PIPELINE COATING

PIPELINE COATINGS & ITS SELECTION

COATING REHABILITATION
NEW TECHNOLOGICAL DEVELOPMENTS IN
THE FIELD OF COATING
BY
RAJESH UPRETY
CHIEF PROJECTS MANAGER
IOCL

CROSS COUNTRY PIPELINE A
DIFFERENT PERCEPTION
JOURNEY OF PIPE :
STEEL PLANT
PIPE PLANT
COATING PLANT
STOCKYARD
CONSTRUCTION SITE
LAID INTO TRENCH
BACK FILLING





CROSS COUNTRY PIPELINE A
DIFFERENT PERCEPTION
JOURNEY OF PIPE :
PIPE CANNOT SPEAK, MUTE SUFFERER
SUBJECTED TO INTERNAL CYCLIC LOADING (BLOOD
PRESSURE)
SUBJECTED TO STATIC & DYNAMIC LOAD (TENSION &
WORRIES)
LAID ON UNEVEN TERRAIN (PIPE NEEDS TO BE DUCTILE &
COATING NEEDS TO BE FLEXIBLE)
PASSES DIFFERENT SOIL CONDITIONS
SUBJECTED TO CATHODIC PROTECTION (ELECTRIC SHOCK)







CROSS COUNTRY PIPELINE A
DIFFERENT PERCEPTION
JOURNEY OF PIPE :
IT IS THEREFORE, OUR SINCERE DUTY TO SELECT RIGHT
PIPE MATERIAL, MANUFACTURE QUALITY PIPES, SELECT
RIGHT TYPE OF COATING, APPLY IT PROPERLY, HANDLE IT
WITH CARE & PASSION AND LASTLY MAINTAIN IT
PROPERLY WITH PROPER & EFFECTIVE CATHODIC
PROTECTION & TIMELY REFURBISHMENT.
WE MUST, THEREFORE, PUT OURSELVES IN PLACE OF
THE PIPE TO UNDERSTAND THE PAIN OF PIPE.







PIPELINE COATINGS
PIPELINE COATINGS FOR NEW PIPELINES

Coal Tar Enamel Coating

3 Layer Polyethylene Coating

3 Layer Polypropylene Coating

Dual Fusion Bonded Epoxy


TYPES OF COATINGS - CLASSIFICATION

SOLID COATING (FBE, DFBE ETC.,)

LIQUID COATING (EPOXY, PU ETC.,)

TAPE COATING (COLD TAPE, VISCO ELASTIC TAPE, HOT
TAPE, 3 LPE ETC.,)




CRITICAL ISSUES FOR COATING OFTEN
NEGLECTED

INADEQUATE MANUFACTURERS TECHNICAL DATA SHEET
HIGH COATING THICKNESS
UV RESISTANCE OF COATINGS
MISCONCEPTIONS ABOUT COHESIVE FAILURE
PRE-HEATING BEFORE SHOT/ GRIT BLASTING SHOULD BE MADE
MANDATORY.
RANDOM CHECKING OF SURFACE PROFILE BY PRESS-O-FILM SHOULD
BE MADE MANDATORY.
RESIDUAL MAGNETISM





CRITICAL ISSUES FOR COATING OFTEN
NEGLECTED
CONTROL ON PROCESS PARAMETERS SUCH AS BARE PIPE TEMPERATURE,
NOZZLE PRESSURE, MILL SPEED ETC.,
WATER QUENCHING SHOULD BE UNIFORM (LIKE AN UMBRELLA)
FLUIDIZED BED SHOULD BE IN AN AC ROOM AND NOT NEAR THE
EPOXY APPLICATION BOOTH
LONG TERM PERFORMANCE TESTS (E.G., HOT WATER IMMERSION
TEST IN TAP WATER FOR 120 DAYS FOLLOWED BY PEEL TEST). ISO
21809 PART-3 HAS NOW INTRODUCED HOT WATER IMMERSION
TEST FOR 28 DAYS FOLLOWED BY PEEL TEST.
DOLLY TEST MUST BE INCLUDED IN THE SPECS






CRITICAL ISSUES FOR COATING OFTEN
NEGLECTED

APPLICATION WINDOW CALCULATIONS TO BE PROPERLY CARRIED
OUT.
MAJOR & MINOR COATING REPAIR TO BE APPROPRIATELY
DEFINED SO AS TO AVOID ANY AMBIGUITY.
CALIBRATION OF EQUIPMENTS SHOULD BE SERIOUSLY REVIEWED.
CONDUCTING RUBBER MUST BE USED IN HOLIDAY DETECTION
MACHINE.
COATING FAILURES TO BE ANALYSED AND DISCUSSED IN
APPROPRIATE FORUMS.




RECENT DEVELOPMENTS IN COATINGS

COATING SELECTION IS NEARLY ALWAYS
BASED ON TEST RESULTS ON NEW
SAMPLES NOT ON AGED COATINGS.

COATINGS NEED TO BE FIRST STRESSED
BY EXPOSURE TO A COMBINATION OF
HEAT, WATER AND TIME, AND THEN
SUBJECTED TO ADHESION TESTS.

SELECTION CRITERIA OF NEW PIPELINE COATING
(A HOLISTIC APPROACH)
REFURBISHMENT COATING SHOULD BE KEPT IN MIND. e.g., 3
LPE COATING IS VERY HARD TO REMOVE
DIAMETER OF PIPE
SOIL CONDITIONS LIKE ROCKY TERRAIN
ABRASION RESISTANCE/ MECHANICAL STRENGTH
JOINT COATING
CONSTRUCTION EXPERIENCE

BASIS OF SELECTION OF MAIN LINE COATING
CONSTRUCTION RELATED
Handling and transportation
Above ground storage
Bending
Stringing and lowering
Withstand high black body temperature and UV
exposure
Easy to repair

IN-SERVICE PERFORMANCE RELATED

Good adhesion to the pipe surface not just at 23
o
C but
at the max. operating temperature of the pipe, and for the
in-service life
Withstand shear forces at the max. operating temperature
of the pipe
Effective moisture and oxygen barrier
Effective electrical insulator
Low cathodic disbondment at holidays
Resist chemical, heat and UV degradation
ISSUES RELATED TO 3 LPE COATING PRACTICAL
EXPERIENCE
3 LPE with excellent insulating properties, although allows water to
permeate, shields CP current in case of a pin hole, leading to
disbondment.
As per DIN 30670 peel test to be carried out within 24 hrs, which is
not correct
In 3 LPE coating, white latex paint is used in the coating plant,
which is washed away in case the storage duration is long or in
case the latex paint is not applied properly, thus causing
degradation of outer layer and disbondment of coating.
In case of refurbishment it is almost impossible to remove 3 LPE
coating.
While selecting a type of coating , refurbishment of coating
related issues also to be kept in mind.
3 LPE does not have good abrasion and gouge resistance. As such it
is not ideally suited for HDD applications.
In case of HSAW pipes, DFBE coating is better as it covers the
intricate parts such as seam weld, girth weld etc., in a uniform
manner.
3- Layer PE
Adhesion
Loss
3- Layer PE
Adhesion
Loss
3-Layer PE: Corrosion in Girthweld Area
What is Dual-Layer FBE?
An anti-corrosion layer of FBE

Overcoated with a 2nd layer for special properties

Application of FBE

Cleaning of substrate by abrasive blast cleaning,
phosphoric acid pretreatment, (chromate)
Pre-heating by induction to 230C
Application by spray with multiple gun set-up
Coating bonds to substrate
Quenching after typically two minutes
QC and testing

Fluid beds
Coating Booths
pipe
Electrostatic
guns
Primary Coat
Dust
Collector
Topcoat
Dust
Collector
DFBE Application
Corrosion Coating Topcoat
Properties of the Corrosion Protection Base Layer
Good adhesion to substrate
Sufficient flexibility
Compatible with the CP system
Good resistance to under creep of coating
Barrier to both oxygen and water
Suitable reactivity to be compatible / work with
subsequent layers
Properties of Protective Layer - 2
nd
Layer
Good adhesion to corrosion protection layer to form a
composite coating

Must complement corrosion protection layer

Needs to have sufficient flexibility

Damage resistant coatings must be capable of withstanding
different types of field damage

Coatings designed for use at high temperatures must give good
barrier properties and sufficient strength at service
temperature
Types of DFBE Coatings
Mechanical protection for damage resistance

High friction for concrete weight coating

UV resistance for storage resilience

Mechanical Protection Systems
What does MPS deliver?
Improved backfill damage resistance
Improved resistance to damage

How do we know this?
Simulation of laying condition back fill
Directional drill and dragged pipe simulation
Gouge test

Improved Backfill Damage Resistance
Evaluated using a stone drop test
- Modified ASTM G13
Crushed riverbed aggregate 25mm
7.5Kg per drop
Impact angle 45 degrees

Improved Damage Resistance
400 microns of standard FBE = holidays

300 microns of standard FBE and 300 microns of
mechanical protection system
using 10 drops = NO holidays
Gouge and Impact Testing of Damage Resistant DLFBE
and PE
Improved Gouge Resistance
Gouge Test
Weight loaded on an
engineered tip

Dragged over test piece

Assessed for penetration
Panel of Damage Resistant DLFBE after 50 kg
Gouge Test
Panel of 3LPE After 40 and 50 kg Gouge Test
50 Kg Gouge Test Results

Coating Initial
thickness
Depth of
Gouge
Coating
remaining
DFBE
950 625 325
3LPE
2625 2325 300


EXPECTATIONS OF REFURBISHMENT COATING
EASE OF APPLICATION & HANDLING
ADHESION
RESISTANCE TO CATHODIC DISBONDMENT
HIGH RESISTANCE TO INDENTATION/ PENETRATION
HIGH SOIL RESISTANCE
RESISTANCE TO BACTERIAL ATTACK
RESISTANCE TO BACKFILL
HIGH ABRASION RESISTANCE
MINIMUM SHIELDING OF CP CURRENT

EXPECTATIONS OF REFURBISHMENT
COATING
EASE OF INSPECTION DURING APPLICATION
FAST CURE TIME AND MINIMUM TIME TO BACKFILL
NO TENTING
EASY TO REMOVE
ENVIRONMENT FRIENDLY
UV RESISTANT
COMPATIBILITY WITH OTHER EXISTING COATINGS
ECONOMICAL
EXPECTATIONS OF REFURBISHMENT
COATING
RESISTANCE TO CREEP
HIGH IMPACT RESISTANCE
LOW MOISTURE PERMEABILITY
FLEXIBILITY
LONG LIFE
HARDNESS
TEMPERATURE RESISTANCE (SERVICE TEMPERATURE)
Determining Pipeline health
Survey is done every 5 years.
CAT (Current attenuation technique)
DCVG (Pin pointing defects)
CIPS
Combination of these to prioritize & finalize the
location and identify interferences etc.,
Bell Hole Survey



PIPE LINE COATINGS
3 LPE (2 to 3.5mm thk)
DFBE (0.7mm thk)
FBE (0.45mm thk)
3 LPP (2 to 3.5mm thk)
PIPELINE COATINGS TEMP RATING
FACTORY APPLIED
COATING
PICTORIAL VIEW MAXIMUM
TEMPERATURE RATING
Coal Tar Enamel 60C
3 Layer Polypropylene 140C

Dual Layer Fusion Bonded
Epoxy
110C
3 Layer Polyethylene 80C
*In case of 3LPE coating the thickness of outer layer varies based on the following factors:-
- Water/Humidity barrier.
- Antirock system(rock shield) required or not.
- Special precaution required during storage, transportation, handling,trench bottom preparation, back filling etc
- -Laying & service conditions.
-- Environmental temperature.


** In case of FBE coating the outer layer thickness is fixed and all necessary precautions have to be taken into
consideration for preventing damage to the FBE coating which are OFFSET by providing higher thickness of 3LPE Coating.

COMPARISON OF 3LPE/DFBE PIPELINE COATINGS
THICKNESS 3LPE DFBE
Anti Corrosion Layer
150 300-350 micron
Hot Melt Adhesive Layer
200 -
Outer Layer
(Mechanical Protection/ARO)
1800 to 3800*

250-350**
COATINGS DURING CONSTRUCTION
Tuesday, July 02, 2013 39
DFBE
3LPE
3LPP
CTE
TYPE OF FIELD JOINT COATINGS
FIELD JOINT COATINGS
TYPE OF MAIN LINE COATINGS
3LPE 3LPP FBE
Three Layer Heat Shrink Sleeves

Liquid Epoxy Coatings

Liquid Tar Urethane Coatings

Liquid Urethane Coatings

Liquid Epoxy Urethane Coatings

Multi layer Cold Applied Tape Coatings

Visco Elastic Tape Coatings

FBE / Adhesive / PE or PP hot tape system

Spray applied FBE powder

Flame Spray PE / PP

PROTECTIVE CURRENT DENSITY
FOR NEWLY COATED PIPES




(*) SOURCE IS 8062-2006 (CATHODIC PROTECTION OF BURIED
PIPELINE/STRUCTURE FOR TRANSPORTATION OF NATURAL GAS, OIL
AND LIQUIDS CODE OF PRACTICE)
SOIL RESISTIVITY
Ohm-meter
3LPE
A/m
FBE/DFBE
A/m
<10 50 70
10-100 25 50
>100 15 25
COATING RESISTIVITY

- COATING RESISTIVITY(FOR 3LPE COATING) > 10
10
ohm-m

- COATING RESISTIVITY(FOR DFBE COATING) 10 ohm-m

- VOLUME RESISTIVITY( FOR DFBE AFTER AGING) > 10 ohm-cm

- VOLUME RESISTIVITY(FOR 3LPE COATING) >10
6
ohm-cm



COATING - PHILOSOPHY
THOUGH PIPELINE COATINGS ARE DESIGNED
TO REMAIN BONDED TO STEEL FOR DESIGN LIFE
OF PIPELINE --- IN REAL LIFE, COATINGS TENDS TO
FAIL PREMATURELY OR AFTER THE DESIGN LIFE
THE PIPELINE OPERATOR STILL WANTS TO OPERATE
THE PIPELINE AND WOULD REQUIRE RE-COATING



CONSEQUENSES
OF
CORROSION

PIPELINE COATINGS FAILURES
FAILURE OF COATINGS LEAD TO CORROSION
PIPE RUPTURE
SEVERE CORROSION
PIPE RUPTURE
FAILURE FROM THE SEAM



WHY DO COATINGS FAIL
?
WHY DO COATINGS FAIL ?
IMPROPER COATING SELECTION

IMPROPER COATING APPLICATION

LAYING DAMAGES

PREMATURE FAILURE OF COATING MATERIAL

IMPROPER CATHODIC PROTECTION


FAILURE OF COATINGS



WHEN COATINGS START TO FAIL WHAT STEPS
ARE TO BE TAKEN ?
CORRECTIVE MEASURES

ENHANCE CATHODIC PROTECTION

RECONDITION / RECOAT

REPLACE THE PIPE LINE


RECONDITION / RECOAT

VARIOUS TECHNOLOGIES OF RECOATING
COAL TAR OVER THE DITCH
HOT APPLIED COAL TAR TAPE
COLD APPLIED TAPE
VISCO ELASTIC TAPE
HIGH BUILD LIQUID EPOXY
LIQUID POLYURETHANE
MCU (MOISTURE CURE URETHANE)
Current Practices/Technologies
COAL TAR ENAMEL
BENEFITS
LOW COST
EASY TO APPLY

LIMITATIONS
LOW SOIL STRESS RESISTANCE
DIFFICULT TO MAINTAIN APPLICATION TEMPERATURE
UNEVEN FLOW OF MOLTEN CTE RESULTING IN
UNEVEN/INADEQUATE COATING THICKNESS PARTICULARLY AT
4 O CLOCK AND 8 OCLOCK POSITIONS
SUSCEPTIBLE TO SCC
HEALTH AND SAFETY CONCERNS



COAL TAR ENAMEL
58
COAL TAR ENAMEL
Current Practices/Technologies
Cold Applied Tape
BENEFITS
NO HEATING
EASY TO APPLY WITH WRAPPING MACHINE
HIGH PRODUCTIVITY
UNIFORM THICKNESS
LESS DEPENDENCE ON HUMAN SKILLS


LIMITATIONS
LOW ADHESION AND SUSCEPTIBLE TO DE-LAMINATION
SUSCEPTIBLE TO SCC
CATHODIC SHIELDING
TENTING EFFECT OBSERVED ON SAW PIPES





Current Practices/Technologies
Coal Tar Based Tapes-Hot applied
BENEFITS
LOW COST


LIMITATIONS
LOW ADHESION AND SUSCEPTIBLE TO DELAMINATION
SUSCEPTIBLE TO SCC
HEATING DURING APPLICATION POSES RISK TO PIPELINE AND
HUMAN LIFE
CATHODIC SHIELDING
TENTING AT WELD SEAM
LUMPING AND THINNING
HOLIDAYS, WRINKLING ETC.,
DIFFICULT TO APPLY
LOW PROGRESS




HOT APPLIED TAPE
61

Current Practices/Technologies
VISCO ELASTIC SELF HEALING COATING
BENEFITS
PERMANENT SOLUTION
IMPREGNATING STEEL
NO ADHESION PROBLEM
COLD APPLIED
NO CRACKS
SIMPLE AND EASY FOR APPLICATOR
ONLY ST 2/3 SURFACE PREPARATION NEEDED
ONE COMPONENT MATERIAL
TENSIONLESS APPLICATION
NO SPECIAL TOOLS NEEDED
REMAINS FLEXIBLE FOREVER
EASY TO MOULD
VERY FAST AND EASY TO APPLY










Current Practices/Technologies
VISCO ELASTIC COATING
BENEFITS
NO WASTE AND NON-TOXIC
HAS NO LIMITS FOR STORAGE SHELF LIFE OR APPLICATION TIME

LIMITATIONS
NO SOIL STRESS RESISTANCE HENCE CAN WRINKLE IN BLACK COTTON
SOIL
CLEANING CLAIM THAT COATING CAN BE DONE IN St-3 SURFACE,
HOWEVER, BASED ON OUR EXPERIENCE/ FEEDBACK BLASTING IS
NECESSARY
REMOVAL IS DIFFICULT






VISCO ELASTIC COATING
Current Practices/Technologies
LIQUID EPOXY COATING
BENEFITS
GOOD ADHESION AND CD RESISTANCE
GOOD SOIL RESISTANCE
GOOD PERFORMANCE IN WET CONDITIONS
NO KNOWN INSTANCES OF SCC
FAST APPLICATION AND LESS DEPENDENCE ON HUMAN SKILLS
NO TENTING EFFECT ON SAW PIPES EXCELLENT BONDING ON ALL
INTRICATE STRUCTURES

LIMITATIONS
LONGER CURE TIME COMPARED TO URETHANE, SLOW CURE BELOW 5
DEG C
INSECT AND DUST CONTROL TILL CURING IS ACHIEVED
PROPER PPE REQUIRED DURING APPLICATION/INSPECTION
LESS SURFACE IMPERFECTION TOLERANT





TYPICAL TEST PROPERTIES LIQUID EPOXY

Property Typical Value
Specific Gravity 1.35 Mixed+_ 0.10
Color Green
Mix ratio 2A:1B by volume.
Shelf Life Min 6 Months.
Dry to Touch Time 24C 2 Hrs Max.
50C 30 minutes Max.
Viscosity in cps
Spray Grade
Part A: 60000-90000.
Part B : 9000-20000
Abrasion Resistance 0.5 g max loss
Impact Resistance At Room Temp Joule Value =2.5
Min
Flexibility 20C 0.5 /PD Min.
Coating Rehabilitation
Current Practices/Technologies
PU COATING
BENEFITS

GOOD ADHESION AND CD RESISTANCE
GOOD SOIL RESISTANCE
FAST CURING AND LOW TEMPERATURE CURE
NO KNOWN INSTANCES OF SCC
HIGHER IMPACT RESISTANCE THAN LIQUID EPOXY SYSTEM
ADEQUATE MECHANICAL STRENGTH TO ABSORB SHOCK, HANDLING,
ABRASION
FAST APPLICATION AND LESS DEPENDENCE ON HUMAN SKILLS
AS COATING DOES NOT SHRINK, EXTREMELY GOOD FOR FIELD JOINTS & ON
WELD SEAMS.
UV RESISTANT BASIC PROPERTY OF PU.
AS TOUCH DRY TIME IS LESS, IT IS FAST PUT BACK INTO SERVICE
VERY DIFFICULT TO REMOVE








Current Practices/Technologies
PU COATING

LIMITATIONS

LESS RESISTANCE TO CD THAN LIQUID EPOXY SYSTEM
INSECT AND DUST CONTROL TILL CURING IS ACHIEVED
PROPER PPE REQUIRED DURING APPLICATION/ INSPECTION
LESS SURFACE IMPERFECTION TOLERANT
LOW POT LIFE OF PU
CARRYING SKID/ SPRAY EQUIPMENT IN ROW
REMOVAL OF PU COATING AT SITE FOR FURTHER REFURBISHMENT
LIMITED APPLICATORS PRESENT IN THE INDUSTRY
VERY DIFFICULT TO APPLY BY BRUSH
Automatic Spray Application

COMPARISON- PU & LQUID EPOXY











S.
No
TEST PROPERTIES TEST
MET
HOD
PU 2 COMP
SOLVENT
FREE EPOXY
(1) THICKNESS ELCO
METE
R
2000
MICRONS
1000
MICRONS
(2) ADHESION D-
4541
1200 PSI 2500 PSI
(3) HARDNESS D-
2240
> 60 SHORE D > 85 SHORE D
(4) WATER PERMEABILITY ASTM
E-96
0.3 gms/24
Hour/M
2

Max.
0.1 gms/24
Hour/M
2

max.
(5) ABRASION RESISTANCE
(1OOO GM LOAD, 1000
CYCLES)
D-
4060
Weight loss
< 0.05 gms
(H10 Wheel)
Weight loss
< 0.05 gms
(H10 Wheel)
COMPARISON- PU & LQUID EPOXY











S.
No
TEST PROPERTIES TEST
MET
HOD
PU 2 COMP
SOLVENT
FREE EPOXY
(6)
CATHODIC
DISBONDMENT
(28 days @ 25
0
C)

G-8
< 5 mm < 4 mm
FUNCTIONAL PROPERTIES OF LQUID EPOXY COATING
ARE FAR SUPERIOR TO ELASTOMERIC
POLYURETHANE COATINGS.
Current Practices/Technologies
MCU COATING
BENEFITS

LONG TERM ADHESION
FAST CURING
EASY TO USE: ONE COMPONENT/AVOID MIXING FAILURES/NO RECOAT
WINDOW
APPLY IN ALL WEATHER CONDITIONS :
6 99% RH
APPLICATION TO DAMP SUBSTRATES
NO DEW POINT RESTRICTIONS
RESISTANT TO FOG, RAIN AND DEW
CURES EVEN AT -15 C
ALL YEAR ROUND AND NIGHT APPLICATION POSSIBLE
SURFACE TOLERANT :
BEST ADHESION ON MINIMAL PREPARED SURFACES
LOW STEEL ROUGHNESS REQUIRED: 25 M OR HAND AND POWER TOOL PREPARED
FLASH RUST TOLERANT











FINAL CONCLUSION
MAINLINE COATING DUAL FBE
GOOD MECH
STRENGTH
REFURBISHMENT
COATING
LIQUID
EPOXY/ VISCO
ELASTIC TAPE

NO TENTING
JOINT COATING LIQUID
EPOXY/ HEAT
SHRINK
SLEEVES
THANK FOR THE
PATIENT
HEARING !