APIA-RSC 20th ForumPerth 25 November 2009Perth 25 November 2009

Evaluation of field applied Evaluation of field applied

L Ed djoint coatingsjoint coatings

Lex Edmond Monash University

Joint coatingsJoint coatings

• ~10% of coated area• Large proportion of corrosion • Large proportion of corrosion

issues• May be poorly specified• Often not considered until late in • Often not considered until late in

the pipeline design process• Contractor responsibility?

Joint coatingsJoint coatings

• Adverse conditions– Hot cold wet humid dust insects!– Hot, cold, wet, humid, dust, insects!

• Remote locations• Inadequate training/equipment• Time pressures• Time pressures• Buried

Test programTest programM l li ti• Manual application– APA Group– Dandenong, Victoria

• Automated application• Automated application– PIH

• Pipeline Induction Heat– Burnley, England

• Simulated joints~600mm long– ~600mm long

Manual trialsManual trialsParent Coating Pipe dia.

(mm / inch)Surface preparation

N 250 / 10 GB 50 70None 250 / 10 GB 50-70µm

T o la er FBE 200 / 8 GB 50 mTwo layer FBE 200 / 8 GB 50µm

Three layer 350 / 14 Solvent wipeThree layer tri-laminate

350 / 14 Solvent wipeGB: “light” 120µm GB: “very heavy” G e y ea y160µm

Liquid appliedcoating systems

System Generic type CommentsSPC 2888 Epoxy with PU

micro-particlesAlso at PIH

ProtegolUR32-55PG

Polyurethane(spray version)

Also at PIHOHSE concerns“lumpy”lumpy

Protal 7200 EpoxyPowercrete R 95 Epoxy Novolac Used in HDDsPowercrete R-95 Epoxy Novolac Used in HDDsHBE 95 Epoxy Novolac Used in HDDs

Liquid applied systems• As supplied/recommended by the

manufacturer• No preheat• Representatives from all companies • Representatives from all companies

except TIB (Protegol) and SPC presentpresent

• Applied to bare areas of pipeSi l d j i– Simulated joints

– ~600mm long• Coating thickness ~1mm

Sleeve & tapecoating systems

System Generic type CommentsRaychem WPC Sleeve 60 ºC preheat

90 ºCRaychem HTLP 80

High temp sleeve 90 ºC preheat

C WLO B Sl 60 ºC h tCanusa WLO-B Sleeve 60 ºC preheatCanusa GTS 65 High temp sleeve 90 ºC preheat

Polyken 1027 2 layer tape No preheat

Field testing gLiquid applied systems

• V-cut adhesion testV cut adhesion test• AS/NZS 3862 App. J• Rating ≤ 2 satisfactory

Adhesion rankingAdhesion ranking

Adhesion results: Liquid applied systems

• Adhesion to steel– Rating 0 to 1– Excellent – Excellent

• Adhesion to 2 layer FBE– Rating 0 to 1– Excellent Excellent

Adhesion ranking: Liquid Adhesion ranking: Liquid applied systems to PE

System Light blast Heavy blastSP 2888 4 3

ProtegolUR32-55PG

4 4

P t l 7200 2 3 1 2Protal 7200 2-3 1-2Powercrete R-95 2-3 1-2

• Solvent wipe

HBE 95 3 1-2

p– Rating 5 (no effective adhesion)

Adhesion results: Sleeves and tapes

• Peel tests• Excellent adhesion in all

tsystems

PIH (automated) trialsPIH (automated) trialsParent Coating Pipe dia.

(mm / inch)Surface preparation

T l FBE 500 / 20 G it bl tTwo layer FBE 500 / 20 Grit blast

Three la er 400 / 16 Grit blastThree layer trilaminate

400 / 16 Grit blast

Joint coating systemsJoint coating systems

System Generic type CommentsSPC 2888 Epoxy with PU Also atp y

micro-particles DandenongProtegol Polyurethane Also atgUR32-55PG

y(spray version) Dandenong

PIH three layer 1. FBE Only for 3LPE pipesystem 2. Powdered

adhesive3 Five layer PE3. Five layer PEtape (~50% overlapoverlap

Liquid applied systems• Four simulated joints coated

– For each of the five pipesp p

• ~90 °C preheat– Except for one SPC 288 joint which was Except for one SPC 288 joint which was

not preheated• To give same condition as for manual • To give same condition as for manual

application

Liquid applied systems• Representatives from TIB and SPC

present (on separate days)p ( p y )• Correct (spray) grade of Protegol

usedused• Coating thickness ~1mm

Liquid applied systems• Direction of the coater then needs to

be reversed– After one revolution– To stop fouling of the attached cablesp g

• Precise control of the timing of the liquid spray is neededliquid spray is needed

• Requires a number of trial joints to be coatedcoated– Up to ten

Liquid applied systems• Uneven coating thickness on 16” pipe• Specimens can still be taken from the Specimens can still be taken from the

cut joints to avoid areas not in the specified coating thickness range. specified coating thickness range.

• Excellent adhesion to steel and FBEM i l dh i ( ti 3) t PE• Marginal adhesion (rating 3) to PE– Only one day after coating

PIH fused system• Three layer system• Fusion bonded epoxyFusion bonded epoxy• Powdered adhesive

Applied in one operation after the – Applied in one operation after the application of the FBE

• Five layer PE tape• Five layer PE tape

PIH fused system• “Flaming” of tape to form monolithic

coatingg– Coating degradation?– Slow

• Coating thickness ~5mm• Excellent adhesion to steel• Excellent adhesion to steel

– After one day180N/10 t i idth– 180N/10mm strip width

Testing planTesting plan• Monash• Monash

– Visual inspectionlid d i– Holiday detection

– Coating thickness– Knife adhesion– Falling weight impact testsFalling weight impact tests

• Also useful capability for the EP CRCIndentation resistance– Indentation resistance

• Also useful capability for the EP CRC

Testing planTesting plan• Herman Research Lab• Herman Research Lab

– Peel tests

• Tyco Water– Dolly pull-off adhesion tests

• For liquid applied coatingsFor liquid applied coatings

Testing planTesting plan• Grant Pearson• Grant Pearson

– CD tests23 d 80 °C• 23 and 80 °C

– Hot water soak• Visual inspection• Knife adhesion tests

IDParent coating

Joint coating

Peel StrengthApp C

Hot water soak 

Adhesion AS 3894.9 Mtd A (3)(Knife test)

Adhesion ASTM D4541     Mtd E (4)

(Pull‐off adhesion)

CD AS 4352 Test cell B(2)

22.5°C28 days @

80°CSteel to FJC

Parent to FJC

Steel to FJC

Parent to FJC

Steel to FJC

Parent to FJC

Steel to FJC

Parent to FJC

Steel to FJC

Parent to FJC

Steel to FJC

Parent to FJC

Steel to FJC

Steel to FJC

P01 2 FBE PU

80°C 22.5°C +/‐ 2.5°C 80°C20°C30 days @ 80°C  

App F  20°C

P01.2 FBE PUP01.4 FBE PU YES YES YES YES YES YES YES YES NO NO NO NO YES YESTesting Cost 700 85

P02.2 3LPE PU YES YES YES YES YES YES YES YES NO NO NO NO YES YES

500

P02.4 3LPE PUTesting Cost 700 85

P03.2 FBE Epoxy YES YES YES YES YES YES YES YES NO NO NO NO YES YESP03 3 FBE Epoxy

500

P03.3 FBE EpoxyP03.4 FBE Epoxy YES YES YES YES YES YES YES YES NO NO NO NO YES YESTesting Cost 1400 170

P04.2 3LPE Epoxy YES YES YES YES YES YES YES YES NO NO NO NO YES YES

1000

P04.3 3LPE EpoxyTesting Cost 700 85

P05.2 3LPE Fused NO NO NO NO NO NO NO  NO  YES ? YES ? YES YESP05 3 3LPE Fused See Note 5

500

P05.3 3LPE Fused See Note 5. 

SummarySummary• Manual application to PE• Manual application to PE

– Very rough blast (160 µm) gives better results than finer blast better results than finer blast (120 µm)

l d– Protal, Powercrete R95 and HBE 95 gave acceptable adhesion

– Wrong Protegol (PU) formulation provided

• Designed for spray application• Very short pot life (<2 min at 20C)y p ( )

SummarySummary• Automated application• Automated application

– Up to ten joints needed to optimise process

– Uneven coating thickness when applied to 16” 3LPE pipe

– Appropriate test specimens selectedpp p p

SummarySummary

• Application of PIH fused system to 3LPEto 3LPE– Process is relatively slow

D t “fl i ” f t ti– Due to “flaming” of tape coating– Hard to assess exact no. of field

joints that could be coated per shift• Depends on the no. of crews• Likely to be significantly less than with

other systems

Future workFuture work

• Finalisation/agreement on test plans– Automatic application– Manual application

• Specimen preparation• Testing• Reportingp g

APIA-RSC Seminar 29 June 2009, Brisbane

AcknowledgementsAcknowledgements• The APIA• The APIA

– Research & Standards Committee– Nick Scott, Ted Metcalfe, Alan

Bryson, … • PIH

Carl Vicent David Jackson – Carl Vicent, David Jackson, …

APIA-RSC 20th ForumPerth 25 November 2009

A k l d tAcknowledgements• Monash University

– Dept. of Materials EngineeringDept. of Materials Engineering• Prof. Maria Forsyth

Mechanical workshop– Mechanical workshop

APIA-RSC 20th ForumPerth 25 November 2009

Th k !

Perth 25 November 2009

Thank you!

Lex EdmondLex Edmond

M h U i itMonash University

Lex Edmond@eng monash edu auLex.Edmond@eng.monash.edu.au