developments in field coating used in new dutch pipelines · summary and conclusions [1] •...
TRANSCRIPT
Developments in field coating used in new Dutch pipelines
Ir. A.M. Dam,
29th February 2012
Content
Introduction
Types of pressings and drillings
Coating approach and choices
Tests and experiences
Developments and improvements
Summary and Conclusions
Introduction [1]
Introduction [2] North – South project
600 km 48 inch pipeline
2 Compressor stations
Investment >2.000 mln euro
Owner: Gasunie
Construction: 2010-2013
Introduction [3]
pressing
drilling
0
20
40
60
80
100
120
140
5 15
25
35
45
55
65
75
85
95
10
5
11
5
12
5
13
5
14
5
15
5
16
5
17
0
length ranges [m 5m]
nu
mb
er
[/
]
Pressings.
Total: 476
≥
±
0
2
4
6
8
10
12
14
32
5
37
5
42
5
47
5
52
5
57
5
62
5
67
5
72
5
77
5
82
5
87
5
92
5
97
5
10
25
10
75
11
25
11
75
12
25
12
75
13
25
13
75
14
25
length ranges [m 25 m]
nu
mb
er
[/
]
Drillings.
Total: 63
±
Types of drillings and pressings [1]
• Open front end pressing
pushing (avegaar)
impact ramming
• Cutter head conventional pressing
Horizontal Directional Drilling (HDD)
pilot drilling + roaming (conventional)
push and pull with “Pipe thruster”
cutter head (“Direct pipe”)
Pressings length most < 100 m
Drillings length > 2750 m and increasing
Types of drillings and pressings [2]
Pushing and pulling:
• on steel => conventional
• on coating
Coating approach and choices [1]
Mill coating.
General => multi-layer coatings
– Anti-corrosion layer
– Mechanical protection layer
Mill coating => 3-layer coatings: chosen by Gasunie:
– Line pipe => PE
– Pressings & drillings => PP with additional thickness:
– ≤ 20”: min. 4.5 mm (3.0 mm on weld seams)
– > 20”: min. 6 mm (4.0 mm on weld seams)
Approval:
– According ISO 21809-1 => PQT, PPT, “production”
– NO standard on mill coating for pressings & drillings
Coating approach and choices [2]
Field coating (1).
General => multi-layer coatings
– Anti-corrosion layer
– Mechanical protection layer
Field coating => options given by Gasunie, choice by contractor
– Line pipe
– Anti-corrosion layer: epoxy or visco-elastic material
– Mechanical protection layer: shrink sleeve
– Fittings
– Visco-elastic material + tape
– Butyl rubber based material + PE-tape
Approval:
– According ISO 21809-3 => PQT, PPT, “production”
Coating approach and choices [3]
Field coating (2).
– Drillings and pressings => options given by Gasunie:
– PP Flame Spray
– Canusa GTS PP
– PUPPlining
Remark: NO GRE / epicoat / wavistrong
Approval:
– NO standard on field coating for pressings & drillings
Tests and experiences [1]
Material Resin : Epikote 828 Hardener : Euredur 43 Glass : Woven, 10 cm wide, 280 gr/m2 360 gr/m2 580 gr/m2 Non woven KH1603
Laminate instructions for steel welded joints for pipe diameter: 16" – 40”
Tests with GRE / epicoat / wavistrong :
Tests and experiences [2]
Experiences with GRE / epicoat / wavistrong:
Tests and experiences [3]
Experiences with PP Flame Spray:
Tests and experiences [4]
Experiences with Canusa GTS PP:
Tests and experiences [5]
Experiences with PUPPlining:
steel
PP mill coating
PP plate
polyurethane
PP “weld”
fibers
Tests and experiences [6]
Tests with PUPPlining:
Test: • 18 m pipe 36” • filled with water => total weight 17.5 ton • length test track app. 1000 m
Tests and experiences [7]
Impressed current tests:
Criterion, where A [m2]:
0 – 1000 m2: Imax = A *0.001 [mA] 1000 – 5000 m2: Imax = 1 + (A-1000)*0.00005 [mA]
DCVG (Direct Current Voltage Gradient) • directly after burial • within 1 year (guaranty period)
0,0
1,0
2,0
3,0
4,0
5,0
0 500 1000 1500
length [m]
cu
rren
t d
en
sit
y [
uA
/m
2]
0,0
0,2
0,4
0,6
0,8
1,0
0 500 1000 1500
length [m]
cu
rren
t d
en
sit
y [
uA
/m
2]
Tests and experiences [8]
steel
PP mill coating
flush
Experiences with HDD’s & pressings (@ e.g. 48” diameter).
steel
PP mill coating
Experiences with HDD forces.
0
100
200
300
400
500
600
700
800
900
0 200 400 600 800 1000 1200 1400
Pipe diameter [mm]
Fo
rce [
kN
]
Loose clay / peat
Stiff clay
Normal sand
Hard sand
R = 800 – 1000 * diameter [m]
R
Tests and experiences [9]
Scratch tests on mill and field coatings (1):
Tests and experiences [10]
Scratch tests on mill and field coatings (2):
y = 0,0003064x
R2 = 0,9943897
y = 0,0002401x
R2 = 0,9845693
0
1
2
3
4
5
6
0 3000 6000 9000 12000 15000
scratch load [N]
red
ucti
on
coati
ng
th
ickn
ess [
mm
]
6 mm PE
6 mm PP
Lineair (6 mm PE)
Lineair (6 mm PP)+ 28 %
0
1
2
3
4
5
6
7
0 3000 6000 9000 12000 15000 18000 21000 24000
scratch load [N]
red
ucti
on
coati
ng
th
ickn
ess [
mm
]
PE mill coating
PE field coating
PP mill coating
PP field coating
8 mm thickness4,5 & 6 mm thickness
Results PE versus PP (6 mm mill coating)
Results mill versus field
Tests and experiences [11]
Scratch tests on mill and field coatings (3): Results PE versus PP (mill & field coating)
0
3000
6000
9000
12000
15000
8:09:36 8:24:00 8:38:24 8:52:48 9:07:12 9:21:36 9:36:00 9:50:24
time [hh:mm:ss]
scratc
h f
orce [
N]
0
3000
6000
9000
12000
15000
8:09:36 8:24:00 8:38:24 8:52:48 9:07:12 9:21:36 9:36:00 9:50:24
time [hh:mm:ss]
pu
ll f
orce [
N]
y = 0,45867x
R2 = 0,37718
y = 0,57257x
R2 = 0,40737
0
3000
6000
9000
12000
15000
0 3000 6000 9000 12000 15000
scratch force [N]
pu
ll f
orce [
N]
PP
PE
Lineair (PP)
Lineair (PE)
diff. 25%
Developments and improvements [1]
Repair:
Developments and improvements [2]
Wehocoat:
Summary and conclusions [1]
• Gasunie is expanding its network with pipelines in 48” size. • the amount and length of drillings and pressings is large and increasing. • there are new methods for drillings: “Pipe thruster” and “Direct Pipe”. • PP is a stronger (± 25%) coating material than PE for use in drillings & pressings. • in the “North-South” project an existing and a new PP field coating system are successfully used. • those field coating systems have the same strength as the PP mill coating. • after some start-up problems the performance of those field coating systems is excellent now. • drillings with increasing pipe diameter give an increase in load on the coating. • the amount of load, a coating can coop, increase with increase in coating thickness. • drillings and pressings with large diameter (eg 48”) pipe require “flush” field coating systems. • the height of weld caps (round, seam or spiral) in steel pipe or pipe connection reduces the effective coating thickness.
Summary and conclusions [2]
• new repair methods for coatings are successfully introduced in the field and which originate from the “plastic industry”. • a new field coating system is under investigation. • the human factor is important and often decisive for the quality obtained especially in the field. • quality checks like “impressed current test” and “DCVG” work very fine. • contrary to line pipe, the pipe in a HDD can NOT be excavated and repaired. A high level of coating quality is compulsory in a HDD !