michael magerstaedt, rosen swiss - wear protection – redefining the design life of slurry pipes
DESCRIPTION
Dr Michael Magerstaedt, Corporate Manager, ROSEN Swiss presented this at the 3rd Annual Slurry Pipeline Conference. The Conference focuses on the design, construction, operation and maintenance of mineral slurry pipelines. For more information, visit http://www.informa.com.au/slurrypipelineconferenceTRANSCRIPT
Michael Magerstädt
3rd Annual Slurry Pipeline Conference · Perth · 14-Nov-2013
WEAR PROTECTION – REDEFINING THE
DESIGN LIFE OF SLURRY PIPES
Slide 2
Michael Magerstädt
ROSEN Swiss AG
Obere Spichermatt 14
6370 Stans
Switzerland
Gunther Blitz, Thorsten Räth, Florian Backherms
ROPLAST GmbH
Am Seitenkanal 8
49811 Lingen
Germany
Please send correspondence relating to this presentation to:
AUTHORS
Slide 3
1. Erosion Protection of Steel Pipes
2. Recap: High Performance Polyurethane Elastomers
3. Most Significant Test Data
4. Field Joining
5. Design Life - - Experience in the Field
6. Outlook and Further Applications
CONTENT
Slide 4
Wear depends on:
• Slurry particle size distribution
• Particle hardness and shape
• Particle concentration
• Velocity
• Doubling velocity increases wear-rate 4-6 times
• Settling slurries, bed loads
• Impingement angle
• Excessive wear on elbows, reducers, etc.
• Other factors:
• Lifetime?
• Maintenance effort?
• Downtime?
• Others?
--- do I need to tell this audience? --
EROSION PROTECTION OF STEEL PIPES
Slide 5
Wear depends on:
• Others?
• Contact surface
• Surface material type
• Surface structure
• Surface properties
• Chemical environment
• Potential for erosion-corrosion (e.g., high or low pH)?
EROSION PROTECTION OF STEEL PIPES
Slide 6
• 2 wear reducing philosophies
• A) “The harder the solids in the slurry and the harder the internal pipe
surface, the less the wear.”
• Material alloying, e.g. by increasing C- and Mn-content
• Steel hardening, e.g. induction heating
• Wear tiles, e.g. cemented carbides
• Double wall pipes
• Bimetallic pipes, e.g. weld overlays
• B) “The harder the solids in the slurry and the more elastic the
internal pipe surface, the less the wear.”
• PE liners
• Rubber liners
• Polyurethane liners
• High-Performance Elastomer Liners
EROSION PROTECTION OF STEEL PIPES
Slide 7
• Both philosophies are justified, depending on the conditions of the
application.
A) Metallic Solutions:
1. High to very high cost
2. Lifetime increase in comparison to mild steel:
• Material alloying, e.g. AR200 piping 1.5 to 2 times
• Induction heating, 3 to 8 times
• Wear tiles, 5 to 10 times
• Weld overlays, 6 to 20 times
B) Polymer Liner Solutions:
1. Moderate cost
2. Lifetime increase 5 to 20 times
EROSION PROTECTION OF STEEL PIPES
Slide 8
B) Polymer Liner Solutions:
HDPE liners are used in some long-distance slurry pipelines where abrasion
is less of an issue („rounded“ particles after first few km)
Advantages:
• Low cost material
• Relatively easy installation, no pipe preparation required
Disadvantages:
• If components of the stream can penetrate the liner (e.g., dissolved
gases), these will accumulate between liner and steel pipe wall.
• back pressure can result in liner collapse
• if these components are corrosive, steel wall corrosion can occur
• HDPE is not very abrasion resistant
• HDPE liners are not chemically bound to the pipe wall liner thickness is
dependent on pipe diameter to provide mechanical stability
EROSION PROTECTION OF STEEL PIPES
Slide 9
B) Polymer Liner Solutions:
Rubber or Polyurethane (PUR) liners (technically: coatings) are applied
where high wear occurs, e.g., station piping, tailings, high turbulence areas.
Advantages:
• Material is chemically bound to the pipe wall, no danger of liner collapse
• High abrasion resistance
• High degree of freedom with respect to geometry; almost every pipe
component can be coated
• In lower wear applications, a much lower material thickness can be used
than with HDPE liner which evens out the higher material price
Disadvantages:
• More expensive per kg than HDPE liners
• Field joining often requires flanges or re-coating of weld areas
• Factory applied
• In case of standard PUR: sometimes insufficient adhesion to steel
EROSION PROTECTION OF STEEL PIPES
Slide 10
1. Erosion Protection of Steel Pipes
2. Recap: High Performance Polyurethane Elastomers
3. Most Significant Test Data
4. Field Joining
5. Design Life - - Experience in the Field
6. Outlook and Further Applications
CONTENT
Slide 11
HIGH PERFORMANCE POLYURETHANE ELASTOMERS
A „construction kit“ system, adjustable to the application.
Millions of possible permutations ( = product properties).
Polyol Isocyanate Crosslinkers
R N C
O
H
O R´
Polyurethane
+ + Chain Extenders,
Catalysts,
other ingredients
Slide 12
HIGH PERFORMANCE POLYURETHANE ELASTOMERS
High Performance PUR Elastomers
- Selected grades and typical applications -
Slide 13
HIGH PERFORMANCE POLYURETHANE ELASTOMERS
Wear protection applications:
•Oil sands hydrotransport
•Ore mining (phosphate, copper, iron, etc.)
•Dredging of rivers, harbors, etc.
•Water injection for Enhanced Oil Recovery
•Concrete mixing
•Fracking runoff from shale gas recovery
•Tailings from the above
Slide 14
1. Erosion Protection of Steel Pipes
2. Recap: High Performance Polyurethane Elastomers
3. Most Significant Test Data
4. Field Joining
5. Design Life - - Experience in the Field
6. Outlook and Further Applications
CONTENT
Slide 15
MOST SIGNIFICANT TEST DATA
Abrasion resistance acc. to. DIN EN 598
Slide 16
MOST SIGNIFICANT TEST DATA
Slide 17
MOST SIGNIFICANT TEST DATA
Cold wall effect; Atlas Cell test
Tinternal (coating) = 50°C
Texternal (Stahl) = -20°C ΔT = 70°C, 17 Weeks
Results: no disbondment, cracks,
holes etc.
Slide 18
1. Erosion Protection of Steel Pipes
2. Recap: High Performance Polyurethane Elastomers
3. Most Significant Test Data
4. Field Joining
5. Design Life - - Experience in the Field
6. Outlook and Further Applications
CONTENT
Slide 19
FIELD JOINING
Welded Joints: Single-weld syetem
Features
Just one weld per pipe joint to be performed in field
No in-field backfilling, no filling holes
Factory-prepared one-sided weld
No cutback
Firmly installed Insulating layer under weld
Patent pending
Slide 20
FIELD JOINING
•The welding process complies with ASME
Sec. IX.
•The field joints in field tests now in
Canada comply with ASME B31.11
•Pressure tested up to 250 bar (3‘000 PSI)
Slide 21
1. Erosion Protection of Steel Pipes
2. Recap: High Performance Polyurethane Elastomers
3. Most Significant Test Data
4. Field Joining
5. Design Life - - Experience in the Field
6. Outlook and Further Applications
CONTENT
Slide 22
DESIGN LIFE - - EXPERIENCE IN THE FIELD
From field trial experience with 1” coating thickness and an i.d. of 30” in oil
sands tailings for over 3 years, it can be concluded that life time of steel pipes
coated with High Performance Polyurethane Elastomers exceeds that of carbon
steel by a factor of approx. 8-10. This translates into approx. 20’000 to 25’000
hours of operation without rotation in a tailings line where carbon steel pipes
need to be rotated every 2’500 to 3’000 hours.
High Performance Polyurethane Elastomer Coatings are now commercially
applied in a number of oil sands tailings and hydrotransport lines; predominantly
in the coating thickness range of 1” up to 2” on pipes of nominal inner diameter
in the 28” to 36” range.
Oil Sands Hydrotransport
Slide 23
DESIGN LIFE - - EXPERIENCE IN THE FIELD
Phosphate Slurry
Slide 24
DESIGN LIFE - - EXPERIENCE IN THE FIELD
Water Injection Lines for Enhanced Oil Recovery
In a trial for water injection for
EOR, a 5 mm coating was applied
due to the smaller (12”) pipe
diameter. The pipes in question
usually contain chromium carbide
overlays (CCO) for abrasion
protection.
In the trial, High Performance
Polyurethane Elastomer coating
lasted as long as the overlay; an
end point has not yet been
determined.
Slide 25
DESIGN LIFE - - EXPERIENCE IN THE FIELD
Erosion-Corrosion in Oil Sands Tailings
In an oil sands tailings line, a high
turbulence area was chosen for a field test
of High Performance PUR Elastomer
coating. In this location, steel pipe with
CCO pipe needs to be rotated every 2’500
to 3’000 hours of operation
Although in tests ASTM G75 and ASTM B
611, CCO shows a significantly lower wear
than High Performance PUR Elastomers,
in this field trial, the Elastomer has reached
4’000 hours of operation without rotation at
the time of this presentation. The most
likely explanation is erosion-corrosion of
the CCO. Further investigation is under
way.
The effect of erosion-corrosion
often is stronger than the sum of
both effects taken separately.
Microscopic erosive damage of the
steel surface can provide an attack
point promoting fast corrosion.
The test spool after 1500 hours of operation
in this high turbulence area
Slide 26
DESIGN LIFE - - EXPERIENCE IN THE FIELD
The manufacturing process
Slide 27
1. Erosion Protection of Steel Pipes
2. Recap: High Performance Polyurethane Elastomers
3. Most Significant Test Data
4. Field Joining
5. Design Life - - Experience in the Field
6. Outlook and Further Applications
CONTENT
Slide 28
OUTLOOK AND FURTHER APPLICATIONS
Low-erosion slurry lines / erosion-corrosion conditions
As mentioned under 1., for conditions of mild wear and / or potential of
erosion-corrosion, often HDPE liners are used. E.g., for long-distance
slurry transport.
• For an 18“ steel pipe ID, minimum structural thickness of an HDPE liner
has to be 13 mm.
• For the same pipe ID, a High Performance PUR Elastomer coating thickness of
3 mm is sufficient.
Material cost similar or lower than with HDPE liner
Installation cost lower due to field welding process
Higher safety against penetration of erosive components
Higher wear resistance – longer design life
Slide 29
OUTLOOK AND FURTHER APPLICATIONS
High Performance PUR Elastomer Wear Protection in Mining
Ball mill lifters in copper mines
Slide 30
OUTLOOK AND FURTHER APPLICATIONS
High Performance PUR Elastomer Wear Protection in Mining
Intelligent ball mill lifters in copper mines
Slide 31
OUTLOOK AND FURTHER APPLICATIONS
High Performance PUR Elastomer Wear Protection in Mining
Hydrocyclone Apex, Slurry Pump Liner, Chute Wear Plates, Tailings Channel Cladding
Slide 32
OUTLOOK AND FURTHER APPLICATIONS
Selected References Mining
www.rosen-group.com
THANK YOU FOR JOINING
THIS PRESENTATION.