coatings – directional boring tim jenkins. coatings – directional boring design considerations...
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Coatings – Directional BoringCoatings – Directional BoringCoatings – Directional BoringCoatings – Directional Boring
Tim JenkinsTim Jenkins
Coatings – Directional BoringCoatings – Directional BoringCoatings – Directional BoringCoatings – Directional Boring
Design Considerations (data collection)Design Considerations (data collection) Contributed coating failuresContributed coating failures
Pre-Operation stepsPre-Operation steps Post-Operation stepsPost-Operation steps
Design – Directional Boring Coatings
Design – Directional Boring Coatings
Data Collection for coating selectionData Collection for coating selection Surrounding EnvironmentSurrounding Environment
Soil composite Soil composite LocationLocation
Foreign lines –Foreign lines –• Other pipelinesOther pipelines• AC Transmission towersAC Transmission towers
Timeframe Timeframe
Powercrete – Powercrete – 12 to 15 mils of FBE (Fusion bonded Epoxy) 3M 12 to 15 mils of FBE (Fusion bonded Epoxy) 3M
62336233 Concrete polymer base outer coat 20mils per Concrete polymer base outer coat 20mils per
application, two applications normally usedapplication, two applications normally used Typically 55 to 60 mils coating thicknessTypically 55 to 60 mils coating thickness
FBE – Dual coatFBE – Dual coat 12 to 15 mils of 3M 623312 to 15 mils of 3M 6233 20 mils of a Dual coat application of 3M 635220 mils of a Dual coat application of 3M 6352 Typically 35 mils total coating thicknessTypically 35 mils total coating thickness
Design – Directional Boring Coatings
Design – Directional Boring Coatings
Time frame considerations –Time frame considerations – Powercrete – hand applied, 4 joints per 2 Powercrete – hand applied, 4 joints per 2
hours can be coatedhours can be coated FBE – Dual coat – assembly line, 3000 feet FBE – Dual coat – assembly line, 3000 feet
in three hoursin three hours
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Durability –Durability – Powercrete – UV protected, more abrasive Powercrete – UV protected, more abrasive
resistance in comparison to the FBE dual coatresistance in comparison to the FBE dual coat Recommended practice – Recommended practice –
Abrasive environment use the Powercrete Abrasive environment use the Powercrete application, application,
In In well knownwell known normal soil application, FBE normal soil application, FBE dual coat acceptable and probably more cost dual coat acceptable and probably more cost effective effective
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Coatings Case history - FailuresCoatings Case history - Failures The most popular coating failure -The most popular coating failure -
Cathodic ShieldingCathodic ShieldingRock formationRock formation
• Pipe wedge next to a rock formation at the point Pipe wedge next to a rock formation at the point of coating holidayof coating holiday
Disbondment coatingDisbondment coating• Coating becomes disbondment from the surface Coating becomes disbondment from the surface
of the pipe, but shields the CP from the surface of of the pipe, but shields the CP from the surface of the metallic structure exposed under the coatingthe metallic structure exposed under the coating
Design – Directional Boring Coatings
Design – Directional Boring Coatings
Cathodic Shielding - RockCathodic Shielding - RockCathodic Shielding - RockCathodic Shielding - Rock
Cathodic Shielding – Coating Cathodic Shielding – Coating DisbondmentDisbondment
Cathodic Shielding – Coating Cathodic Shielding – Coating DisbondmentDisbondment
Coatings Case history - FailuresCoatings Case history - Failures Thickness of coating application –Thickness of coating application –
The thicker of the coating, less durable, The thicker of the coating, less durable, more brittlemore brittle
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Harlem RD Bore – Coating Harlem RD Bore – Coating FailureFailure
Harlem RD Bore – Coating Harlem RD Bore – Coating FailureFailure
Coatings Case history - FailuresCoatings Case history - Failures Powercrete –Powercrete –
Flexibility – Degrees per pipe diameterFlexibility – Degrees per pipe diameter 1.41.4° for 35 mils° for 35 mils .75° for 55 mils.75° for 55 mils
FBE – Dual Coat – FBE – Dual Coat – Flexibility – Degrees per pipe diameterFlexibility – Degrees per pipe diameter 2.82.8° for 35 mils° for 35 mils
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Coatings Case history – FailuresCoatings Case history – Failures
FBE Dual coat more flexible than FBE Dual coat more flexible than PowercretePowercrete
But,,, But,,, Powercrete more impact resistance than Powercrete more impact resistance than
FBEFBE
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Powercrete application adhesive bond to the Powercrete application adhesive bond to the FBE, and the dual coat 3M will result of FBE, and the dual coat 3M will result of complete pull out of coating application complete pull out of coating application from the metal surface due to, coating from the metal surface due to, coating flexibility angle being too greatflexibility angle being too great
In a normal pulling process, coating will be In a normal pulling process, coating will be disbondment by layers and normally does disbondment by layers and normally does not result in total removalnot result in total removal
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Girth Welds –Girth Welds – Two part Liquid Epoxy usedTwo part Liquid Epoxy used
Protal 7200 - 50Protal 7200 - 50° or greater° or greaterProtal 7125 - 50° or lessProtal 7125 - 50° or lessR95 – Powercrete J (new)R95 – Powercrete J (new)
Pipe Preparation – Pipe Preparation – Sand blasting – NACE 2 or SSPC-SP10Sand blasting – NACE 2 or SSPC-SP10
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Northern Loop – Hoover Bore Northern Loop – Hoover Bore Girth WeldsGirth Welds
Northern Loop – Hoover Bore Northern Loop – Hoover Bore Girth WeldsGirth Welds
Transmission Class pipelineTransmission Class pipeline ECDAECDA
Pipe thickness designPipe thickness design %SYMS%SYMS
ICDAICDA Internal CouponsInternal Coupons ProbesProbes Inclination angle considerationInclination angle consideration
Do not get greater than the Critical Inclination angleDo not get greater than the Critical Inclination angle Inline Inspection – smart piggingInline Inspection – smart pigging
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Design – Directional Boring Design – Directional Boring CoatingsCoatings
Pre-Operation StepsPre-Operation StepsPre-Operation StepsPre-Operation Steps
Columbia Gas needs to inspect all coated pipe line Columbia Gas needs to inspect all coated pipe line at the coating mill before the pipe is coatedat the coating mill before the pipe is coated
Corrosion Technicians are being trained, KTA Corrosion Technicians are being trained, KTA certifiedcertified
Communication should be placed to Corrosion Communication should be placed to Corrosion FLL by Supply chainFLL by Supply chain
Need to consider cost of technician or coating Need to consider cost of technician or coating inspector to work order budgetinspector to work order budget
Corrosion Department InspectingCorrosion Department InspectingPowercrete application for Powercrete application for Maumee River CrossingMaumee River Crossing
Corrosion Department InspectingCorrosion Department InspectingPowercrete application for Powercrete application for Maumee River CrossingMaumee River Crossing
Pipe Inspected in the field by the corrosion departmentPipe Inspected in the field by the corrosion department Determine any coating defects due to shipmentDetermine any coating defects due to shipment
Pipe and girth welds coatings inspected in the field by the Pipe and girth welds coatings inspected in the field by the corrosion technicianscorrosion technicians Dew point readingsDew point readings Pipe TemperaturePipe Temperature Chloride checkChloride check DFTDFT WFTWFT Observe Jeeping process – recommend voltage settingObserve Jeeping process – recommend voltage setting
Pre-Operation StepsPre-Operation StepsPre-Operation StepsPre-Operation Steps
Post Operation StepsPost Operation StepsPost Operation StepsPost Operation Steps
Survey – Coating and CPSurvey – Coating and CP CP – CP –
CIS – Close Interval surveyCIS – Close Interval surveyExternal Coupons usedExternal Coupons used
CoatingCoatingDCVG – Direct Current Voltage GradientDCVG – Direct Current Voltage GradientACVG – PCM – Alternate Current Voltage ACVG – PCM – Alternate Current Voltage
GradientGradient Cost of survey new steel pipe by corrosion department Cost of survey new steel pipe by corrosion department
should be considered on the work order budgetshould be considered on the work order budget