surface radial to the axial second channel. A fastener secures the first and second annular buoy halves together around a pipe that passes through a pipe channel formed by the axial first and second channels, such that the exterior first and second mating surfaces are face-to-face.

Abstract: An insulated length of pipe includes a length of pipe and a flexible insulating material coating lengthwise surrounding the length of pipe. The flexible insulating coating comprises syntactic foam and a length conformable tape including a relatively narrow elastomeric extrusion spirally wrapped around the length of pipe and embedded within the syntactic foam where the elastomeric extrusion comprises a gelatinous filler. The majority of the insulating coating includes syntactic foam whose flexibility is increased by relatively narrow conformable tape wound spirally (e.g., helically) around the pipe.

Abstract: A fairing includes two half-shells of fiber reinforced plastic or fiberglass. The shell halves are shaped to close around the buoyancy modules (e.g., cylindrical syntactic foam buoyancy modules) commonly used on deep-water risers, but with an extended trailing edge. The fairing includes a tail that streamlines the riser and reduces/prevents formation of the vortex, which causes drag and vibration. Hinges at the tail join the halves and enable them to be opened for assembly around the riser pipe as it is being run into the water. The fairing may be fastened together by bolted stainless steel tensioners that tightly draw together straps of high strength aramid fiber, such as KEVLAR®. The fairing is positioned on the riser such that the fairing is free to swivel and rotate into the current, while integral buoyancy blocks support the tail. To prevent movement up or down the riser string, the fairing is held in place by a channel clamp gripping the outside diameter of the syntactic foam buoyancy module.

Abstract: A plurality of concentric plastic tubes are drawn over a steel flowline pipe, with the annuli thus formed between the successive layers of tubing filled with an appropriate insulating material to form a length of pipe suitable for use in a subsea pipeline. The length of steel flowline pipe is at least partially encased lengthwise by a first insulating core of interstitial material. A first length of polymeric tubing is coaxial with the length of steel pipe and radially separates the first insulating core and a second insulating core of interstitial material. A second length of polymeric tubing is radially exterior to the second insulating core, and provides a protective coating for the pipe. Advantageously, the insulated length of pipe may be formed without extruding or molding, and as a result expensive dies and molds are not required.