Download - Pipeline Coating Failures
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Pipeline Coating Failures
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Corrosion Protection
Subsoil Exposure Coatings- Designed
to protect the pipe surface from its external environment. Adhesion Thickness Hardness Dielectric Strength
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Corrosion Protection Cathodic Protection-
Designed to protect the pipe from corrosion should the coating be damaged or become disbonded from the pipe.
Electrical current -850 to 800 mv potential
range (Coatings / CP) Temperature Soil resistivity
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Supply Chain
The “Supply Chain” is the sequential efforts of Engineers, Suppliers, Services and Installers. Each party has a well defined role to accomplish specific tasks that will result in a completed pipeline project.
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Supply Chain
Project Sequence Design Manufacture Surface Preparation Coating Handling Storage Transportation Construction
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Design
Atmospheric Exposure UV Degradation Abrasion Environmental Airborne
Contaminants Structural Supports Operating
Temperatures
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Design
Subsoil Exposure Operating
Temperature Cathodic Protection Pipeline Insulation pH / Moisture Abrasion / Impact
Resistance Backfill Composition Chemical Resistance
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Design
Immersion / Marine Operating
Temperature Cathodic Protection Water Resistance Weight Coating Resistance to Water
• Fresh• Salt• Brackish
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Design
Cathodic Protection Cathodic Disbondment
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Construction
Cathodic Protection CP Sheilding
• Occurs after coating failure• Prevents CP current access to the steel• Limited to buried pipelines onshore.
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Design
Fasteners Field Joints Nuts & Bolts Crevices Welds
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Manufacture
Fabrication Rolling defects Weld Spatter Sharp edges Surface defects
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Manufacture
Material Type Carbon Steel Galvanized Steel Aluminum Copper Ductile iron Concrete
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Surface Preparation Decontamination
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Surface Preparation
Surface Cleanliness
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Surface Preparation
Abrading- Abrasive Surface Profile Anchor Pattern Mechanical Tooth
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Surface Preparation
Abrading- Abrasive Surface Profile Anchor Pattern Mechanical Tooth
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Surface Preparation
Quality Control Environmental
Conditions• Air temperature• Relative humidity• Dew point
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Surface Preparation
Quality Control Surface Conditions
• Contamination• Weld defects• Profile
Too deep Too shallow
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Surface Preparation
Quality Control Adhesion
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Coating
Coal Tar Enamel Water resistant Moisture resistant Chemical resistant
• Acid• Alkali
Petroleum products Surface tolerant Bacteria resistant Dielectric strength
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Coating
Coal Tar Enamel Coating System
• Coal Tar Enamel• Glass Reinforced
Inner Wrap Outer Wrap-
Saturated• Kraft Paper Protection
UV Rays
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Coating
Curing Function of time and
temperature Uncured coatings will
absorb moisture• Amines- Epoxies• Isocyanates- PUR
FBE- Passivation• Chromate wash• Phosphate wash• Acid wash
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Coating Quality Control
Pipe Temperature• Temple sticks• Infrared sensors (mixed
results) Dry Film Thickness
(DFT)• Surface Temperature
Holiday detection Traceability of pipe
• Barcodes Standardization
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Handling
Damage Lifting and Loading
• Trailers• Trains• Vessels- Maritime
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Handling
Equipment Fork Lifts Grippers Pipe Hooks Minimize Damage
• Hydraulic Spreaders• Vacuum Lifters
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Storage
Stacking Causes stresses on the piping. Deforming the diameter of the pipe. Stress is increased at every level
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Storage
Stacking Causes stresses on the coating. Stacking- Abrasion and Impact damage where the
pipes touch. (3 & 9 o’clock positions)• Pipe stacks should be blocked to prevent rolling.
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Storage
Environment Soluble Salts
• Chlorides• Nitrates• Sulfates
Dirt, Dust & Mud Oil, Grease &
Lubricants Chemicals
• Acids• Alkalines
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Storage
Exposure UV Degradation Chalking:Deterioration of the resin
/ binder because of UV exposure.
Loss of plasticizers will make the coating brittle and eventually checking in the coating.
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Transportation
Damage Abrasion from travel
movement Loading & Unloading
• Handling
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Transportation Damage
Supports and Stops• Abrasion and Impact
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Transportation
VDI 2700 Association of German Engineers Manual- Securing of loads on road vehicles
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Transportation
Climate / Environment
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Construction
Handling
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Construction
Field Welds Surface Preparation
• Abrasive blast cleaning• Hand / Power tool cleaning
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Construction
Field Welds- Surface Preparation Nace No. 2 SSPC SP 10
• Minimum cleaning standard
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Construction
Field Welds- Surface Preparation Surface Profile
• 2.0- 4.0 mils
Measurement method• Testex tape
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Construction Field Welds (HSS)
Heat- Shrinkable Sleeves• 30 year history• Cross linking polyolefin.• Cured by “Electron
irradiation” Polyethylene and
Polypropylene coatings Epoxy primer is used for 3-
layer systems Peel test- Adhesion and
cure.
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Construction (HSS)18 in Oil Pipeline 3 layer Polyethylene In Line Inspection (ILI)
Corrosion 1st 15 km 131F Operating Temp Service- 15 yrs Wet, compacted sand pH
5.4 HSS
Hot melt type / Epoxy Primer
Surface Prep Power tool
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Construction (HSS)18 in Oil Pipeline Massive disbonding of
HSS Steel surface 3LPE coating system
Significant corrosion Field joint Steel surface
No significant corrosion at lower operating temperatures.
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Construction (HSS)18 in Oil Pipeline Longitudinal cracking at
the 3 and 9 o’clock positions.
Showed signs of thermal aging Brittleness Lack of flexibility
Issues: Storage conditions Soil exposures Service conditions
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Construction (HSS)16 in Oil Pipeline 3 layer Polyethylene In Line Inspection (ILI)
Severe external corrosion Pitting- “Craters” at field joints
122F Operating Temp Service- 12 yrs Brackish w/ 2g/liter chlorides HSS
Hot melt type / Epoxy Primer Surface Prep- Wire brush Millscale on surface Overlap 1 cm (~ 1.2 in)
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Construction (HSS)16 in Oil Pipeline Disbonding of HSS
Steel surface 3LPE coating system
Significant corrosion Field joint Steel surface Salt crystals under HSS
Disbondment fo coating system
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Construction (HSS)Causes of Disbondment Surface preparation
Minimum Near white blast
Application Fish mouths Overlaps
Service Conditions Operating temperature Soil conditions
UV Degradation during storage.
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Construction
Field Welds- PUR Liquid applied
Polyurethane Epoxy modified Operating temperature
176 F
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Construction
Backfill Materials Select according to
coating type Pipeline Research
Council Interantional Catalogue
• No. L52208 July 2005• Smaller particles do
less damage• Average 20 mm size
produce the least amount of holidays
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Internal Coatings Coating Selection
Chemical Resistance• Carbon Dioxide• Hydrogen Sulfide
Abrasion Resistance• Erosion
Impact Resistance Temperature Resistance VOC Requirements Corrosion Under Insulation
• CUI
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Internal Coatings
Immersion Exposure Water / Moisture Microbiologically
Induced Corrosion (MIC)
• Planktonic Bacteria• Sessile Bacteria• Sulfate Reducing• Anarobic
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Internal Coatings
Immersion Exposure Abrasion Resistance
• Impact• Sludge
Chemical Resistance Inhibitors
• Scavengers Oxygen Sulfide
Biocides- MIC Fighters
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Internal Coatings
Vapor Exposure Hydrogen Sulfide H2S
• Concrete and steel deterioration
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Case History Water main 48 in.
Pre- stressed Concrete Cylinder Pipe PCCP
25 years service Wrapped with High
strength reinforcement wire- externally
Coated with cement rich mortar
No Cathodic Protection Backfill native soil
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Case History Water main 48 in.
Failure location• 10 ft long• Along pipe wall
Concrete coating deteriorated and spalled
Reinforcement wires broke
Exposed steel substrate to soil conditions
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Case History Water main 48 in.
High sulfate levels Water in soil Corrosion of concrete,
steel wires and steel pipe
Water pressure exceeded the strength of the deteriorated pipe
BURST!!
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Coating Maintenance Program1. Identify the service conditions2. Coating selection3. Coating specification4. Identify inaccessible areas5. Contractor capabilities6. Coating inspection7. Pre- job meeting8. Teamwork- communication9. Document all phases10. Monitor performance after installation
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The End