coating presentation tp bangkok - 23 jan 2014
DESCRIPTION
Corrosion protection by coating methodologies.TRANSCRIPT
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Coating Overview
Audrey BERGERON Bangkok January 23rd 2014
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About the instructor
Title Coating specialist
Region / Entity Asia Pacific / TPS
Business segment Subsea Onshore Offshore
Education Meng./ Chemical Engineering
Contact [email protected]
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About Technip Singapore
Shallow to deep water (3000 m)
S-laying Rigidd pipes (4 to 60 ) Piggy-backed pipeline
installation Pipe-in-pipe, CRA
OFFSHORE PIPELINE INSTALLATION
Lifting up to 1200 tons Installation of
platform, subsea structures, skids, modules, etc.
OFFSHORESTRUCTUREINSTALLATION,HEAVY LIFTING
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About Technip Singapore
Spools Risers Buckle Initiator Structures PLEM Manifolds Skids Crossing Structures Installation Aids
FABRICATION SERVICES
Full-time divers Saturation to 300m Pipelines, platform, SCM
de-commissioning / removal
DIVING, IMR, DECOMMIS-SIONING
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About Technip Singapore
G1201 - 3rd Generation DP Pipelay Vessel incl. 1200MT Pedestal Crane
Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
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3LPP/PE:CS:
CUI: CWC: FBE: FJC:
GSPU: HP/HT:
HSS: MLPP/PE:
PE:PFP:
PP:PU:
SPU:SS:
TSA:
Three Layer PolyPropylene / PolyEthyleneCarbon SteelCorrosion Under InsulationConcrete Weight CoatingFusion-Bonded EpoxyField Joint CoatingGlass Syntactic PolyUrethaneHigh Pressure/ High TemperatureHeat Shrinkable SleevesMulti-Layer PolyPropylene / PolyEthylenePolyEthylenePassive Fire ProtectionPolyPropylenePolyUrethaneSyntactic PolyUrethaneStainless SteelThermal Spray Aluminum
Abbreviations
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Summary
1. HSE moment2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
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1. HSE moment
Find the difference:
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1. HSE moment
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Summary
1. HSE moment
2. Reason for coating3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
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2. Reason for coating
Why do we need coating? What kind of coating?
Corrosion protection
Anti corrosion paint
Passive Fire Protection (PFP)
Intumescent Epoxy Cementitious coating
Fouling release
Anti fouling paint
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2. Reason for coating
Mechanical protection
Polyolefin coatings
Negative buoyancy
Concrete weight coating
Prevent CUI(corrosion under insulation)
Metallizing (Thermal spray aluminum)
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2. Reason for coating
Anti slip
Paint + natural aggregate
Insulation
PU foam
Aesthetic aspect Polyurethane, Acrylic
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
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3. Introduction to corrosion
According to NACE: Corrosion is a deterioration of a material because of reaction with its environment.
Liquid water is in contact with metal AND
corrosive agent is present in the waterCORROSION =
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3. Introduction to corrosion
Corrosion impact:
o Safety: unsafe corroded structures / equipment
o Cost: For the US, the annual cost of corrosion worldwide is around 3% of GDP (US$ 250 Billion)
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3. Introduction to corrosion
Different types of corrosion Uniform corrosion
o Uniform loss of mass for external surfaces. Concerns mainly carbon steel and cast iron.
o Solution: corrosion allowance (3 to 6 mm), painting, cathodic protection.
Galvanic corrosiono Creation of an electric current between 2 materials with
different potential. o Common cases: aluminum/stainless steel, carbon
steel/stainless steel. o Solution: isolation joints, cathodic protection, coating
Erosion corrosiono Erosion (abrasion): removal of metal by mechanical
action of liquids (or solids). Erosion-corrosion :removal of corrosion products by mechanical action of liquids ( or solids).
o Solution: improve flow by design of the piece, change for better material, corrosion allowance
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3. Introduction to corrosion
Different types of corrosion
Pitting corrosiono High chloride concentration leads to passivation layer
breakdown. o Affects stainless steel, aluminum, titaniumo Solution: increase molybdenum content in SS (CRA),
coating
Chloride stress corrosion crackingo Combined action of seawater and mechanical stresso 316 Austenitic stainless steels subject to CSCC if
chloride concentration > 50 ppm and temperature > 50
o Solution: coating, change material grade (316 SS to 22Cr or 25Cr)
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3. Introduction to corrosion
Corrosion preventionCorrosion prevention
Design
Coating
Chemical treatment
Cathodicprotection
Material selection
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3. Introduction to corrosion
How to prevent corrosion?
Design: avoid water retention, moisture / salts entrapment
Inhibitors: chemical added into a fluid to decrease corrosion rate Material selection. Examples:
o SS 304L very sensitive to CSCC in offshore environment. SS 316L, 22Cr duplex or Inconel 625 are preferred.
o Carbon Steel can be selected for offshore structures, provided it is protected by coating and cathodic protection.
Cathodic protection: protection of the surface by another sacrificial metal (Zn, Al, Mg, ) who has a more electronegative potential.
Protective coating
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
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Clean the surface from contaminant
Create roughness for coating adhesion.
4. Surface preparation
objectives
Surface preparation: The key step to the coating success
dustgrease
mill scale
oil
Soluble salts
Former coating
contaminants
Long term stability to the coating
Did you know? 75% of premature coating failures are caused by inadequate or improper surface preparation
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Substrate: carbon steel, stainless steel, Aluminum, galvanized steel
Degree of cleanliness required (paint system type and thickness)
Geometry of the piece (area difficult to access with machines)
Place where surface is prepared (on site, applicators plant)
Selection of the method depends on:
4. Surface preparation
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1. Prior to commencement
check for fabrication or welding defaults: rough edges, cuts and welds shall be rounded to a 2mm radius to improve coating coverage and adhesion on the surface.
remove weld spatters.
4. Surface preparation
2. Solvent cleaning.Degrease and remove oil, grease, soluble contaminants with solventcleaning (fresh water, emulsion cleaners, detergents, organic solvents,petroleum based solvents, alkaline cleaners). Does not removeChlorides, mill scale or other inorganic materials.
3. Abrasive blasting or other method
Remove chlorides and sulfates, create desired surface profile forprimer adhesion, create a uniform aspect.
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steel shot or grit (carbon steel surfaces),
aluminum oxide or garnet sand (stainless steel or carbon
steel surfaces).
Projection of abrasive particles to remove rust and other contaminant and create a rough surface
Abrasive blast cleaning
4. Surface preparation
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4. Surface preparation
Abrasive blasting equipment
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Surface preparation: other methods
Power tool cleaning (hand or mechanical). Example: rotary wire brush.
Water jetting. Only to remove previous coating, does not create roughness.
Pickling. Dipping of steel in an acid bath
4. Surface preparation
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4. Surface preparation
Substrate Type of system Cleanliness (ISO 8501-1 or SSPC)
Profile surface (ISO 8503)
Carbon steel external surfaces
Typical paint system with DFT > 200m
Sa 2 eq. to SSPC SP10 50-75 m
Carbon steel internal surfaces
Internal coating (lining)
Sa 3 eq. to SSPC SP5 or Sa 2 eq. to SSPC SP10
50-75 m
Stainless steel, Galvanized steel
Typical paint system Sweep blasting eq. to SSPC SP7 20-40 m
- Carbon steel - Stainless steel
TSA - Sa 3 eq. to SSPC SP5- Sweep blasting eq. to SSPC SP7
70-120 m
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating6. Pipe & field joint coating
7. Coating qualification process and requirement
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5.1 Corrosion protection coatings
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Definition Application Selection Protection mode Specification
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5.1. Corrosion protection coatings - Definition
PAINT= A+B
Binder (polymer)
Pigments + fillers
Solvent
Additives
Reactive + solvent
Component A
Component B
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5.1. Corrosion protection coatings - Definition
2 component- thermoset coatings Excellent adhesion, chemical and water resistance Shall be top-coated by UV-resistant topcoat
EPOXY
2 component Resistant to UV, good gloss and color retentionPOLYURETHANE
2 component min. zinc content 85% Very high substrate adhesion good chemical resistance Max thickness 80 m, subject to mud-cracking -careful with
repairs INORGANIC ZINC
Cure at ambient temp. or with help of heat For heat resistance up to 600 , or foul releaseSILICONES
2 component coatings Very good for immersion service Suitable up to 230
PHENOLIC EPOXIES
2 component used as linings very resistant to chemicals and temp.
High thickness (2 x 1000 m)VINYL ESTER
2 component short pot life (45 min at 20 ) - Glass flake reinforcedExcellent resistance to abrasion, water and moisture good for salt and fresh water environment and walkways
POLYESTER
Major paint used for corrosion protection purpose
Spray application : Air spray vs Airless spray
- Spray pattern easily adjusted - High quality of finishes (automotive)
- Overspray causes high loss of coating- Add solvent to improve atomization but leads to low thickness
Air spray
Airless spray
- Less overspray- Heavier film built- Better production rates
-Little control of coating quantity- Speed makes it difficult for small pieces
5.1. Corrosion protection coatings Application
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Brush application
Brush is only for o Small areas not easily
accessible by sprayo Repairs and touch-upo Stripe coats, corner, edges,
welds, bolting, flangeso When environmental conditions
prohibit the use of spray
Roller application Do not use roller unless specific client approval
- Helps coating to have a good adhesion on substrate (for primers and underwater coatings)- Good penetration into surfaces that cannot be properly cleaned
- Slow application (can be an advantage in some cases)- Low DFT achieved
5.1. Corrosion protection coatings Application
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Finish coat (polyurethane)
Intermediate coat (Epoxy based)
Zinc rich primer (inorganic zinc, zinc rich epoxy)Primer with inibitors (zinc phosphate)
1 Barrier
2 Galvanic
3 Inhibition
Impermeability to water vapor, oxygen and salts (Chloride), thick film, electric resistance pigmented epoxies (high solid content, mica flakes)
1. Barrier effect
Primer contains a metallic pigment with a more electronegative potential inorganic zinc silicates and zinc rich organic primers (epoxies)
2. Galvanic effect
Isolation of the substrate surface by addition of a metallic compound chemically bonded to the surface zinc phosphate pigment
3. Inhibition
5.1. Corrosion protection coatings Protection mode
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Selection of coating depends on:
Atmospheric corrosivity of environment (marine C5M, industrial C5I, high C4, )
Substrate (carbon steel, stainless steel, galvanized steel, aluminum, CRA, )
Equipment operating temperature
Durability of the coating / installation
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5.1. Corrosion protection coatings - Selection
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5.1. Corrosion protection coatings Specification
Frequently encountered coating systems Onshore offshore systems
Substrate System DFT (m)CS operating below 120 (Uninsulated)
Zinc rich primer (epoxy or inorganic zinc)Epoxy high build Polyurethane topcoat
50-75150-20050
CS operating between 120 and 450 (Uninsulated)
Inorganic zinc primerAl pigmented siliconeAl pigmented silicone
50-752525
SS operating below 120 (Uninsulated)
Epoxy primer, zinc freeEpoxy high build Polyurethane topcoat
50150-20050
SS operating between 120 and 600 (Uninsulated)
Al pigmented siliconeAl pigmented silicone
2525
Insulated CS and SS operating below 200
Epoxy phenolicEpoxy phenolic
100100
Insulated CS and SS operating between 200 and 600
TSASealer (silicone)
25040
Bulk items (any substrate, any temperature, valves, piping, )
Universal coating, inorganic copolymer (compatible with PU topcoat for color marking)
As per manufacturer
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Frequently encountered coating systems Onshore offshore systemsInternal coatings (Carbon steel surfaces)
Application System DFT (m)Potable water below 60 Solvent free epoxy
Solvent free epoxy300300
Crude oil, diesel, condensate, below 60 : bottom up to 1m + roof and upper 1m of wall
Abrasion resistant epoxyAbrasion resistant epoxy
150-180150-180
methanol, MEG below 80 Inorganic zinc primer 60
Process vessel below 120 Solvent free epoxy Novolac 300-600
5.1. Corrosion protection coatings Specification
Galvanized surfaces
Substrate System DFT (m)Galvanized steel operating below 120 Epoxy primer, zinc free
High build epoxyPolyurethane
5010050
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Frequently encountered coating systems Subsea systems
Substrate System DFT (m)
CS and SS in splash zone operating below 100
Abrasion resistant epoxy (glass flakes)Abrasion resistant epoxy (glass flakes)
300300
CS and SS immersed operating below 100
Abrasion resistant epoxy or high build epoxyAbrasion resistant epoxy or high build epoxy
175175
5.1. Corrosion protection coatings Specification
Antiskid surfaces
Substrate System DFT (m)Carbon steel Epoxy primer
Ultra high build epoxy + non-skid aggregatesPolyurethane
50600-300060
Note: 1. Surface friction coefficient may need to be indicated. 2. Use of Aluminum oxide (and other non-ferrous irregular surfaces) is preferred
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Checks and Quality Controls
Before painting applicationo Operator and inspector Qualification certificateso Instrumentation device calibration certificates
Surface preparationo Environmental conditions (Dew Point, surface TC and Ambient TC measurement),o Abrasive contamination,o Grade of cleanliness + surface roughness,o Chloride content + dust level
Painting applicationo Wet and dry film thickness,o Visual inspection
After painting applicationo Curing of inorganic zinc,o Adhesion testo Pinhole detection (only for immersed, underground and internal coatings)
5.1. Corrosion protection coatings Specification
5.2 Specific coatings
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Metallizing Passive Fire Protection Fouling-release coatings
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Thermal Spray Aluminum Spraying of molten Aluminum wire by flame spray or arc spray Good for immersion and CUI prevention. Applied on Carbon steel or Stainless steel operating up to 600
- Excellent corrosion protection properties- Excellent resistance to mechanical damages - Very high durability (up to 50 years)- Zero VOC.
- Porous: need to apply a sealer on top (epoxy or silicone).- Cost effective process - HSE rules must be strictly followed. - Critical surface preparation: high degree of cleanliness required
5.2 Specific coatings: Metallizing (TSA)
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5.2 Specific coatings: Metallizing (TSA)
TSA coating systems
Substrate System DFT (m)
CS and SS operating below 120
TSAEpoxy sealer compatible with TSA
25040
CS and SS operating above 120
TSASilicone sealer compatible with TSA
25040
Application examples Bulk valves (all temperatures, CS and SS) Offshore or immersed structures Flare top
TSA applicators Norimax WASCO MTM Metalization
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5.2 Specific coatings: Metallizing (TSA)
Splitter column Turret component
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5.2 Specific coatings: Metallizing
Other Thermal Spray Coatings:
Zinc Al-Zn Stainless steel Inconel Copper Nickel Monel Hastelloy
Harder material Higher operating temperature gun
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Steel begins to lose strength as its temperature rises in a fire structural collapse. PFP is designed to protect structures supporting high risk and valuable equipment. Objective: prevent the substrate to rise in temperature during a fire to avoid steel to collapse:
o Jet fireo Hydrocarbon fire o Cellulosic fire
0
200
400
600
800
1000
1200
1400
0 30 60 90 120 150 180
Tem
pera
ture
C
Time (minutes)
Fire Curves
Cellulosic
Hydrocarbon
Jet Fire
Jet fire: Release of hydrocarbon fuel under pressure through a relatively small opening such as a crack or hole high levels of turbulence, erosion of the PFP coating.
Pool fire: Hydrocarbon fuel burning under atmospheric pressure.
5.2 Specific coatings: PFP
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- Provides corrosion protection- Low DFT for 2h protection (2-10 mm)- Low density
- Requires the use of skilled applicators- Cost effective
Organic coatings: Intumescent epoxyThey are inert at ambient temperature but react when exposed totemperatures above about 200C. The reacted coating forms a thick carbonbased char. Applied with reinforcement mesh
5.2 Specific coatings: PFP
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Spray application equipment
Source: PPG
Typical Plural Component Pump
Typical plural component mixing block and spray gun
5.2 Specific coatings: PFP
Thickness of PFP is determined by:o Size, shape of steel section to protect (beams, hollow section)o Critical failure temperatureo Duration of protection needed
Calculation of DFT with Hp/A value.
Low A
High Hp
Fast Heating
Low Hp
High A
Slow Heating
Source: PPG
Hp = heated perimeter exposed to fireA = cross-section area of steel element
The higher Hp/A value, the higher PFP thickness will be required.
5.2 Specific coatings: PFP
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5.2 Specific coatings: PFP
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- Cheap, easy to install and repair- Hard and durable
- Heavy- Thickness around 25 mm for a 2h fire protection- Poor flexibility- Risk of hidden corrosion in reinforcement by water ingress
Inorganic coatings: CementitiousLightweight with nominal density around 500 kg/m3.Must be topcoated with a high water vapor permeabilitycoating. Must also be applied with mesh reinforcement.
5.2 Specific coatings: PFP
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5.2 Specific coatings: PFP
PFP systems
Substrate System DFT (m)
Fireproofed carbon steel surfaces
Zinc rich epoxy or inorganic zinc silicateIntumescent PFP epoxyPolyurethane
50As calculated50
Fireproofed stainless steel surfaces
Zinc free epoxy primerIntumescent PFP epoxyPolyurethane
50As calculated50
Fireproofed carbon steel surfaces
Zinc rich epoxy or inorganic zinc silicateHigh build epoxyCementitious PFP
50150As calculated
Fireproofed stainless steel surfaces
Zinc free epoxy primerHigh build epoxyCementitious PFP
50150As calculated
Objective: prevent formation of biofouling on vessels and structures (mussels, barnacles, algae, etc.). 2 mechanisms: fouling release coatings and antifouling coatings (biocide release).
Fouling release coatings: - Silicones- Fluoro-polymer Prevent attachment of micro-organisms on the structure by creating a smooth finish with low surface tension.
5.2 Specific coatings: Fouling release coatings
Source: PPG
TBT-based coatings are prohibited54
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5.2 Specific coatings: Fouling release coatings
Fouling release system
Substrate System DFT (m)
Any (riser, structure, hull, etc.) Epoxy primerFoul release coat (1 or 2 coats)Finish coat
50-100200-600100-150
Note: Fouling release systems depend on each coating manufacturer; all products of the system should be compatible with each other. The proposed system is for example only.
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5.2 Specific coatings: Shop primers
Thin film inorganic zinc primer applied on applicators plant for more accurate control of application process.
Typical application: steel plates for tank storage. Purpose: Protect against corrosion and environment during
transport and before erection.
Primer is applied automatically or not at 15-30 m.
Source: TOTAL GTS presentation
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5.2 Specific coatings: Shop primers
Source: TOTAL GTS presentation
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5.2 Specific coatings: Shop primers
Source: TOTAL GTS presentation
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating7. Coating qualification process and requirement
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6.1 Pipe coating
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Selection Properties Standards Systems Subcontractors Futures challlenges
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6.1. Pipe coating - Selection
Pipeline protection = Combination of
Adequate protective coating, Supplementary cathodic protection
Selection of the coating system depends on: o Pipe material characteristicso Service / design temperatureo Pipeline design thermal profileo Maximum water deptho Specific properties requirement (cathodic disbondment, elongation, strength, )o Laying method
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Properties for Corrosion protection coating
Main properties
o Strong adhesion to the pipeo Corrosion propertieso Strong resistance to cathodic
disbondment
o Durability for design life of the pipe
o Good mechanical strength
6.1. Pipe coating - Properties
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Properties for Thermal insulation coating
Pipes are insulated to prevent hydrate formation, waxing and to satisfy separator arrival temperature.
Main propertieso Thermal conductivityo Densityo Adhesion to base material
Properties for Weight coating
Main propertieso Densityo Compressive strength
6.1. Pipe coating - Properties
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Types of pipe coatings
o Fusion Bonded Epoxy (FBE), Liquid epoxy
o 3-layer Polyethylene (3LPE) / Polypropylene (3LPP)
o MLPP Foam / syntactic
o GSPU, SPU
o Concrete Weight Coating (CWC)
Corrosion protection
Flow assurance
Negative buoyancy
6.1. Pipe coating - Properties
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International standards in pipe coating: ISO 21809
3LPE/PP: ISO 21809 - 1 FBE: ISO 21809 - 2 CWC: ISO 21809 - 5ISO 21809 replaces DIN (German), NF (French), CSA (Canadian)
Other standards or specifications AWWA (American Water Works Association): AWWA C213-07 (FBE) DNV-RP-F106 (FBE, 3LPP, 3LPE) NACE RP0394-2002 (FBE) DNV-OS-F101 (CWC)
NO STANDARD FOR INSULATION COATING
6.1. Pipe coating - Standards
Liquid coating- Mainly used for buried pipe operating at elevated temperature, where 3LPE and 3LPP cannot be
considered.
- Generally a high built coating applied by airless spray with DFT up to 3000 m.
- Maximum service temperature can go up to 200 , depending on the type of resin (epoxy, epoxy novolac, phenolic epoxy, vinyl ester).
- Can be reinforced with glass flakes to improve moisture and mechanical resistance.
- Can be applied as an internal lining to protect against corrosive fluid. In this case, thickness up to 300 m.
6.1. Pipe coating - Systems
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Fusion Bonded Epoxy (FBE)
Coating system description Single layer fusion bonded epoxy
Type of protection Corrosion protection
Typical coating thickness 350-500 m
Design temperature 90
Water depth limit Unlimited
Major characteristics - Excellent long term corrosion resistance to steel, - Cathodic disbondment resistance (reduce cost of
cathodic protection) - Good chemical resistance.
6.1. Pipe coating - Systems
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FBE coating process
Source: Bredero Shaw
6.1. Pipe coating - Systems
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Three Layer Polypropylene (3LPP)
Coating system description FBE + PP Adhesive + Solid PP
Type of protection Corrosion protectionMechanical protection
Typical coating thickness 2- 4.5 mm
Design temperature 110 (up to 130 with high temperature FBE)
Water depth limit Unlimited
Major characteristics - High film thickness- Good PP flexibility mechanical protection to the
pipe.- Good impact strength
6.1. Pipe coating - Systems
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3LPP coating process
Source: Bredero Shaw
6.1. Pipe coating - Systems
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Three Layer Polyethylene (3LPE)
Coating system description
FBE + PE Adhesive + Solid PE
Type of protection Corrosion protectionMechanical protection
Typical coating thickness
2- 4.5 mm
Design temperature 80
Water depth limit Unlimited
Major characteristics - Cheaper than 3LPP, but does not have as good mechanical characteristics as 3LPP.
3LPE process is the same as 3LPP
6.1. Pipe coating - Systems
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Multilayer PP (MLPP) Foam MLPP
Coating system description
FBE + PP Adhesive + (Solid PP) + PP Foam + Solid PP
Type of protection Corrosion protection + Mechanical protection + Thermal insulation
Typical coating thickness
Depends on thermal requirements
Design temperature 120Water depth limit 600 m
Major characteristics K-value around 0.17 W/m.K, density 600-800 kg/m3
1. FBE2. 2. PP adhesive3. Solid PP4. PP foam5. Outer PP shield
Source: Bredero Shaw
6.1. Pipe coating - Systems
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Multilayer (MLPP) Glass syntactic MLPP
Coating system description
FBE + PP Adhesive + (Solid PP) + GSPP + Solid PP
Type of protection Corrosion protection + Mechanical protection + Thermal insulation
Typical coating thickness
Depends on thermal requirements
Design temperature 130Water depth limit 3000 m
Major characteristics K-value around 0.16 W/m.K, density 650-700 kg/m3
Hydrostatic pressure resistance is reinforced by glass microspheres added into the PP matrix.
6.1. Pipe coating - Systems
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Syntactic PU - polymer syntactic (sPU)
Coating system description
FBE + sPU
Type of protection Corrosion protection + Thermal insulation
Typical coating thickness
Depends on thermal requirements
Design temperature 115Water depth limit 300 m
Major characteristics - K-value around 0.12 W/m.K, density 600-700 kg/m3
- Thin wall + low polymer mechanical properties decrease compression resistance of the foam.
6.1. Pipe coating - Systems
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Syntactic PU - Glass syntactic (GSPU)
Coating system description
FBE + GSPU
Type of protection Corrosion protection + Thermal insulation
Typical coating thickness
Depends on thermal requirements
Design temperature 130Water depth limit 3000 m
Major characteristics - K-value around 0.16 W/m.K, density 800 kg/m3- Hydrostatic pressure resistance reinforced by glass
microspheres added into the PU matrix. - Grade of glass influences the collapse pressure and
theoretical maximum water depth.
6.1. Pipe coating - Systems
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Injection moulding PU process
Source: Bredero Shaw
6.1. Pipe coating - Systems
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Concrete Weight Coating (CWC)
Purpose: provide negative buoyancy and mechanical protection to the pipe.
Mixture of cement, iron ore and wire wrap
Main properties:o Density (1900-3700 kg/m3): varies iron ore
quantity. o Compressive strength: depends on cement
and water content. o Thickness: depends on pipe diameter.o Water absorption: ISO standard recommend
a maximum of 5% vol.
Reinforcement o Rigid preformed cageso Wire mesh fabric
Source: Bredero Shaw
6.1. Pipe coating - Systems
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Concrete Weight coating
Type of protection Negative buoyancy + Mechanical protection
Typical coating thickness Depends on pipe diameter
Design temperature N/A
Water depth limit Unlimited
Major characteristics Density (1900-3700 kg/m3): varies with iron ore quantity.
6.1. Pipe coating - Systems
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Concrete Weight Coating (CWC)
Impingement method
Source: Bredero Shaw
6.1. Pipe coating - Systems
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Concrete Weight Coating (CWC)
Wrap-on method
Source: Bredero Shaw
6.1. Pipe coating - Systems
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6.1. Pipe coating - Systems
Elastomer coatings (Neoprene, EPDM, butyl rubber, etc.)
Mainly used for splash zone protection
Be careful of chamfering can cause failure of
the bond
Source: Yadana riser F. Duesso
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APAC Bredero Shaw WASCO Energy
Americas Bredero Shaw CRC Evans
EMEA Bredero Shaw Eupec Socotherm Tenaris
6.1. Pipe coating - Subcontractors
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Operators - Gap analysis with ISO 21809-1: Microsoft Excel Worksheet
6.1. Pipe coating - Operators
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Microsoft Excel Worksheet
Operators - Gap analysis with ISO 21809-1:
ENI = based on ISO TOTAL SHELL and PETRONAS: more stringent on different tests
6.1. Pipe coating - Operators
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HT/HP- R&D programm in different pipe coating applicators and manufacturers
to test different materials like glass syntactic silicones
Arctic- Bredero Shaw involved in JIP for new material in arctic conditions
Flexible weight coating Ultra deep waters thermal insulation
6.1. Pipe coating Future challenges
6.2 Field joint coating
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Definition Selection Standards Systems S-Lay installation Subcontractors
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Field joint definition: Part of pipe left bare for welding prior to installation
Purpose of FJC: anticorrosion or thermal insulation.
Field joint is the weak point in a pipe coating system. Welded joints are highly sensitive to corrosion.
pipe
3LPP coating
Cut back length shall be predetermined and mainly depends on type of FJC.
Properties shall be the same as the parent coating (pipe coating).
FJC are mostly applied in field application shall be easy, fast and reliable.
FJC = FBE, HSS, Polyolefin tapes, IMPP, IMPU, PE, PP, liquid resins
FJC
6.2. Field joint coatings - Definition
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density, thermal conductivity (if thermal insulation), coating breakdown factor
Line pipe working conditions
mechanical protection expected (impact strength, abrasion, compressive strength, flexibility, water absorption, curing time)
Pipe laying environment
Parent coating
Parent coating FJC possibilities
FBE FBEHeat Shrinkable SleevesLiquid coating
Polyethylene HSSLiquid coatingPE flame spray
Polypropylene PP flame spray / tapesIMPUIMPPLiquid coating
Concrete coating HSS + HDPUF
6.2. Field joint coatings - Selection
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6.2. Field joint coatings - Standards
International standards in field joint coating: ISO 21809
ISO 21809 - 3
Other standards or specifications DNV-RP-F102 NACE RP0303 - HSS EN 12068 tapes and HSS
NO STANDARD FOR INSULATION COATING
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FBECoating system description
FBE
Type of protection Corrosion protection
Typical coating thickness
350-500 m
Design temperature 90, modified epoxies can withstand higher temperaturesWater depth limit Unlimited
Major characteristics - The most widely used coating - Good chemical resistance- Very good corrosion protection - Very common and easy to find subcontractors- Low impact resistance
Overlap on parent coating
50 mm
6.2. Field joint coatings - Systems
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Heat Shrink Sleeves: 2-layers (mastic HSS)
Coating system description
Mastic adhesive + Polyolefin backing on St3 steel
Type of protection Corrosion protection
Typical coating thickness
2 mm
Design temperature Up to 100 (depending on product: PE or PP)Water depth limit 3000 m
Major characteristics Manual application with gas torch
Example of HSS system PE: - KLNN Canusa- WPC 100M (Berry Plastic)PP: - GTS PP 100
Overlap on parent coating
100 mm
6.2. Field joint coatings - Systems
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Heat Shrink Sleeves: 3-layers (hot-melt HSS)
Coating system description
Liquid epoxy + hot-melt adhesive + Polyolefin backing on Sa 21/2 steel
Type of protection Corrosion protectionTypical coating thickness 2 mm
Design temperature > 100 (depending on product: PE or PP)Water depth limit 3000 mMajor characteristics Manual application with gas torch
Example of HSS system PE: - GTS 80 (Canusa)- HTLP80 (Berry Plastic)PP: - GTS PP (Canusa)
Overlap on parent coating
100 mm
6.2. Field joint coatings - Systems
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PP tape wrapCoating system description
FBE + Adhesive PP + PP tape
Type of protection Corrosion protectionTypical coating thickness
3 mm
Design temperature 110Water depth limit 3000 mMajor characteristics - Applied in spiral or wrapped by hand or by wrapster
with the determined overlap (50% recommended). - Only compatible with 3LPP pipeline coating
Example of tape wrap system
FBE: Scotchkote 226N (3M)Adhesive: Hifax EP 510/60m (Basell)PP tape: Hifax EP 510/60 (Basell)
Overlap on parent coating
70 mm
6.2. Field joint coatings - Systems
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Flame spray PPCoating system description
FBE + Adhesive PP + PP powder
Type of protection Corrosion protectionTypical coating thickness
3 mm
Design temperature 110Water depth limit 3000 mMajor characteristics Similar to tape wrap
Overlap on parent coating
70 mm
6.2. Field joint coatings - Systems
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Injection moulded polyurethane (IMPU)Coating system description
FBE + Solid PU or PU primer + Solid PU
Type of protection Corrosion protection + thermal insulationTypical coating thickness
+4 mm
Design temperature Up to 130Water depth limit 3000 mExample of system FBE: Scotchkote 226N (3M)
Solid PU: Hyperlast FJ302 (DOW)
Overlap on parent coating
70 mm
6.2. Field joint coatings - Systems
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Injection moulded polypropylene (IMPP)Coating system description
FBE + PP adhesive + Moulded PP
Type of protection Corrosion protection + thermal insulationTypical coating thickness
4-10 mm
Design temperature Up to 110 (130 with high temp. FBE)Water depth limit 3000 mExample of system FBE: Scotchkote 226N (3M)
Adhesive: BB 127E (Borealis) or Hifax EP5 10/60 (Basell)Solid PP: EA 165E (Borealis) or CA 197 (Basell)
Overlap on parent coating
70 mm
6.2. Field joint coatings - Systems
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6.2. Field joint coatings S-lay installation
S-lay: Firing line is horizontal Pipeline is support by a stinger to avoid high bending stress.
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6.2. Field joint coatings S-lay installation
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6.2. Field joint coatings Subcontractors
BrederoShaw
Canusa CPS
PIH
OJS
FBE, IMPU, IMPP
HSS, liquid epoxy, tape wrap
FBE, flame spray PP & PE, HSS, IMPU, IMPP, PU foam infill
HDPUF, HSS
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
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7. Coating qualification
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Painting Pipe and field joint coatings
7. Coating qualification - Painting
Norsok M501 rev.6
CS surfaces operating < 120
Ballast water tanks/ seawater filled vessels
Anti-slip for walkways, escape routes, lay down areas
Intumescent epoxy + cementitiousPFP
Splash zone and immersed surfaces
1
3B
4
5
7
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7. Coating qualification - Painting
Norsok M501 rev.6
Test (acc. to ISO 20340) Assessment method Acceptance criteriaSeawater immersion- 4200h- For system 3B, 7A, 7B, 7C and 1 when used in tidal or splash zone
ISO 4624- pull-off testISO 4628-3,4,5,6
5MPaNo defect
Ageing- 4200h- For system 1, 3B, 4, 5A, 5B, 7A
ISO 4624- pull-off testISO 4628
5MPaNo defect
Cathodic disbonding- 4 weeks- For system 3B, 7A, 7B, 7C, 1 whenused in splash or tidal zone
ISO 15711 Max. 20 mm
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7. Coating qualification
Shell systems that need to be qualified as per DEP
TSA (DEP 30.48.40.31)
DFT checking
Ballast water tanks/ seawater filled vessels
Anti-slip for walkways, escape routes, lay down areas
Intumescent epoxy + cementitiousPFP
Splash zone and immersed surfaces
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7. Coating qualification
Test Assessment method
Measurement Acceptance criteria
Visual examination ISO 14918 100% surface Uniform appearance, no defect or blisters
Coating thickness ISO 2808 Min. 5 Min. 250 m
Coating adhesion ISO 4624 Min. 3 > 7 MPa
Overall quality Bend test (DEP) Min. 3 Minor cracks
Sealer Visual inspection 100% surface No open pores at the surface
Shell systems that need to be qualified as per DEP - TSA
Check every step of the ITP. The process leads to qualification of:
o operators (blasters, sprayers),o equipment,o subcontractor coating procedure.
Example of PQT done for Prelude FLNGMicrosoft Word
7 - 2003 DocumenAdobe Acrobat
Document
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7. Coating qualification Pipe & FJC
Qualification of 3LPE and 3LPP as per ISO 21809-1: Adobe Acrobat Document
Properties 3LPE 3LPP
Continuity Zero defect Zero defect
Impact strength > 7 J/mm > 10 J/mm
Indentation at 23 Indentation at max temp.
< 0.2 mm< 0.4 mm
< 0.1 mm< 0.4 mm
Elongation at break > 400 % > 400 %
Peel strength at 23 Peel strength at max. Temp.
> 15 N/mm> 3 N/mm
> 25 N/mm> 4 N/mm
Cathodic disbondment 23 , 28 dCathodic disbondment 65 , 24 hCathodic disbondment max. temp., 28 d
< 7 mm< 7 mm< 15 mm
< 7 mm< 7 mm< 15 mm
Hot water immersion test (80 , 48h) Average < 2 mm and max. < 3 mm
Average < 2 mm and max. < 3 mm
Flexibilitty No cracking at 2 angle No cracking at 2 angle
Curing of epoxy As per manufacturer As per manufacturer
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Sources
Bibliography:
[1] NACE CIP 1 Manual
[2] Encyclopedie de la peinture: formuler, fabriquer, appliquer, tome 1
[3] ISO 8501-1
[4] ISO 21809-1 to 5
[5] PPG PFP and Fouling release coating presentation
Websites:
[6] www.nace.com
[7] http://www.corrosion-doctors.org/Seawater/Fouling.htm
[8] www.brederoshaw.com
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Thank you
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