Masterbook SFL Industries v.may2016 by Seal For Life

SFL master

Engineering book

Think. Design. Protect.

I n d u s t r i e s

2014

Importance of High Dieletric Strength and/or Specific Electric Resistence of Coatings

esse caest au‑ dem iam

Georg Ohm “Any resistance can be overcome.”

esse caest au‑ dem iam

esse caest au‑ dem iam 3

Preface seal for life is more than an endline, and dare to care isn’t simply a slogan. The original slogan of our Stopaq member has become the tradename of our umbrella brand. And not without good reason. It’s not just a slogan, but a statement we are making to the market: thanks to its ‘literally smart cross-bonds’, Seal For Life Industries is able to offer new, sustainable solutions within the oil, gas and water – i.e. pipeline – markets. Our constant pursuit of quality and way of thinking enable us to give guarantees that others simply cannot fulfill. Our synergies also enables us to take advantage of our leadership position in niche markets. For instance, we can successfully tackle the cable joint market through a broader, yet at the same time deeper, focus on civil infrastructural challenges. Our views on markets and applications demand not only knowledge but also courage. That’s because introducing new methodologies and ways of thinking into traditional markets is a brave thing to do. But we have already noticed both within and outside Seal For Life, that our vision is leading to success: ‘Dare to Care’ is not only a slogan, but also a clear statement to our stakeholders, clients and application engineers.

Nt coNteN As Seal For Life, we are the ‘lifeguards’ of (often) vulnerable systems, not just on land but also offshore. An increasing number of clients no longer accept short-term solutions, but instead are convinced by our vision and can see our growth and expansion into other

market areas. What’s more, through our global dedicated market

management for offshore, we can also take a leading position in the field of pre-insulated pipe plant coating and plant coating in general.

2014 SEPTEMBER 2 44

By means of exclusive partnership services, we can boost

This is no longer just something for the future; our Stopaq

sales concepts for a whole range of specific applications

member is already carrying out applications involved

and uses, such as casings, j-tubes, subsea structures,

with raising dyke walls in relation to these changing

surface preparation, pre-engineering, factory-applied

circumstances in the Netherlands. If there were no levees,

pipeline coating concepts, storage problems, application

45% of this particular country would disappear under water.

training, corrosion monitoring and after-sale service. In short, ‘Dare to Care’ is no longer limited to below-ground Changes on our planet also offer new opportunities to

pipeline and traditional markets, but means ‘Total Care’ for

put the innovative strength of Seal For Life into practice.

Seal For Life nowadays. Seal For Life’s playing field has

For instance, pipeline and ‘bedding solutions’ in unstable

become not only very broad, but also specialised. This

infrastuctures, our solutions for applications in polar regions

demands a lifelong learning process – continuing education

and the solutions that we as a group can offer in relation to

– from engineers and application teams, but also from

the rise in water levels, worldwide.

ourselves.

2014

coNteNt CONTENT SEPTEMBER 2014 8 integrated approach

04 poLar

iam averfeculius vitimandam. movero esse caest au‑ dendiis, patu manum, ve,markets quidem iam Totalnosterei care and our About markets and approaches

06 Water WorLd

iam averfeculiuspreparation vitimandam. moveroof essesteel caest au‑ surface dendiis, nosterei patu manum, ve, quidem iam

09 WorLd External coating rehabilitation 36 our iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

40 gaS 12

cathodic protection

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

repair of damages

14 reVoLutioN

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patuof manum, ve, quidem iam Philosophy testing

Nt coNteN 18 chaLLeNge

150

iam averfeculiusheating vitimandam.& movero esse caest au‑ district cooling dendiis, nosterei patu manum, ve, quidem iam

22 my viscoWay elastic coating 184

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

2014 SEPTEMBER 2 6

pipeline tape technology 280 27 Big SucceS Polyken

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

2014

coNteNt CONTENT SEPTEMBER 2014 300 HEAT shrinkable coatingS Covalence

04 poLar

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

328 non-aging tape solutions SynergyQ

06 Water WorLd

334 ELASTOMERIC COATING SOLUTIONS iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam EasyQote

09 our WorLd turn-key applications 366

iam vitimandam. movero esse caest au‑ SFLaverfeculius Services dendiis, nosterei patu manum, ve, quidem iam

patents 420 12 gaS

Continuous Innovation

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

422 SFL CLIENTS

Our clients are our reference

14 reVoLutioN

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

424 global coverage

Global Coordination, to serve locally

18 chaLLeNge

426 SFL headquarters

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam One family, one mission

22 my Way SFL 112 years of innovation 428

iam averfeculius vitimandam. movero esse caest au‑ Celebrating a century of innovation dendiis, nosterei patu manum, ve, quidem iam

doing more with less 430 27 Big SucceS

iam averfeculius vitimandam. movero esse caest au‑ dendiis, nosterei patu manum, ve, quidem iam

An integrated approach to pipelines corrosion prevention

The corrosion protection measures applied to a pipeline at the construction stage represent only 3-4% of the overall cost of a pipeline system. If the corrosion protection systems are chosen, applied and maintained/monitored wisely then the cost of the corrosion protection system is small relative to the value of the pipeline and the product using it. Unfortunately, this fact can lead to the materials, application, construction and maintenance of the coating system often being inadequately resourced and applied. Effective corrosion control should not be overlooked because the consequences can be catastrophic. It should be engineered from the outset to provide the most effective, long-term solution for the life of the pipeline. Selection, application, construction and maintenance of the corrosion system should be approached as a key facet of the pipeline operation and performed by suitably qualified professional coatings engineers.

Nt coNteN

2014 SEPTEMBER 2 88

REDEFINE

PERFORMANCE We need to: • Redefine specifi cations • Redefine standards & norms • Redefine test methods • Redefine interpretations (wording!) • Redefine surface preparation • Redefine installation • Redefine monitoring • Redefine TCO (Total Cost of Ownership) AND: Let’s redefine testing and methods for performance based specifications. Always flip the coin. There is a difference between watching or seeing it. Like old soccer star Johan Cruyff said: you only get it if you see it and you only see it, if you get it.

2014

organized to ENGINEER solutions An organization must be ready for the future. And a successful future can only be guaranteed if that organization has staying power. The following organizational model is heartwarmingly simple and therefore very clear: its metaphor is the Christmas tree. Staying power is essential to create a healthy, green Christmas tree. a. The basis, the seed-bed: true, Staying power consists of 3 building blocks: 1. standardization (low costs) 2. partnership 3. people focus (distributors, appliers, project managers)

important core values for staff: what do we stand for? b. The trunk: aim for 100% ‘people focus’ and therefore dedicated staff and satisfied clients c. the lower part of the triangle: the support organization/engi-neers,

People focus is the core of staying power: people must want to work in a motivated way, they must understand and be enthusiastic about why they are doing something for the organization. The most important aspect of the organizational model is to see ‘people focus’ in our organization as a Christmas tree: 10 10

who always offer support and service d. the top of the triangle: – the ‘moment of truth’ – it’s here that the product or service is delivered e. the star: – that’s what we all do it for – 100% satisfied clients. They are the stars!

A. The rich earth as the basis

center. It’s an important shoot of the tree

This is the seed-bed, the nutrient (soil) and the

where you can also find aspects such as PQT

core essence of Seal For Life Industries. It’s

training, certificates, partnerships (such as

the fertile ground that gives the synergy its po

with Falck). But beware: it’s not a headquarters.

wer, based on our SFL mission, vision, belief,

Thinking in terms of ‘headquarters’ is so old-

attitude and approach. It’s our combined quality

school!

that must be safeguarded and constantly fed. D. the top part of the triangle: sales & customer B. the trunk as transporter

service. Here is the ‘moment of truth’ for the

Within this, the ‘people focus’ that makes the

sales organisation. Can we turn our abilities

appliers happy is central. It ensures both

and beliefs into reality?

personal growth and development, all through the ‘one family’ mentality. Here is also where

E. The star: these are our clients. With names

you find the ambassadors (distributors and

we must really take care of: GasUnie, Fluxys,

appliers) who are the messengers.

Pemex, Petrobras, Gazprom, Eni, Chevron, Saudi Aramco, Petrochina, Statoil, QP,

C. the lower part of the triangle: engineering & services. This is where the innovations and

ADNOC, GNPOC, Sasol, Lukoil, Exxon and BP.

ideas come from; it’s the worldwide support

'DON'T BE INNOVATIVE JUST TO BE INNOVATIVE' 11 11

THE CORE ESSENCE Our core essence, the basis for our

tested against our norms

growing power, consists of many

beyond design life

important aspects. But altogether,

“I did it myself”

you may confidently assume that the core essence of Seal For Life

SFL systems make a difference.

Industries forms a rich seed-bed for

The SFL systems redefine perfor

optimal growing power. In this and

mance. It’s for life and “WOOW”.

the next few pages, we will set out what all these aspects are. Some

SFL’s core essence also includes:

demand further explanation, while

The SFL brands, sub-brands &

others will immediately be clear.

future brand extensions, quality manufacturing, specifications,

The core essence represents

innovations of the past (ruytrans),

our energy to bring new ideas.

clean operations, non-toxicity,

Generating new ideas is our DNA.

safety, no risk, reliability and

This “DNA” is a test for new ideas

discipline.

to stop or to go ahead with. Seal For Life is:

Last but not least, the basis of

•

easy to apply

everything is also the ‘courage’

•

risk free

factor. The courage to be the

•

unique

first, the courage to dare and the

•

total care solution

courage and motivation to want

•

clean

to be innovative.

•

a reliable system

•

repeatable

1. be first

•

guaranteed to work

2. be daring > make sense = SFL

affordable and can be delivered 12 12

3. be innovative

WHAT DOES SEAL FOR LIFE CARE

What about the innovatiVE

ABOUT? People, Planet, Profit,

power of Seal For Life?

Safe, REACH-compliant products, Pre-treatment of steel/concrete &

•

product or system is developed

quality check, Labour Application Technique & quality check,

Already in place before a

•

Is all about permission (and expectations!) from the client

Materials (adhesion, insulation, mechanical, sound damping, shrink,

•

Goes step-by-step

toxicity, flame-retardent, etc.),

•

Redefines performance

Proof that it works, Environment,

•

Makes sure we are different

Total costs of ownership, Product

•

Keep It Simple, Stupid (KISS)

datasheet & information, Standards,

•

Let the industry talk about us

Company specifications, Training,

•

Is intriguing (not boring)

Innovative attitude.

•

Enables us to change the ‘status quo’

The above components are part

•

Involves the client

of our core essence. It’s a neat

•

Has resulted in partnerships

summary, but they do have to

with firms like Käfer, Falck, Ehri,

be individually recognized and

BASF, Avery Dennison, Millikon

implemented, otherwise they are

and FDT

nothing more than words. We must go to bed with a dream, but wake up with a purpose. We can explain not only our successes but also our failures and get to work on what we’ve learned.

'HARD CORE COMPETENCES CAN'T BE MIXED WITH SOFT CORE VALUES' 13 13

THE TRUNK manuals, PDS, MSDS, labels

THE TRUNK THAT DISTRIBUTES •

and packaging

•

Passes on the message

An energy float that enables

•

(Spreads the word)

personal growth

•

Seeing is believing

THE ESSENCE • •

Trains the next generation and engages them in the process

THE TRUNK IS ESSENTIAL

Inspires the next generation

TO PASS ON OUR TRIBE

and

This won’t just happen all by itself

tells them how valuable our

by going onto automatic pilot.

way

A recognizable mistake is to

•

of thinking is

assume that ‘someone else in the

•

Inspire applicators

organization is sure to think of it’.

•

Enables us to act like one

That’s why we’ve got two extra

family sharing the same values,

slogans:

mission & vision

•

‘Do it yourself’

Recognizes the importance of

•

‘Go beyond’

• •

•

movies, newspapers, papers,

14 14

Itâ&#x20AC;&#x2122;s all about people. We work for sustainable solutions

15 15

ENGINEERING & SERVICES THE TRIANGLE WHAT DO WE REALLY KNOW

we are recognized by clients and

ABOUT CORROSION? ARE WE

appliers alike. That’s how we do

THE WORLD’S TOP SPECIALISTS?

it! These are the hard values with

It’s logical that our authority in

which we do our work every day,

the market is determined by

anywhere in the world. The most

our knowledge of the business

important of these are:

we’re in. What do we really know about corrosion? What exactly

•

Knowledge of sealing,

do we know about the synergistic

insulation, corrosion and

possibilities of our family members?

electrochemistry

About the cross-links? About the

•

Experience: sharing best practices

new markets awaiting us? •

Application skills and tools

Who has a convincing, honest

•

Cross-linking technology

and sound answer to the question

•

Adhesives, composites,

why we are 25% more expensive

shrinking, non-cross-linkable

in certain solutions? Are we also

mastics, mechanical shields

25% better? Or 125%? Indeed:

•

Liquid cure and cathodic protection

it’s a challenge to excel in the application itself, but also in service

•

Turnkey Installations

and after-sales. Sleeping clients

•

Manufacturing capabilities

just don’t exist!

•

In-house testing

The core competences of Seal For Life are instrumental matters. They are our operational skills, for which

16 16

'BE

AMAZING'

However, the hard core competen

rrow’. Of course matters must of

ces are supported by what else

ten be organized in an intelligent,

where may be referred to as the

centralized manner, but the heart

‘soft values’ of our organization.

of the organization should beat

But in our case, these values that

everywhere. Ideas, suggestions

complete our added value are not

and improvements come from every

soft, but just as hard and concrete

side of the organization, so there

as our skills:

should be no borders, barriers or ‘old-school’ hierarchical hindrances.

•

Our Mission

We have by now set up 8 sales

•

Power of 7 combined

tech offices and 5 manufacturing

technologies

plants across the world, as well

21 markets to sell into ‘1001’

as the Polyken and Powercrete

applications are possible

operations in Kentucky. The heart

•

12 million m2 contribution to

of the Seal For Life organization

•

a sustainable world yearly

is beating at all these locations

•

The durability we offer

too. In addition, each location has

•

The stability we provide

business knowledge, passion and

•

an unwavering belief in the future of NO ‘HEADQUARTERS’ ATTITUDE

the Seal For Life approach. All this

In many companies, there’s a ‘them’

makes our company futureproof.

and ‘us’ culture when it comes to ‘headquarters’ and ‘the others’. Company policy just somehow appears and ‘the direction to be followed will be in our inbox tomo-

'stick to the plan' 17 17

WHERE IT ALL HAPPENS SALES & CUSTOMER SERVICE If the top triangle of the Christmas

•C lients care about performance

tree has enough nutrients, our sales

(to reduce their dependence), so

and service operations can achieve

expect questions.

healthy growth.

•D on’t waste your time going after business you don’t really want.

But even then, attachment points, stakeposts and guidelines are

FOCUS!!!!! •T he boss usually decides - not the

necessary to clarify matters, ensure

assistant treasurer. Do you know

the correct direction and enable

the boss?

an objective viewpoint. In fact, we

• I t’s just as easy to get a first-rate

need to open our eyes to appliers

piece of business as a second-rate

and clients, but sometimes also to

one.

internal departments and teams. The following are the most important assets from SFL’s sales focus model:

•Y ou never learn anything when you’re talking. •T he client’s objective is more important than yours.

• Sales representatives, consultants

•T he respect of one person is worth

or distributors cannot sell all 5

more than an acquaintance with

technologies.

100 people.

• They can sell a maximum of 1 or 2, unless brand leaders are appointed within a company to lead a brand or technology and find followers. • It’s all about credibility in the market.

•W hen there’s business to be found, go out and get it! • I mportant people like to deal with other important people. •A re you one? •T here’s nothing worse than an unhappy client. • I f you get the business, it’s up to you to see that it’s handled well.

18 18

The appliers are also part of

a track record and so will also be

our tribe. They are essential to

unable to offer a technical service.

our organization. Through good

• The applier is your frontman or

communication, information and

frontwoman. Just look at their

training, appliers will become fans,

role in operations for Saipem, JR

instead of just operators! A number

McDermott, Valentine, Subsea7,

of aspects of this group deserve

Acergy and Technip and onshore

particular attention:

for firms like A.HAK, VSH, Max Streicher, Michels Corporation,

• Partnerships are essential.

L&T, Punj Loyd, Bonatti, CAT or

• Be good and tell it.

CCC.

• Don’t just sit quietly and wait – shout it out! Make an impression and show you’re there. • We sell solutions based on vision and business knowledge, and our partners need to sell these systems (including our tapes, sleeves and paint). • Don’t go shopping and buy cheaper locally; this would mean we’ve done our approvals, qualifications and tests for nothing. • If you deviate from our basic principles, you will never build up

'be focused on performance' 19 19

Job Assessment

s on

Cold Applied Tape

PE ms

Syste

Leopard spots Cathodic Disbonding

e rag Sto

Dea

dw Loa eight ds

Cu Co t bac rro k sio n Cr ac kin g Lo Ad s he s o si f on

tic sta o r g yd tin l H Tes a ic chan

Me age Dam

Insufficient Overlap

Tenting / B ri d g ing Seam Weld

m Po et or er in g

-m

He Shr at ink

No a at 6 dhes o’c ion loc k

r te

Liquid

layer

Be Co nd ld in g

id s qu m Li ste Sy

gin

g Sa

Three

licati

FBE

Blister

ns de tr fectucti

app

ss/ hne s g u l Ro nho e Pi Poor sion d A he

Adhesion to the metal substrate

licati

Site

h ug ro ess Th n es ick ti th per o pr

app

• Site application • Construction defects • Plant application • loss of adhesion due to water ingress • Soil interaction • Material properties

ion

s clu

plant

caused by:

m oa

Nt coNteN

2014 SEPTEMBER 2 20 20

Nt a

2014

p l tia th: nt re en wi me atu t n r Po ro e vi mp En Te

pH gh C i H SC

interacti

L de ow n PE sity UV No filt er

Low density PE

Em UV br me ittlent

M PR ATE OP RIA ER L TIE S

w Lo sity n e d PE

SION LOSS OF ADHE ESS GR IN ER AT W

ial rob Mic rosion r Co

e ibl pt l ng e h sc ee cli wt su st Cy pH ro ases g e k ss ne l e ac cr re kali ntia Cr te inwithratur ng t S i ra Al Pote pe ycl r tem ss c d fo tion re de itia th St nee k in row s rie ac g H va cr nd

So ad il ing Lo

d Pitting an l ra e Gen Corrosion

Complete CP shielding

Near Neutral pH SCC

P ll C rtia ding a P iel sh

Soil water pH5-B Free Corrosion Potential Susceptible Steel

Operating Stress Pressure Cycles Axial SCC

NAEC

il So ing ss e r St

Stress Crackin g

n ge xy ty /o ili er eab at W erm P

Unstable Sl opes Cirumfere ntial SCC

il So ep re C

Stone Penetration

om nd y Ra t-Dr g We ssin e Str

n tio ca ill slo wnh Do

Di W 3 & rink 9 o ling ’cl at oc Cr ac k 12 king o’c a loc t k

Stones

Pro ble m :

Coating Awareness 21 21

total care

04 02

1. End-sealing casings 2. Harbour Wall Protection 3. Harbour Wall Protection 4. Windmill Splash zone 05

5. Visco-Elastic flooring systems 6. Offshore Jacket leg Splash zone 7. Subsea Station Coating Repair 8. Pipeline Laybarge Joint Coating 9. Jetty Pile Splash Zone Systems 10. HDD-Factory Applied Coating Systems

Nt coNteN 11. Home Roof Repair

12. Home Gutter Leakage Repair 13. Internal Wing Sealing 14. Under Carpet Tape

15. Above Ground Flange Filler

2014 SEPTEMBER 2 16. Pipeline Cathodic Protection by a polymeric anode wire

22 22

13 14

2014

23 23

total care and our markets

about markets and approaches

Seal For Life Industries is a wholly-owned subsidiary of the Berry Plastics Corporation and features a number of industry leading brands in the corrosion protection sector. Headquartered in Stadskanaal, the Netherlands, SFL Industries operates worldwide through a number of manufacturing facilities and sales offices. This enables SFL to be close to its partners and customers offering the highest levels of technical expertise and field support. SFL INDUSTRIES

SFL INDUSTRIES

marine

splash-zone & underwater installation

Nt coNteN services

building & construction

turn-key applications

2014 SEPTEMBER 2 cathodic protection

24 24

home do-it-yourself

Innovation and Cooperation

SFL Industries is constantly

From oil platforms to

As an owner of industry leading

pushing the boundaries of its

domestic bathrooms

corrosion prevention brands, SFL

existing technologies to innovate

Our solutions and products matter.

Industries offers a wealth of expertise

new solutions. We actively seek

We are integral to the oil and gas

and experience to offer clients

partnerships to share experiences

industry as we help transport

the best possible solution for their

and develop new products, systems

the worldâ&#x20AC;&#x2122;s energy commodities

corrosion protection needs.

and applications. Never still, always

safely over land and sea. Our

SFL's technologies and products are

probing, innovation lies at the heart of

applications minimize risks and

approved, specified and deployed

our business and our values.

thereby improve safety in urban areas

by many of the largest players in our markets worldwide. External

One World, One Mission

active of contemporary infrastructural

evaluations and test reports have

Sustainability lies at the center of our

challenges such as dike

confirmed that the characteristics of

world view because long-term viability

embankments and new requirements

the properties and features of our

and success can only

with regard to offshore or sub-sea

corrosion prevention technologies

be founded on the sustainable

operations.

conform to Industry standards (ISO

production and offering of safe,

21890-3 and ISO 15590-1).

energy-efficient and environmentally-

We are present in the aviation

friendly sealing and anti-corrosion

industry. We have solutions in the

solutions. Among, other things, this

field of traditional anti-fouling. And

means immediate and permanent

there are endless opportunities for

adhesion without costly, polluting, or

applications of our products in and

dangerous surface preparation. Safe

around the home. It is this breadth

and easy-to-apply applications are

of coverage, the synergies between

inherent in our products, reflecting

our products, and the combination

our belief that safety should be

of our technologies, that makes us a

intrinsic to all that we do.

reliable, inspiring and expert partner

FAST aerospace

SFL INDUSTRIES

mobile pipeline coating

onshore oil & gas pipelines

offshore

district heating & cooling

with a realistic view of people, planet Markets

and profit.

Seal For Life Industries is a leading market player and partner across numerous market sectors

SFL INDUSTRIES

casing filler

power

flooring

subsea refinery

2014

and pristine rural areas. We are

and industries. This reach enables us atmospheric paintable solutions

to tackle an endless variety of fascinating and complex challenges in the field of corrosion prevention and sealing.

SFL INDUSTRIES

telecom

pulp & paper plants

transportation

infra

water pipelines 25 25

Surface Preparation of Steel General Surface preparation of the steel before external coating application is the foundation of any corrosion control program. Any compromise made in the degree of surface preparation will affect coating performance regardless of how high the technical quality of the coating is. There are many degrees and methods of surface preparation ranging from simple dusting or blowing away loose dirt to the complete removal of all contaminants. These methods include the use of steam cleaning, chemical

Surface preparation is defined as the cleaning or treating of the metal surface to ensure the best possible bond between the surface to be coated and the coating to be applied.

Nt coNteN cleaning, hand tools, power tools and abrasive blast cleaning.

An important rule to remember when selecting both the degree and

method of surface preparation is that the service and life expectancy of a given coating or coating system is directly proportional to the degree of surface preparation done prior to that coatingâ&#x20AC;&#x2122;s application.

2014 SEPTEMBER 2 26 26

Objectives The first objective of surface preparation is to remove surface contaminants that will affect the performance of a coating. These contaminants can include: •O il and Grease – Prevent good coating adhesion and must be completely removed. •S alts – Increase moisture penetration through the coating and accelerates the rate of corrosion. •D ust and Dirt – Prevent the application of a smooth, uniform film thus weakening the adhesion of a coating to the substrate. •R ust – Often cannot be penetrated by most coatings resulting in uneven films with exposed metal where corrosion can take place. •R ust Scale and Mill Scale – Cannot be penetrated by most coatings and will eventually break free from the substrate taking any coating with it. •O ld Coatings – May lift from the surface when over coated causing peeling or delamination. The second objective is to remove surface imperfections over which it is difficult to obtain adequate coating dry film thickness (thin layer coatings). Some of these are: • Weld Spatter • Sharp Edges • Burrs • Slivers

2014

• Laminations • Pits • Porosities • Crevices The third objective of surface preparation is to provide an “anchor pattern” or “surface profile” which improves the mechanical bonding of a coating to the prepared surface by increasing the surface area. 27 27

Standards Coating specifications should always incorporate or reference one of the written and/or visual/photographic surface preparation standards. Such standards exist to eliminate misinterpretation, questions, disagreement, etc., related to the quality of surface preparation desired. The two most commonly used surface preparation standards are those published by the Steel Structures Painting Council (SSPC) and the National Association of Corrosion Engineers (NACE). The following chart summarizes these standards.

Surface Preparation Standards System

SSPC Codes

Solvent Clean

SSPC.SP1

Hand Tool Clean

NACE

CDN. Govt. (CGSB)

Swedish Standard

SSPC.SP2

31 GP 401

St. 2 (approx.)

Power Tool Clean

SSPC.SP3

31 GP 402

St. 3

Flame Clean (new steel)

SSPC.SP4

31 GP 403

White Metal Blast

SSPC.SP5

NACE #1

31 GP 404

Sa. 3

Type 1 Commercial Blast

SSPC.SP6

NACE #3

31 GP 404

SSPC.SP7

NACE #4

31 GP 404

BS4232 First Quality

Sa. 2

Type 2 Brush Off Blast

British Standard

BS4232 Third Quality

Sa. 1

Light blast to brush-off

Type 3 Pickling

SSPC.SP8

Weather and Blast

SSPC.SP9

Near White Blast

SSPC.SP10

Nt coNteN NACE #2

Sa. 2 1/2

BS4232

Second Quality

Power Tool Cleaning to

SSPC.SP11

Bare Metal

Non-Ferrous Metals

Aluminium

Brass, Bronze, Copper, Lead, Terne, Galvanized Metal

2014 SEPTEMBER 2 28 28

Definition Solvent Cleaning SSPC-SP1 Definition: Solvents such as water, mineral spirits, xylol, toluol

completely. Tight mill scale and tightly-adhered rust, paint and coatings are permitted to remain.

etc., are used to remove solvent-soluble foreign matter from the surface of ferrous metals. Rags

However all mill scale and rust must have been exposed to the abrasive blast pattern sufficiently

and solvents must be replenished frequently to avoid spreading the contaminant rather than

to expose numerous flecks of the underlying metal fairly uniformly distributed over the entire

removing it. Low-pressure (1500 - 4000 psi) high volume (3 - 5 gal/min.) water washing with

surface.

appropriate cleaning chemicals is a recognized "solvent cleaning" method. All surfaces should be should be cleaned per this specification prior to using hand tools or blast equipment.

Brush Off Blast SSPC-SP10 (SSI-Sa2 Â˝), or NACE #2 Definition: In this method, all oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter have

Hand Tool Cleaning SSPC-SP2 (SSI-St3) Definition: A mechanical method of surface

been completely removed from the surface by abrasive blasting, except for very light shadows,

preparation involving wire brushing, scraping, chipping and sanding. Not the most desirable

very slight streaks or slight discolorations caused by rust stain, mill scale oxides or slight, tight

method of surface preparation, but can be used for mild exposure conditions. Optimum

residues of paint or coating. At least 95% of each square inch of surface area shall be free of all

performances of protective coatings should not be expected when hand tool cleaning is

visible residues, and the remainder shall be limited to the light discolorations mentioned above.

employed.

From a practical standpoint, this is probably the best quality surface preparation that can be expected to today for existing plant facility maintenance work.

Power Tool Cleaning SSPC-SP3 (SSI-St3) Definition: A mechanical method of surface preparation widely used in industry and involving the use of power sanders or wire brushes,

Power Tool Cleaning to Bare Metal SSPC-SP11 Definition: Utilizing same equipment as

power chipping hammers, abrasive grinding wheels, needle guns etc. Although usually more

Power Tool Cleaning to remove all visible coatings and contaminants to bare metal substrate.

effective than hand tool cleaning, it is not considered adequate for use under severe exposure conditions or for immersion applications.

Aluminium Definition: Remove water-soluble dirt and chemicals with water and detergent; solvent-soluble contaminants with solvent. Rinse, allow to dry, them power or hand abrade to

White Metal Blasting SSPC-SP5 (SSI-Sa3), or NACE #1 Definition: The removal of

remove the thin film of aluminium oxide. Moderate exposures require only one or two topcoats.

all visible rust, mill scale, paint and contaminants, leaving the metal uniformly white or gray

Avoid using lead pigmented primers and topcoats. Exposure to corrosive chemicals calls for an

in appearance. This is the ultimate in blast cleaning. Use where maximum performance of

epoxy primer followed by an appropriate topcoat for the environment.

protective coatings is necessary due to exceptionally severe conditions such as constant immersion in water or liquid chemicals.

Brass, Bronze, Copper, Lead, Terne Definition: Remove contaminants with a combination of water, detergents and solvents (same as aluminium). Allow the metal to dry, then power or

Commercial Blast SSPC-SP6 (SSI-Sa2), or NACE #3 Definition: All oil, grease, dirt, rust

hand abrade to remove oxides. Conventional oil and alkyd base primers or finishes may be

scale and foreign matter are completely removed from the surface and all rust, mill scale and

used.

old paint are completely removed by abrasive blasting except for slight shadows, streaks or discolorations caused by rust stain, mill scale oxides or slight, tight resides of paint or coating

Galvanized Metal Definition: Clean same as aluminium and Brass etc, or allow to weather

that remain. If the surface is pitted, slight residue of rust or paint may be found in the bottom of

for six months. Caution: Be sure the manufacturer of the galvanized metal has used a paintable

pits; at least two-thirds of each square inch of surface area shall be free of all visible residues

"white rust" preventative. Conventional coatings containing oil or alkyd resins must not be used.

and the remainder shall be limited to the light residues mentioned above.

Specify only special primers made for use on galvanized metal. In severe Type A environments,

2014

Brush Off Blast SSPC-SP7 (SSI-Sa1), or NACE #4 Definition: A method in which all oil,

or in areas of high humidity or continuous condensation, brush blasting is recommended to assure maximum system adhesion and performance.

grease, dirt, rust scale, loose mill scale, loose rust and loose paint or coatings are removed 29 29

The SSPC and NACE standards are also approved by the

involved present during their preparation. Once the specified

following organizations:

cleanliness and appearance is agreed upon by all parties, these sample/standard panels should be protected from corrosion/

- American Society for Testing Materials (ASTM)

contamination and maintained as the visual standards for the

- American National Standards Institute (ANSI)

duration of a project.

- Swedish Standards Institute (SIS)

- Danish Standards Association

Methods

- Standards Association of Australia

To achieve the different surface preparation qualities, numerous methods may be employed. Some of the most commonly used

In addition to the above mentioned standards, other written

methods are:

Examples of hand tools

and photographic/visual surface preparation standards are available, some of which are:

Hand Tools Preparing surfaces using hand tools is one of the oldest

1. American Rust Standard System – Illustrates 24 degrees of rusting on uncleaned hot rolled steel.

methods known. It is generally used when power tools or other type of cleaning equipment cannot be used or are not available. It is also used when the areas to be cleaned are fairly

2. The Production Technical Society – Illustrates wash primed

small or inaccessible.

and zinc rich primed steel before and after weathering and recleaning.

Hand tool cleaning is designed to remove only loose rust, loose mill scale, loose paint and any other loose contaminants or

3. The Society of Naval Architects and Marine Engineers (SNAME) – Illustrates typical appearances of painted steel

detrimental foreign matter. It is not intended to remove right rust, mill scale, paint, etc.

before and after being abrasive blast cleaned to grades between SSPC-SP5, SP6, SP7 and SP10.

Tools normally used in hand cleaning include wire brushes, scrapers, chisels, chipping hammers, knives, abrasive pads

4. Shipbuilding Association of Japan – Illustrates the appearance of painted, unpainted, welded and flame-

or any type of non-powered tool that achieves the desired cleaning quality.

Nt coNteN cut steel before and after various degrees of damage or weathering.

Hand tool cleaning can be slow and therefore expensive given the manpower required.

Site Standards:

Due to variations in initial surface conditions, types of abrasives

Deep marks, burrs, etc. are often left on the surface from tool

used, etc., surfaces will often appear differently than those

impact and can interfere with coating performance.

shown in the recognized photographic/visual standards. For

2014 SEPTEMBER 2 these reasons it is recommended that samples, representative

Special surface tolerant coatings are also normally required

of the degree of cleaning specified, be prepared with all parties

when using hand tool cleaning.

30 30

Power Tools Power tool cleaning is intended to remove loose rust, mill scale, paint, and such materials and is not designed to address tightly adhering rust, mill scale, paint, etc. Like hand tool cleaning, it can also be slow due to high equipment wear, high worker fatigue and high manpower requirements. Power tools normally used include chipping and scaling hammers, needle guns, bumble bees, etc., all of which are piston driven. Rotary type tools such as abrasive discs and flap wheels are also used. Power wire brushes may also be used but are not recommended as they tend to burnish a surface which limits the mechanism bond between the coating and surface. Special surface tolerant coatings are normally required when coating surfaces prepared in this manner.

2014

31 31

Surfaces are cleaned using pressurized equipment that meters abrasive particles into a stream of compressed air conveying the particles through a “blast hose” and, finally, a “blast nozzle” onto the surface to be cleaned. The end effect of this process is the removal of mill scale, rust paint and other detrimental contaminants by the blasting action of these abrasive particles to the quality of cleaning specified. Sand and / or grit blasting equipment is usually very portable and available at reasonable costs throughout the world. Two drawbacks of this type of surface preparation, however, are its limitation to outdoor use due to dust and abrasive fallout and its susceptibility to weather changes. Dust and fallout can be limited somewhat by using “wet blasting” equipment. This equipment wets the abrasive flow with water, thereby reducing dust levels. Rust inhibitors or surface tolerant coatings are normally required when using this type of equipment. Centrifugal Wheel Blasting – This method was first introduced in 1932 and is mostly used in shop environments, although several types of portable units are now available for onsite use. Basically, this method uses motor driven bladed wheels that throw abrasive particles by centrifugal force. These wheels are available in several sizes and are powered by electric motors of up to 100 horsepower. Most machines have at least four wheels, which are positioned so that the abrasive particles reach the entire surface to be cleaned.

Nt coNteN The material to be cleaned is passed through an enclosed cabinet where the wheels are located using a conveyor system. The abrasive is thrown

against the material, then dropped into hoppers located beneath the blast area and is sent to the abrasive reclaiming system for reuse.

Rates and quality of cleaning can be varied by changing the number of

wheels used, speed of material past the wheels and type of abrasive used.

2014 SEPTEMBER 2 This method offers considerable savings in time, labor, energy and abrasive 32 32

consumption versus abrasive air blasting. For example, a

especially useful for maintenance surface preparation due to

four wheel, A 30 horsepower wheel unit will throw about

the lack of sand and grit that may get into equipment.

3,200 pounds of abrasive particle per minute. A “sandblast” operation would require 44 3/8 inch diameter nozzles and a

Sand / grit injection units or attachments are available that will

3,00 horsepower compressor to equal that abrasive capacity.

assist in the removal of extremely tight coatings and produce surface profiles.

Another pattern will also stay constant due to the automated system.

required when using this method of cleaning. One extremely important point to be observed in this method is the requirement of pre-cleaning all materials to be blasted

Worker fatigue can be high in this method due to back

per SSPC-SP1 to ensure that all oil that oil and grease are

pressure developed at the nozzle. Newly developed equipment

removed. If this is not done, or not done properly, the recycled

has reduced this factor.

abrasives will become contaminated and will contaminate contaminate each part going through the cabinet and

The high pressure involved in this method also requires

increasing chances for premature coating failure.

following good safety practices.

Water Blasting – This method began in the early 1950’s and is

The foregoing is a brief overview of the most commonly used

being employed regularly today.

methods for preparing a surface for coating. If greater detail is required, additional information on surface cleaning methods

Definitions of “Water Blasting”:

may be found at NACE or SSPC, or from the equipment

•L ow Pressure Water Washing – pressures less than 350 bar

manufacturers themselves.

(5,000 psi) •H igh Pressure Water Cleaning – pressures of 350 – 700 bar (5,000 to 10,000 psi) •W ater Jetting – pressures above 700 bar (10,000 psi) •H igh Pressure Water Jetting – pressures of 700 – 1700 bar (10,000 to 25,000 psi) •U ltra-High Pressure Water Jetting – pressures greater than

2014

Rust inhibitors and/or surface tolerant coatings are normally

1700 bar (25,000 psi)

Usually anything that can be removed by hand tool, power tool or abrasive blast cleaning can be removed with a stream of high pressure water. While its rate of cleaning is faster than hand and power tool, it does not always remove tightly adhered coatings. It uses the cheapest abrasive available – water, and is 33 33

Nt coNteN Unfortunately, choosing the type and size of abrasive that will economically and effectively produce the desired surface finish is not an exact science.

2014 SEPTEMBER 2 34 34

Abrasives

Specific information on types of abrasives is available on

As a rule is it always advisable that an abrasive blast cleaned

Unfortunately, choosing the type and size of abrasive that

request from the manufacturers or suppliers.

surface is coated within eight hours. Under no circumstances should the steel be allowed to rust before coating is applied

will economically and effectively produce the desired surface finish is not an exact science. Some of the parameters to be

Surface Profile

regardless of the time elapsed. One exception to this rule,

considered when choosing an abrasive are:

Surface profile or anchor pattern is a measurement of the

however, would be the use of surface tolerant coatings which

roughness of a surface which results from abrasive blast

are designed for application over rusted surfaces.

• Shape – angular or round

cleaning. The profile or anchor pattern is measured from the

• Hardness – hard or soft

bottom of the lowest valley to the top of the highest peaks.

Abrasive blast cleaning should not be conducted when the surface temperature is less than 3°C above the dew point.

• Density – heavy or light • Size – large or small

The depth of profile will be directly related to the size, type

Moisture can condense on the surface if it is colder than the

• Type of surface – new, light or heavy rust, coated, steel,

and hardness of the abrasive as well as its velocity and angle

surrounding ambient air temperature and rust back can occur.

aluminum, etc.

of impact and the hardness of the surface being cleaned. The

• Profile required – light or heavy

maximum allowable depth (height) will depend on the coating

Rust Inhibitors:

• Coating system to be used

system dry film thickness. A rule of thumb states that profile

When using water blasting or wet abrasive blasting, the

• Degree of cleaning required

depth (height) should not exceed 1/3 of the coating systems

cleaned surface will rust very rapidly. It is therefore essential

• Environmental constraints

dry total film thickness.

that a “rust” inhibitor be applied to the surface itself immediately after cleaning or mixed in the water used during

Some of the types of abrasives available are:

Rust Back

the actual cleaning process.

Rust back occurs when freshly cleaned steel surfaces are 1. Cast Steel – shot and grit

exposed to high humidity, rain or a corrosive atmosphere.

Use of any “rust” inhibitor should always be cleared through the

2. Naturally Occurring – mineral and silica sand, flint, garnet

The time involved in getting rust back can vary tremendously

coating manufacturer to insure that incompatibility problems

ranging from minutes to weeks.

between the inhibitor and coating to be used do not occur.

and zircon. 3. By-Product – slags (boiler, copper, nickel), walnut shells, peach pits and corn cobs. 4. Manufactured – silicon carbide, dry ice, baking soda, sponges, aluminum oxide and glass beads. Of the above abrasive types, the most commonly used are the cast shot and grit for shop applications, where recycling

Nt equipment is in use, and silica and mineral sands and boiler and copper slags for field applications where recycling of abrasives is impractical.

A general rule to follow is to select the smallest size abrasive

that will produce the specified degree of cleaning and surface

profile. Normally the smaller size abrasives will clean faster and

2014 cost less than the larger sizes.

35 35

external coating rehabilitation Nt coNteN Dependence on blasting profile, sa 2,5 cleanliness grades, dust or salt/chloride removal is not always necessary

2014 SEPTEMBER 2 36 36

The selection of a suitable pipeline repair/replacement coating

prevent moisture ingress and to resist soil stresses. This is

is from a technical point of view the major decision to be made

very dependent upon surface cleanliness and profile prior to

for a rehabilitation project. Rehabilitation seeks to re-establish

coating application.

coating efficacy to its original state. This does not mean that the same coating must be used for rehabilitation; often more state-of-the-art coatings are employed. The problem is that there is a wide variety of coating systems that have been used with varying degrees of success as pipeline coatings. A closer examination of many of these systems reveals very few have been subject to exhaustive testing to ensure the coating is fit for purpose.

under the prevailing environmental conditions. 4. The coating must be capable of being repaired and to withstand holidays over time. 5. The coating or supporting techniques must be available to cover the repair of the overlap areas onto the parent coating. 6. The coating must be tolerant to alkali generated by cathodic protection

In order to specify the requirements of a protective coating and ensure correct testing it is useful to understand their major failure mechanisms. Current thinking on the mechanism of failure of thin film liquid applied coating (epoxy) requires different coating parameters to those used for example in evaluating tapes. With thin film coatings, the penetration of water and subsequent osmotic pressures developed will result in many small canals creating further water uptake. Eventually the thin film coating becomes transparent to moisture and becomes a semi-permeable membrane which, under the influence of cathodic protection draws water through the coating to collect at the steel coating interface as a blister which eventually bursts and allows further undermining of the coating. Coating failure is accelerated by increasing temperature. This failure

The coating must have a long useful lifetime. A wide variety of tests are used to evaluate and select a suitable coating.

mechanism is not applicable to tape coatings. A coating used for the rehabilitation of a pipeline must fulfill the

2014

3. The coating must be capable of being applied in the ditch

following requirements:

The following Program of Work should be followed: 1. Define the size of the coating problem by coating defect

1. T he most important and fundamental requirement of a coating is that it must separate the pipe from the moist soil. To do this the coating must have a high resistance to permeability / water uptake.

2. T he coating must have a good bonding to the steel pipe to

surveys, cathodic protection surveys and metal loss surveys. 2. Analyze survey data to decide priorities and what needs repair and what can be left without repair. 3. Select pipeline repair coating(s). This is a critical and important decision making process.

37 37

In order to confirm the scope of work for coating rehabilitation

tolerated. It must be appreciated that not every defect will be

what needs repair, a full Scope of Work for a complete

based upon coating and pipe-to-soil potential surveys and to

cost effective to repair.

rehabilitation project should be established.

confirm the difficulties specified, it is necessary to carry out

•D efect corrosion behaviour as predicted by:

limited exploratory excavations. These exploratory excavations

cathodic protection.

will not only confirm the accuracy of the defect locations and the size and importance of the defect, but visual examination will allow the pipe coating to be studied to determine the mode of coating failure and the steel pipe inspected for any corrosion and other damage. Exploratory excavations should be carried out to maximize information about the whole of the pipeline length to be refurbished. Hence, rather than being chosen at random, selection of possible defect locations to be verified should be considered on the basis of the following parameters taken from a detailed analysis of survey data:

o Pipe to soil potential and regions of generally poor

oA nodic/cathodic behaviour as predicted by DC voltage gradient technology.

•R egions of low soil resistivity which are usually regarded as more corrosive •T errain variations and presence of rocks as rock will affect trenching ability and requirements for imported back-fill. •N eed to inspect locations spread over the full distance of the pipeline under repair. •T o examine selected areas for signs of Stress Corrosion Cracking.

At each defect location the following work needs to be carried out: 1. Site clearing and grading 2. Hand excavation to locate pipeline 3. Mechanical excavation to fully uncover the pipeline 4. Inspection of existing coating 5. Removal of existing coating 6. Visual inspection of the steel surface before surface preparation 7. Surface preparation 8. Any visual corrosion as general corrosion, pitting, MIC, etc. 9. NDT inspection for SCC 10. Surface preparation and profiling

• Defect location. A defect at a road crossing or near areas frequented by people is of a higher priority than for example a

Exploratory excavations are recommended not only to gather

11. Application of repair coating

defect in the middle of a desert.

the above information but also to understand and work out

12. Backfilling and reinstatement

methods for different aspects of rehabilitation activities.

13. Retesting for coating defects

• Proximity of defects to one another. The close proximity of defects could require complete coating replacement on that

Record detailing all findings should accompany a pre-planned

section of the pipeline, particularly if there is poor adhesion

detailing all findings to a preplanned questionnaire, pipeline

Even after the rehabilitation project has been completed,

and easy disbondment occurs.

excavation report, together with photography of all interesting

there will still be large amounts of parent coated pipe in the

findings particularly coating damage and steel pipe surface.

ground. Therefore, there is a need to understand the coating

• The size and importance of the defect. It is common to find

The type and nature of any films and calcareous deposits on

failure mechanisms to work out if these mechanisms can be

metal loss at larger defects. However, a variety of different

the steel surface are particularly important as they reflect the

managed to extend the life of a pipeline.

sized defects should be excavated to provide information

effectiveness of the cathodic protection at individual defects.

on what must be repaired and what type of defects can be

From a detailed analysis of survey data, and having identified

Nt coNteN

2014 SEPTEMBER 2 38 38

"Exploratory excavations are recommended not only to gather information about the source and type of corrosion but also to understand and work out the methods

for different aspects of rehabilitation activities."

2014

39 39

cathodic protection

Nt coNteN

2014 SEPTEMBER 2 40 40

The primary barrier against external corrosion of underground steel pipelines is the application of an external coating system.

Positive metal icons

However, no coating will be 100% damage proof. During the construction of a pipeline or in the operating phase, damage of the coating can occur and as a consequence, the protection against corrosion will decrease. In addition, every type of external coating will suffer to some extent from deterioration. The deterioration process over time

Figure 5

is however not the same for different coating types. External influences and their interaction with the coating can also affect

The dissolved metal ions are positive ions. The bar becomes

the deterioration rate.

negative because electrons stay behind when the positive ions leave.

Because coatings can lose their protective performance, cathodic protection is added as a secondary line of defense

The dissolution of an electrolyte is different from metal to

against corrosion.

metal. The more a metal has the tendency to dissolve, the less noble the metal is. Zinc (not passivated) is less noble than iron,

Cathodic Protection provides a secondary line of protection against external corrosion.

so zinc has a greater tendency to dissolve in water; and in the same way iron is less noble than copper. In figure 6 it can be seen that magnesium has a greater tendency to dissolve than iron. Magnesium is less noble than iron.

In this chapter, the principle of cathodic protection will be

Due to the fact that more Mg 2+ – ions dissolve than Fe2+ –

explained.

ions, the Mg bar will become more negative than the Fe bar.

Particular attention is given to the application of cathodic protection on underground pipeline systems.

The principle of cathodic protection

2014

metal

All metals in contact with an electrolyte (a water solution with

Fe2+

Mg2+

ions) have the tendency to dissolve (see figure 5). The general chemical formula for this process is given as: Me → MeX+ + xe–

Figure 6

41 41

At a certain moment, no further positive ions will dissolve into

Type electrode

Me/Men+ - System

Electrolyte

Potential against the normal H2 – electrode (mV)

Temperature dependence (mV/0C)

Application

Cu/CuSO4

Cu/Cu2+

Sat. CuSO4

+320

0,97

Normal soil Water

Ag/AgCl

Ag/Ag+

Sat. KCl

+200

1,0

Sweet- en see water

Ag/AgCl

Ag/Ag+

Seawater

+270

n.a.

Sea water

bar has reached a certain positive potential; this potential is

Sat. Calomel

Hg/Hg22+

Sat. KCl

+240

0,65

Water Laboratory

characteristic for that particular metal. This point is called the

1 M Calomel

Hg/Hg22+

1 M KCl

+290

0,24

Laboratory

Thalamite

Ti/Ti+

3,5 M KCl

-570

< 0,1

Warm media

the solution because the bar has such a negative potential that it hinders the ions to leave the bar. At that moment, there is a balance between the negative bar and the positive ions in the solution. When balanced the metal bar reaches a certain potential which is characteristic of the particular metal. The metal

electrochemical potential of that metal.

Table 5: Some reference electrodes and their characteristics

This specific potential can be measured against a reference electrode. The reference electrode consists of a metal – electrolyte combination with a stable and well known potential. The standard reference electrode is arbitrarily chosen as the

Metal

Potential (Volt against H2 in own salt solution)

Potential (Volt against Cu/CuSO4 in soil / sweet water)

Magnesium (Mg)

-2,37

-2,69

Aluminium (Al)

-1,66

-1,98

Zink (Zn)

-0,76

-1,08

In practice, however, this hydrogen electrode is difficult to use.

Iron (Fe)

-0,44

-0,76

Therefore, other reference electrodes are with their own fixed

Cadmium (Cd)

-0,40

-0,72

potentials against the hydrogen electrode.

Nickel (Ni)

-0,25

-0,57

Table 5 shows some reference electrodes with their specific

Tin (Sn)

-0,14

-0,46

characteristics.

Lead (Pb)

-0,13

-0,45

Hydrogen (H)

-0,32

Copper (Cu)

+0,35

0,03

Silver (Ag)

+0,80

0,48

Platinum (Pt)

+1,20

0,88

Gold (Au)

+1,60

1,28

hydrogen electrode such that the following electrochemical reaction is in balance: H2

2 H+.

The potential of this balanced reaction is stated to be 0 Volt.

So it is possible to fix the balance potentials of metals in their own electrolyte. If this is done in a salt solution with a fixed concentration of own metal ions, the theoretical electrochemical potential table can be determined. In the table, the potentials are expressed in Volt against the hydrogen

Nt coNteN Table 6: Electrochemical table of metals

electrode. However, it is more practical to express potentials

in Volts against an easier reference electrode such as the Cu/ CuSO4 in a certain environment such as soil or sweet / salt water.

In the previous example, the Mg bar has become more

Connecting both bars with a metallic wire creates two effects:

In table 6, the electrochemical potentials of some metals

negative than the Fe bar because more Mg2+ – ions went into

- the Mg bar will become more positive again and as a result,

is given against the theoretical hydrogen electrode and the

the solution than Fe ions.

practical Cu/CuSO4 reference - electrode.

Where both bars are connected with a metallic wire, a current

more Mg2+ ions will go into the solution, and

- the Fe will become more negative and as a result less Fe2+

2014 SEPTEMBER 2 of electrons would appear from the Mg bar in the direction of the Fe bar.

42 42

ions will go into the solution (see figure 6).

By connecting a metal with a less noble metal in a solution the less noble metal will corrode and the more noble metal will be protected against corrosion. In this example, the Fe bar is said to be the cathode and the Mg bar the anode. The Fe bar is cathodically protected by the Mg bar. This is the basic principle of Cathodic Protection! The Fe bar is the object to be protected while the Mg bar is the galvanic anode, the so called ‘sacrificial anode’. By convention, it is understood that the direction of the electric current is opposite to the direction of the current of electrons (see figure 6). To recap: • The cathode is the electrode where the direction of the electric current is from the electrolyte toward the metal bar! • The anode is the electrode where the direction of the electrical current is from the metal bar to the solution!

2014

connecting a metal with a less noble metal in a solution, the more noble metal will be protected against corrosion 43 43

The following reaction takes place at the anode:

Inert means that at the anode this anode does not suffer from loss of material. The anodic reaction at the anode is not:

+ 2e (anodic reaction) –

C A T H O D E

The following reaction takes place at the cathode Fe

+ 2e

–

Where there are no Fe2+ ions available in the solution, the following reaction takes place: O2 + 2H2O + 4e–

+ A N O D E I

Figure 8: Making an anode and a cathode by using an external direct current source

4OH– (cathodic reaction)

Mex+ + xe–

But as in the example of magnesium and iron above: 2H2O

4H+ + O2 +4e–

or, if chloride ions are present : 2Cl–

Cl2 + 2e–

The external current source ensures the production of electrons

In acidic environments, the following reaction can also Cathodic protection with galvanic or sacrificial anodes.

in the anode. These electrons provide a negative polarisation of

Materials often used as sacrificial anodes include:

the object to be protected against corrosion.

- Magnesium, onshore application

The reaction at the cathode, which provides protection for the

Where a metal acts as protection against corrosion by con-

- Aluminium – alloys, offshore application

object is the same reaction as that using sacrificial anodes:

necting it to a less noble metal, the process that takes place

- Zinc, mainly used offshore, (at max. soil resistivity

occur: 2H+ + 2e

–

of 1500 Ω.cm

is called:

O2 + 2H2O + 4e–

4OH–

C A T H O D E

Mg A N O D E

We have seen that by making the Fe bar negative through a

When an external direct current source is used to protect a

supply of electrons dissolution of the Fe2+ ions is prevented

metal to corrode, this is called:

(no corrosion of the Fe bar).

This was achieved by connecting the Fe bar with the less noble

Cathodic protection with impressed current.

Mg bar (the sacrificial anode).

In principle, there is no difference between cathodic protection

with sacrificial anodes or cathodic protection with impressed

However, there is another way to ensure that the Fe bar

current. Both applications will render the protected object to be

becomes negative:

negatively polarised.

And that is to use an external current source (see figure 8).

In practice however, there is a big difference between the two

Nt coNteN I

Figure 7: The Mg bar dissolves (anode) while the Fe bar is protected against dissolving (cathode)

applications. When using sacrificial anodes, the difference

The negative side of the direct current source is connected to

between anode and cathode potential is the driving force for

the object to be protected while the positive side of the current

protection of the object. When using impressed current for

source is connected to an inert anode.

protection, the necessary driving force can be installed by using

2014 SEPTEMBER 2 the current output from the rectifier. The output of a rectifier

can be much larger than the potential difference between the

44 44

sacrificial anode and the object to be protected.

Anode type

Content (%)

Density (g/cm3)

The advantage of using impressed current is that larger objects FeSi

can be cathodically protected and larger distances can be bridged. Current sources for protection with impressed current are:

Fe3O4

- Rectifiers

Graphite

14 Si, 1 C, Rest Fe (5 Cr Or 1Mn of 1 – 3 Mo

7,0 - 7,2

Fe3O4 + Additions

5,2

100 C

1,6 - 2,1

Anode current density (Amp./m2) Max. Gem. 300

50 - 150

Anode consumption (g/Amp/year)

10 - 50

90 - 250

90 - 100

1,5 - 2,5

10 - 50

30 - 450

- Diesel generators

Table 7: Data of inert anode material

- Panels on sun energy Chemical properties

For underground pipelines, inert anode materials for impressed current systems used most often are:

Element Percentage

- Car iron with high content of silica, ≈ 14% (FeSi) - magnetite (Fe3O4)

Carbon Manganese Silica Chrome Molybdenum Copper

- graphite ITable 7 set out data concerning inert anode materials. So called LIDA anodes are also used for cathodic protection

0.7 – 1.1 1.5 max. 14.2 – 14.75 3.25 – 5.00 0.2 max. 0.5 max. Photo 12: Example of inert Fe/Si anode material with chemical properties

of underground pipelines. These anodes are titanium based materials with metal oxide alloys. The protection criterion

In this diagram it can be seen that iron will not corrode at

Above we have seen that steel will not corrode if it is made more

a potential more negative than ca. -950 mV against a Cu/

negative. The question now is:

CuSO4 reference electrode, independent from the acidity (pH). In practice however, the corrosion rate of steel will

“How negative must steel be made, to prevent corrosion to occur?”

already be very low at potentials more negative than –850 mV. This value of –850 mV against a Cu/CuSO4 reference electrode is under normal conditions considered as the pro-

Nt The Pourbaix diagram of iron can inform us on this question. This diagram gives information about the behaviour of iron (potential)

as a function of the acidity (pH) in water at a temperature of 25 0C (see figure 9).

2014

tection criterion. A criterion of –950 mV against a Cu/CuSO4 reference electrode is used under oxygen free conditions (anaerobe) because under such circumstances, bacterial corrosion could occur: Sulphate Reducing Bacteria (SRB) can produce hydrogen sulphide (H2S) which leads to a very corrosive environment. Often less negative potentials are used as protection criteria under circumstances with higher soil resistivity. The Dutch Standard on cathodic protection criteria are listed in the table below.

-2

16 pH 45 45

cathodic protection and interaction with coatings Introduction The rehabilitation of oil and gas pipelines is in many cases forced upon operators by the detection

is able to quantify the severity of the defect based on the magnitude and direction of the potential

of coating defects by internal measuring techniques such as intelligent pigs , or by above-ground

gradient. Best results are obtained at coating defects on an otherwise well coated pipeline. Results

non-intrusive techniques such as direct current voltage gradient surveys (DCVG), alternating current

on large extents of poorly coated pipeline are not always so definitive. The technique is effective even

voltage surveys (ACVG) and close-interval potential surveys. Visual inspections combined with

in areas of d.c. stray current and a.c. interference.

coating evaluation, wall thickness and pit depth measurements at selected bellholes can also be carried out. Analysis of the results from any of these, or a combination of these, surveys can be

Alternating Current Voltage gradient Survey (ACVG)

used to establish suitable remedial measures to extend the pipeline operational lifecycle by coating

ACVG surveys are conducted in a similar manner to the DCVG except the applied signal is at a

application and/or cathodic protection system remediation.

selected frequency. Foreign contacts and coating defects can also be identified in the same way as the DCVG. Unlike the DCVG, however, ACVG will give no information about the effectiveness of

Intelligent Pig Run

applied cathodic protection. This technique will provide an indication of overall coating quality based on the attenuation (i.e. signal loss) of the applied signal. The technique is effective even in areas of

The pipeline wall thickness can be determined through an Intelligent Pig (IP) run. A correctly selected

d.c. stray current and a.c. interference.

IP can identify the extent of any metal loss and whether or not the metal loss is internal or external. In the case of external metal loss, the IP results can be categorized as general corrosion or local attack

Visual Inspection:

such as pitting, Microbiological Induced Corrosion (MIC), Hydrogen Induced Corrosion (HIC) or AC-

Visual inspections provide direct information about the coating condition, remaining wall thickness,

induced corrosion.

pit depths, microbial activity and soil corrosivity. Provided that the visual inspections are carried out at

Nt coNteN representative locations and the number of visual inspections is statistically significant then the data

Direct Current Voltage Gradient Survey (DCVG)

DCVG surveys are conducted above the pipeline and are able to detect the direction and magnitude

can be used as a basis for developing rehabilitation programs. Summary of above ground survey techniques.

of cathodic protection current flowing to a pipeline. This technique enables accurate location of areas of protection current demands to pipelines. These locations would typically be at coating defects,

Specialised surveys shall only be conducted by personnel who have received training in the survey

foreign contacts (e.g. foreign pipelines or earthed systems). The technique can also identify areas of

techniques and have a certificate of competence. Some above ground surveys are highly dependent

poor coating. The technique does not permit accurate physical sizing of the defects but it

on operator performance and data interpretation (e.g. DCVG).

2014 SEPTEMBER 2 46 46

Survey

Description

Limitations

DCVG

Direct Current Voltage Gradient

ACVG

Alternating Current Voltage Gradient

Evaluates coating condition by measuring signal loss from the pipe. Requires transmitter and special receiver. Frequency selection is coating related. Provides no information about the cathodic protection system.

Pearson

Early form of ACVG.

Gradient of injected a.c. signal is measured between two operators wearing ground contact boots and connected together with a cable. Subject to interference from a broad spectrum of radio frequencies. Large variations in soil resistivity can give false indications of coating faults.

CIPS

Close Interval Potential Survey

Resistivity

Wenner 4 pin soil resistivity measurements

Requires d.c. source e.g. impressed current cathodic protection (either permanent or temporary). Results are operator dependent.

Measures the pipe-to-soil potentials along the entire pipeline route. Requires specialized instrumentation with synchronised switching of cathodic protection power sources and the actual measuring instrument. Trailing wire connection between test posts required. Data may be unreliable in areas of a.c. and/or d.c. interference. Difficult to apply in urban and city areas. Values measured can be compared with the corrosion risk values provided in the standards.

Nt Table xx Priority Matrix example

To ensure that the bellhole excavations for the visual

A typical Priority Matrix is given in Table xx. More, or less,

inspections are carried out at meaningful locations a Priority

stringent weighting factors can be applied depending on the

Matrix should be developed for the entire pipeline section in

pipeline section in question.

2014 question to establish high and low risk areas for corrosion.

47 47

From the Priority Matrix it is possible to select locations for

• Coating

In most cases total replacement of a pipeline is necessary

excavations and visual examination. A control location should

o Type (tape, FBE, bitumen etc)

(based on technical and financial considerations), particularly

also be selected. In this context a control location is one

o Number of layers

if the weak areas of the steel can be identified. If the pipeline

where the Priority Matrix indicates a low priority for excavation.

o Appearance (wrinkles, rips etc)

suffers from Stress Corrosion Cracking then the affected

The purpose of the control location is to validate the matrix,

o Bond to pipe

sections shall be replaced and the sections with degraded

because if active corrosion is identified at the control location

• Cathodic protection

coating shall be refurbished. Whilst operating conditions can

then the matrix needs to be revised.

o Type (Impressed current, galvanic, none)

be modified to reduce the propensity to SCC, no method

o Pipe to soil potential (a.c. and d.c.)

exists to repair SCC although the pipe can be reinforced by

At the excavation a number of measurements and

o Are potentials fluctuating?

metallic sleeving. The affected pipe has to be cut out and

observations are required. These are listed in Table xxx.

• Longitudinal weld data (if applicable)

replaced rather than risk pipeline failure by rupture that can

Table xxx. Test, Measurements and Observations at

occur with SCC (stress corrosion cracking). Special attention

excavations.

• Field weld data

shall be paid to the coating and cathodic protection of the

• Date

o Weld appearance

replaced sections of pipe since the new steel will act as an

• Bellhole number

o Field joint coating type and quality

anode to the old steel and rapid corrosion of the new steel will

• Chainage

o Any visible cracks?

occur if there is inadequate cathodic protection and there are

• Weather conditions

• Ultrasonic inspection report

• Inspector name

o Grid spacing

• Report reference number

o Wall thickness and co-ordinates

Pipeline rehabilitation may be defined as follows:

• Photograph number

o Pit depths and locations

“The assessment, renovation and reclassification

o Location data

o Calibration results

work necessary to establish a level of integrity, based

o Location

• Other observations

o GPS Latitude and longitude

o Additional location information

o Weld orientation (top, bottom etc)

coating defects on the new section.

on known values, that enables an existing pipeline to continue in service, safely, and economically, for a

For example, on a pipeline in service, external corrosion over

determined period.”

• Pipeline data

large areas has been detected and the cathodic protection

o Year of construction

cannot maintain the required potentials along the pipeline

In the context of this standard rehabilitation means undertaking

o Current service (e.g. crude, diesel)

due to a combination of coating degradation and current

the necessary repairs and improvements to a pipeline to

o Past service

distribution. In this situation, the pipeline operator may consider

restore it to an acceptable operational condition for the

• Pipe details

to refurbish or rehabilitate the pipeline (or the suspect pipeline

required operational lifetime. This would typically require

o Measured diameter

sections). The rehabilitation program can be scheduled to

the repair of significant areas of metal loss and the repair/

o Type of pipe (ERW, spiral weld, seamless etc.)

take place over an extended period of time based on the

refurbishment of the existing coating and cathodic protection

o Original wall thickness

survey data and the relevant criticalities. ASME B 31G can

system.

o Overall appearance of pipe

be used to calculate the remaining strength for corroded

o Any corrosion observed?

pipelines. Combined with a knowledge of the required

Nt coNteN • Terrain data

operating pressures it is possible to determine which sections

o Terrain description (flat, rocky, sandy etc)

of the pipeline do not meet the desired operational pressure

o Is this location in a low area?

requirements.

o Depth of pipeline cover

o Soil resistivity from excavation

2014 SEPTEMBER 2 48 48

Scheme for pipeline integrity check

There are a number of factors to be considered when determining the need for refurbishment of the coating.

Pipeline Rehabilitation

Integrity of Pipe Steel

External Corrosion Control

Protective External Coating

Factor

Criterion

Remarks

Cathodic protection cannot be achieved over the entire section without exceeding the limit potential

-1.2 Volts (typical IR free value)

Refer to cathodic protection standards and design documents for acceptable limit potentials

Protection current densities exceed the values given in table xxx

Coating type and coating age dependent

Required operating pressure

Wall thickness shall be capable of withstanding the required pressure.

Additional mechanical strength will be required as well as coating refurbishment.

Remaining life requirements

Corrosion rate and wall thickness to be taken into account.

Coating and cathodic protection can reduce the corrosion rate to acceptable limits.

Monitoring

Measurement of wall thickness/pit depths and continuous monitoring of corrosion rates at pre-determined critical locations can be used to validate the effectiveness of cathodic protection.

Increased electrical interference

Installation of new tractions systems or HVDC/HVAC transmission systems may require coating refurbishment and cathodic protection augmentation

Coating type

Age of pipeline

Remarks

0-5 years (mA/m2)

5-15 years (mA/m2)

15-30 years (mA/m2)

Asphalt bitumen (AB)

0,004

0,10

0,50

Butyl rubber Based

0,004

0,10

0,20

Fusion bonded epoxy (FBE)

0,01

0,02

0,05

Liquid epoxy

0,01

0,02

0,05

Coaltar

0,01

0,02

0,05

Polyethylene (PE)

0,002

0,005

0,01(3LPE) 0,20 (sinter)

Polypropylene (PP)

0,002

0,005

0,01

Polyisobutene (PIB) based coating systems

<0,001

Cathodic Protection

Operational and Environmental Restrictions Rehabilitation projects shall consider the operational restrictions and the environmental conditions that determine how the project will be carried out. Environmental conditions include ambient temperatures (affected by wind, humidity, rain, cold, and salinity), soil conditions and access. Operational service restrictions are

Nt line flow, line pressure and minimum or maximum temperature ranges.

From a safety perspective, the rehabilitation of live gas pipelines imposes a number of constraints with the need for careful

working practices that may be of lesser importance when working on a non-operational pipeline. From a financial perspective, the

2014

restrictions of working on a live pipeline (which can be hot or cold) mean that the cost per meter is higher than for working on a nonoperational pipeline.

Typical interference sources would be trams, railways, windfarms, and electrical transmission systems (buried or aerial)

Table xxx: Mean current (design) densities for coatings (DEP 30.10.73.21, Shell Amsterdam, 1992) 49 49

External Coating Assessment

out more than one kind of survey to determine coating defect

for an example of a pipeline excavation report), together

Program of Work

areas before excavating. The defect locations can be further

with photographs of all relevant observations and findings,

The following overall Program of Work needs to be performed:

assessed on the basis of the following parameters from a

particularly any coating damage and the steel pipe surface.

1. Determine the integrity of the pipe by above ground coating

detailed analysis of survey data:

The type and nature of any films and calcareous deposits on the steel surface are particularly important as they could

and cathodic protection surveys and/or metal loss survey. 2. Analyze the survey data and select locations for excavation for visual, coating and metal loss measurements. 3. Analyze inspection data to determine a rehabilitation program and decide which pipe sections require coating

- Defect location. A defect at a road crossing or near areas frequented by people is of a higher priority than, for example,

be related to the effectiveness of the cathodic protection at individual defects.

a defect in the middle of a desert. - Proximity of defects to one another. The close proximity of

Based upon a detailed analysis of survey data (as given in

repair or coating refurbishment and/or cathodic protection

defects could require complete coating replacement on that

Appendix A) and having identified what needs repair, a full

improvements and which sections can remain as they are.

section of the pipeline, particularly if there is poor adhesion.

Scope of Work for a complete rehabilitation project needs to

4. Select pipeline repair coating(s) and refurbishment coating(s).

- A variety of defect %IR sizes should be excavated to provide

be established.

5. Design cathodic protection system improvements

information on what must be repaired and what type of

6. Develop a rehabilitation strategy that prioritizes the

defects can be tolerated. It should be appreciated that not

At each defect location the following work needs to be

remediation works required and schedules the rehabilitation

every defect can be cost effectively justified for repair. The

carried out:

program. The program may extend over many years to

number of excavations should be statistically meaningful.

2. Hand excavation to locate pipeline

provide an acceptable combination of operational safety and long-term requirements.

In predicting corrosion behavior at coating defect locations, the following should be considered:

Exploratory excavations Exploratory excavations should be carried out to confirm the scope of work for coating rehabilitation, based upon metal loss surveys, coating and cathodic protection surveys. These exploratory excavations will confirm the defect locations and size/importance of the defects and will allow visual examination of the pipe coating to determine the general condition of the coating (bonding, degradation) and the mode of coating failure.

- the pipe to soil potential and regions of generally poor cathodic protection are of importance. - Regions of very high soil resistivity which are usually regarded as less corrosive, except for microbiological corrosion - Terrain variations and presence of rocks, as rock will affect trenching ability and the requirement for imported back-fill. - Inspection of locations over the full distance of the pipeline under repair. - To assist in examination of predicted areas for signs of Stress

Exploratory excavations can be carried out to maximize

Site clearing and grading

Corrosion Cracking.

3. Mechanical excavation to within 1 m of the pipeline, thereafter hand excavation 4. Inspection of existing coating 5. Removal of existing coating 6. Visual inspection of the steel surface before surface preparation 7. Surface preparation 8. Observations on visual corrosion 9. Mark a grid on the exposed section and measure the wall thickness and pit depth in each grid square. 10. Using approved codes and standards, calculate the remaining strength of the steel in the exposed section

Nt coNteN information about the whole pipeline length to be refurbished.

- Environmentally sensitive areas

taking into account the remaining wall thickness, pit depth

The position of the coating defect can be determined by above

- Areas of critical supply (e.g. hospitals, power stations)

measurements and pit locations.

11. Non-Destructive Testing inspection for Stress Corrosion

ground surveys (e.g. CIPS, DCVG or ACVG). This information

Cracking

is based on electrical measurements, but it does not directly

Some exploratory excavations are essential, not only to gather

give indications on the coating defect size, shape or existing

the above information but also to understand and work out the

12. Surface preparation and profiling if required

metal loss. A Priority Matrix will enable excavation locations

methods for different aspects of rehabilitation activities.

13. Application of a compatible repair coating 14. Backfilling and reinstatement

to be determined based on the criticality of the pipeline at

2014 SEPTEMBER 2 different locations. Reliance on only one survey technique may

Each excavation should be accompanied by records detailing

15. Retesting for coating defects

lead to false indications, for this reason it is prudent to carry

all findings to a pre-planned checklist (see appendix B

16. Re-energise the cathodic protection system

50 50

The use of adequate test methods and correct interpretation of the results from testing is paramount for obtaining an impression about long term performance and failure mechanisms.

2014

51 51

Priority 3: Small defects whose repair is not anticipated at

Diagnosis of the current coating state

actual status of the pipe to fulfill its functions and its fitness for

Coating assessment should be preceded by a preliminary

purpose. The combination of coating defects and inadequate

present but will need to be monitored in a revised

visual inspection with the aim to verify the extent and type of

cathodic protection increases the possibility of metal wall loss.

future monitoring program.

coating damage and whether it is to be considered beyond repair (widespread and deep cracks, detachments areas,

Point B determines the location of weak areas of pipe due

The main input to categorize defects is from DC Voltage

presence of water in the interface substrate/coating, roots,

to corrosion. In general the Cathodic Protection is often

Gradient surveys. DC Voltage Gradient surveys are performed

rock or foreign matter intrusion, modification due to the

inadequate and the coating shows loss of adhesion to the

to identify and provide data for characterizing the coating

soil characteristics or by chemicals, oil, solvents pollutants,

metal of the pipeline.

defects. CIPS surveys are potential monitoring surveys used to identify regions of CP under protection. Pipeline sections under

deformations, burned areas, etc.). This inspection should also determine the possibility and convenience for the coating

Point C indicates known problem areas

protection may indicate concentration of larger coating defects but can also be the result of other influencing factors such as

applied on operational piping to be adapted for actual use and the lay-down conditions with the application of extra

Information from points A, B and C form the basis for

inadequate CP interference, stray currents, foreign contacts

protection (composite materials, reinforcements, extra anti-rock

development of a Scope of Work for the rehabilitation program.

etc.

protection, etc.)

The available data is a major input for determining the rehabilitation of the pipeline and originates from the following:

Cathodic Protection Assessment for Rehabilitation

Repaired sections shall be subject to visual and holiday

• DCVG

Post rehabilitation Check

detection tests. Holiday detection tests shall be carried out at

• ACVG

The electrical characteristics can change after the pipeline has

the appropriate voltage levels for the applied coating.

• CIPS

been rehabilitated and due care shall be taken to ensure that

• Cathodic protection records

these do not have an adverse effect of the safety of persons

Even after the rehabilitation project has been completed, it is

• Soil resistivity surveys

and the cathodic protection systems.

possible that there will still be significant amounts of pipe in the

• Metal loss surveys

ground with the original coating. Therefore, there is a need to

• Leak history records

Personnel safety

understand the coating failure mechanisms to work out if these

•O perating records (e.g. products, temperature, existing and

Acceptable step and touch potential values are not universally

mechanisms can be managed to extend the life of the pipeline.

anticipated operating pressures) • Remaining pipeline life

agreed. A detailed explanation is not provided in this standard, and the relevant electrical safety standards should be consulted. Step potential is the voltage between the feet of a

The first step in any coating rehabilitation project is to scope the extent of the problems to be fixed. This involves gathering

Analysis of Survey Data

person (or animal) standing near an energised pipeline. The

data from a number of sources, in particular:

A comprehensive analysis to provide a prioritized Scope of

magnitude of the voltage is directly related to the proximity to

Work requires the analysis of data of several parameters, all of

power lines (buried or aerial), the soil resistivity, and the pipeline

which can influence the long term integrity of a pipeline.

coating conductance. If we assume that only the coating

Nt coNteN a. Inadequacies in the cathodic protection and the

conductance has changed due to the rehabilitation then it is

location and characterization of coating defects.

To analyze available data it is important that the following

possible that the soil voltage gradients can change and the

strategy be followed.

step potential exceed acceptable limits.

Located defects should be split into three categories of priority:

Touch potential is the voltage between the energized pipeline

These main sources of data are complementary.

Priority 1: Top priority defects for immediate repair

and the feet of a person in contact with the object. Typical

Point A determines the breakdown of the coating and areas of

Priority 2: Medium priority defects that will need repair

objects include valve stems and valve fences. If all other factors

inadequate cathodic protection, but gives no information of the

principally to make the cathodic protection effective.

remain unchanged, the rehabilitated coating can increase the

b. Identification of external metal loss areas where the pipe has been potentially weakened.

c. Known areas of previous pipe failure

2014 SEPTEMBER 2 52 52

a.c. voltage on the pipeline (since the high quality coating does not permit voltage discharge through the coating to the soil) and hence the touch voltage. Remedial measures are provided in the relevant standards but can include such things as: • Additional pipeline earthing via an a.c. discharge device • Gradient mats in the soil to reduce the gradients • Non-metallic or insulated controls on valves Cathodic protection Limit Once the pipeline coating has been rehabilitated it is possible that the current demand from the cathodic protection system can be significantly reduced. It is necessary, therefore, to adjust the cathodic protection system to ensure that there are no risks of exceeding the limit potential (i.e. the most negative potential acceptable – typically -1.2 volts (IR free)). The distribution of the current will be significantly better and areas that were previously not cathodically protected could now be protected. A comprehensive cathodic protection survey shall be carried out after the rehabilitation is complete and the cathodic protection adjusted to suit the new coating conditions. The use of coupons to verify the protection levels in the areas of rehabilitated coating should be considered. The Cathodic Protection system shall be checked to fulfill all requirements stated in: - ISO 15589-1:2015 Petroleum, petrochemical and natural gas industries -- Cathodic protection of pipeline systems -- Part

Nt 1: On-land pipelines

- EN-ISO 15589-2:2014 Petroleum, petrochemical and natural gas industries. Cathodic protection of pipeline transportation systems. Offshore pipelines

2014

Exploratory excavations can be carried out to maximize information about the whole pipeline length to be refurbished. 53 53

PDO Oman, pipeline rehabilitation and inspection

Appendix A Comprehensive documented information is required for each excavation. The information should include the reasons for the excavation, the details of the excavation and measurements and observations at the excavation. An example of an excavation report form is provided in this appendix. 1. General Information

Pipeline identification (name) Reason for excavation

e.g. priority matrix, visual leak evidence

Nominal outside diameter (mm) Year of installation Operating pressure

If known

Steel grade

If known

2. Excavation details

Date of excavation Location description

e.g. 25 m from road crossing

Latitude (WG 84 datum) Longitude (WG 84 datum) Altitude Soil description

e.g. clay, sand, rocky

Chainage (m) Pipeline depth (m)

Nt coNteN Weather conditions

2014 SEPTEMBER 2 54 54

3. Measurements and observations

Coating type

Appendix B: Pipeline excavation report

Coating defects visible

Pipeline name: ........................................................Sub sector : ................................................................................

Coating condition

e.g. good, poor, bad, non-existent

Defect number: ................................. Defect epicenter distance: ............................................................................. m Repair start: ................................m .......................Repair finish: ............................................................................. m Ground conditions: ............................................ Rocks present: ............................................................................... .

Photograph number before assessment

Soil resistivity: .............................................................. Ohm.cm CP potential: ON: ............ mV OFF: ........ mV ON at 90 degrees: ........................................................................... mV

Adhesion to pipeline

Wetness of soil at pi per depth: ............................. Salt present: ................................................................................

pH of liquid beneath coating

Coating type: ..............................................................................................................................................................

Primer present

Thickness: ... Liquid under coating:...................................... pH: ................................................................................

Pipeline outside diameter (m)

General appearance of excavated pipe: ......................................................................................................................

Pits present

Orientation of major defect around pipe: ..................................................................................................................... Cracks in coating: ........ Orientation: ............................................................................................................................

Visible cracks

Approximate size of coating fault: .sq. cm

Soil resistivity near pipe

Any obvious cause of coating fault: .............................................................................................................................

Soil pH near pipe

Calcareous deposits present: .Amount: .......................................................................................................................

Pipe-to-soil potential (ON)

Extent of any coating disbondment: ..................................................................................................................sq. cm Photographs taken on excavation: O . f coating damage: ..............................................................................................

4. Ultrasonic Measurements

Of surface films: O . f corrosion damage: ...................................... Give code numbers of photo's.

Grid size for Ultrasonic measurements

Adhesion of parent coating at top of pipe: ................ At bottom: ................................................................................

Schedule of ultrasonic measurements

Colour of films on steel surface: Black: ....................... Red rust: ................................................................................

Schedule of pit depth measurements

(Ignore white/grey calcareous deposits for above observations). Amount of coating to remove: ....m

5. Schedule of photographs

Description

File name(s)

Any corrosion of the steel pipe: .......................................... Size: .................................................................... sq. mm Pitting present: ......... Depth of pits: ...................................................................................................................... mm

Prior to excavation

Number of pits: ........ Colour of pits: ............................................................................................................................

Exposed pipe before inspection

Orientation around pipe circumference: ......................................................................................................................

Nt Coating examination

Orientation of major corrosion damage to axis of pipe: ..............

Coating removal

Check for Sulphate Reducing Bacteria: ............ SRB' s present: ................................................................................

Bare pipe

Ultrasonic measurement grid

Level of SRB activity: ..................... Any visual Stress Corrosion Cracks: ............Magn. Part. Result: ................................................................................ Replacement pipe fitted: .... Length: ......................................................................................................................... m

Coating surface preparation

New pipe coating: ........ Thickness: ...................................................................................................................... mm

Coating application

Holiday test result at 5 V per micron:...........................................................................................................................

Coating tests

Sand padding used ....................................................................................................................................................

2014 Backfilling

Site on departure

55 55

repair of damages to the external coating system Introduction The coating system is the primary barrier against external corrosion. The function of an external coating system is to

Nt coNteN separate the pipe from the surrounding (aggressive) soil.

For this reason, damage to the external coating should be avoided to the extent possible.

Damages may occur during plant application at the mill, during storage of the coated pipe, during transportation of the pipe to the work site, during construction of the pipeline, or even during operation.

2014 SEPTEMBER 2 56 56

Soil resistivity

operational, this can result in large scale disbonding of the

Corrosive soils where oxygen and water are present can lead to

coating.

external corrosion at damaged areas of the coating. Acidic soils, for example in forest areas, and polluted soils where aggressive

At the mill, all externally coated pipes are checked for coating

chemicals can be present are also examples of problematic soil

holidays by means of spark testing. The sparking voltage used

types.

is dependent on the coating type. A few examples can be given:

The conductivity of the soil also influences the possibility for

- asphalt – bitumen : 4,5 kV per mm layer thickness

corrosion to occur.

- polyethylene

: 25 kV

The lower the electrical resistance, the higher is the corrosiveness

- epoxy paints

: 6 V per μm

of the soil. The soil resistance (soil resistivity) is expressed in

- poly isobutylene

: 45KV for 2mm layer thickness

Ohm.cm or Ohm.m. All damaged areas found during spark testing must be repaired In general, a rough indication of the corrosiveness of the soil

before the pipes are transported to the work site.

compared to the soil resistivity is given in table 1.

Soil resistivity (Ohm.cm)

Corrosivity

< 2000

Very corrosive

2000 – 5000

Corrosive - very corrosive

5000 – 10.000

Moderate corrosive corrosive

> 10.000

not corrosive - moderate corrosive

Table 1: Relation between soil resistivity and corrosiveness of

During storage and transport (handling), damage of the external coating may occur. The maximum pile of the pipes during storage is important because too many layers of pipes may damage the external coating. Therefore the maximum number of pipes in a pile is a measure of the diameter of the pipe. Normally, this is mentioned in the internal standards of the company. For PE coated pipes, the following table could be used as a standard:

soils (rough indication) Soils with relative high soil resistivity can also be aggressive due to the presence of corrosive components (often salts).

2014

Damage during storage and transportation

Damage during the application of the external coating at the mill To avoid direct contact between the steel pipe and the surrounding soil, the pipeline is protected by the application of an external coating. The pre treatment of the steel surface (pickling, grit blasting and the application of the primer) is very important to achieve

Diameter (mm)

Maximum pile

75 – 150

200 – 250

300

400 – 450

500

600 – 750

900 – 1200

Table 4: Relation between diameter and the advised maximum pile of PE coated pipes

a good quality coating. A bad pre treatment may result in poor adhesion of the coating on to the steel. When the pipeline is 57 57

In the same way, the maximum pile of pipes during transport

protection test posts: in most cases the coating defect is related

could be regulated.

to poor recoating after applying the cathodic protection cables.

During storage and transport of the coated pipes, the influence

Damage during backfilling

of ultra violet sunlight (UV) should be avoided.

Damage may occur to the external coating during the backfill of the pipeline ditch.

During handling of the pipes, the external coating can easily be

Stones and other sharp objects in the backfill soil may damage

damaged by the use of cables, chains and the like.

the external coating even before the pipeline is operational. The use of fine grained sand at the bottom of the ditch is

Damage in the field during pipeline construction

recommended. Another possibility is to sift the original sand and

In the construction phase, a lot of human activities are taking

use this sifted sand in the ditch.

place around the pipeline. Pipeline and damage to the external coating can easily occur. Employees walking over the pipes,

Damage in the operating phase

construction tools falling on the coating, pipe laying in the ditch

When pipelines go into operation, they are expected to operate

are all possible culprits.

without problems for many years. Damage to the external coating may occur during this phase to due to many different

Coating application at the circumferential welds

causes:

Because a circumferential weld is present every 12 or 16 m in a pipeline, proper application of the coating system at the weld is

Mechanical damages

very important.

Mechanical damages may occur in many ways:

The pre-treatment of the steel surface at the factory coated

- Sharp objects may be pushed through the external coating

area around the weld should be performed according to the

-F armers with deep ploughs may damage the external coating

recommendations of the weld coating system supplier.

-C onstruction activities near the pipeline (changes in the Right

Poorly coated areas may lead to damage of the coating in the

of Way, tapping, etc), may damage the external coating

near future. The overlaps of the coating on to itself (wrapping

-A t times the exact location of the pipeline is fixed by using

systems) and the overlap onto the factory coating can be

a steel pin driven into the soil and this pin may the external

troublesome areas. In case of poor application, this may lead to

coating

disbondment in a short time. By spark testing of the weld area in the field, poor overlap at

Nt coNteN wrapping coating systems may not be detected!

Damage of the coating after the application of the cathodic protection cables

The removal of a small area of factory applied coating in

unavoidable when applying cathodic protection cables to the

steel surface. It is critical that this area is recoated in a proper

2014 SEPTEMBER 2 way. When performing a coating survey on a pipeline, many

indications of coating damage are detected around cathodic

58 58

Root ingrow into the external coating

becomes dissolved. Blistering occurs (influenced by the use of

the coating type, the adhesive properties of the primer and the

Asphalt bitumen is the only external coating which may suffer

cathodic protection) and then disbondment can take place on

resistance of the total system to disbondment.

from root ingrow.

a large scale.

In the space between the steel surface and the coating, water and other contaminants containing positive ions may

Roots from trees and deep rooting bushes can grow into and Cathodic Protection influence on coating quality

accumulate.

The application of cathodic protection also a negative influence

In the disbonded area sufficient current from the cathodic

Deterioration of the external coating

on the quality of the external coating:

protection system cannot be applied. As a consequence,

All types of external coating will suffer from deterioration. The

• Blistering

external corrosion is likely to occur. This process is referred to

process of deterioration however, is highly dependent on the

Applying too much cathodic protection current onto the pipe

as ‘Cathodic Shielding’ at the disbonded areas.

type of coating.

may lead to overprotection of the steel.

Asphalt bitumen coatings for example can deteriorate in a

This results in the production of hydrogen gas at the steel

period of 20-25 years. This process is accelerated in situations

surface.

where pipeline depths are at ground at water level.

With thin layer external coatings such as liquid epoxies and

through this coating onto the steel surface.

FBE, the production of hydrogen gas will result in blistering of The deterioration process often begins with the embrittlement

the coating and in time it will break down.

of the asphalt bitumen coating followed by the disbonding of

• Cathodic disbondment

the coating and the ingress of water in between the coating

Disbondment of the external coating may occur around a

and the steel. The primer of the factory applied external coating

coating defect. The extent of disbondment is dependent on

2014

59 59

Rehab Planning Nt coNteN Process 2 2014 SEPTEMBER 60 60

Perform in line inspection

Perform close interval survey

Bellhole examination

Meet criteria?

YES

Monitor annually

Wall loss? YES

Fails wall thickness requirements

YES Maintain operating pressure

YES Analyze options

Analyze options

Replace pipe

Repair pipe

2014

Recoat

Continuous CP Anodeflex

Verify results

Monitor annually

Economic evaluation

Field implementation

61 61

corrosion under insulation

Nt coNteN

2014 SEPTEMBER 2 62 62

Corrosion is the biggest enemy of metals. It occurs when metal reacts with oxygen and moisture under the influence of the temperature. If corrosion occurs under an insulation layer, it is difficult to detect and counteract. This â&#x20AC;&#x2DC;corrosion under insulationâ&#x20AC;&#x2122; (CUI) poses a serious threat to the stability of the metal. It becomes visible on the surface only once a critical stage has been reached. The insulation layer is not the cause of the corrosion. At most, it creates a space where oxygen and moisture can accumulate. In some cases the insulation layer intensifies the corrosion, for example when it is made of a material that absorbs a lot of moisture or when chlorides and acids leach out of the insulation layer. That gives rise to the question of how moisture gets under the insulation layer. Two causes can be identified. The first is when moisture seeps through small leakages in the watertight covering of the insulation layer. This gives rain, production water, steam or groundwater the chance to reach the metal surface. These leaks in most cases should have been prevented. They are often the result of poor design, poor fitting of the insulation, poor use of the material

or poor maintenance. Moisture under the insulation layer can also be caused by the forming of condensation. If the temperature of the metal surface is lower than the atmospheric dew point, condensation forms on the surface.

2014

63 63

Sabkha Area Osmosis with 3 year old Epoxy

Nt coNteN

2014 SEPTEMBER 2 Disbonded mainline coating

64 64

The possibility of Moisture under the insulation must be taken into account early during the design phase so that the appropriate type of insulation can be chosen. The corrosion process can be intensified by dirt. Here too, cracks in the insulation layer can result in the penetration of moisture. Chloride, acid and salt also pose special threats to the metal. substances are sometimes This possibility mustThese be taken into account as early aseven during the present indesign the insulation layer If the insulation type layerofcomes into can be of an item so itself. that the appropriate insulation contact with moisture,corrosion these subjects can leach out and corrode chosen.The process can be intensified by dirt. Here too, the underlying dirt concentration increases if theof moisture. cracksmetal. in theThe insulation layer can result in the sharply penetration moisture Chloride, evaporates when rises. Temperature is also acid andthe salttemperature pose a special threat to the metal. These a factor that contributes corrosion.even Although evaporation reduces substances are to sometimes present in the insulation layer itself. the duration of insulation contact between the moisture and with the metal, the If the layer comes into contact the moisture, these higher temperature intensifies theand corrosion. in turn reduces subjects can leach out corrodeThat the underlying metal.the The dirt metal’s lifeconcentration span. There is a good chance corrosion occurring at when increases sharply of if the moisture evaporates temperatures between -4°C (25°F) and 175°C a contributes lower the temperature rises. Temperature is (350°F). a factor At that to temperature the metal is protected against corrosion by the cold, corrosion. Although evaporation reduces the duration of contact at higher between temperatures the heat and keeps metal There are few the moisture thethe metal, thedry. higher temperature objects with a temperature that remain constantly below above life span. intensifies the corrosion. That in turn reduces theormetal’s the criticalThere point.isThis is because operation, a good chance of of variable corrosion occurringtemperature at temperatures variationsbetween in parts of the(25°F) objectand or different temperatures of parts -4°C 175°C (350°F). At a lower temperature connected to the object. Corrosion under insulation can occur the metal is protected against corrosion by the cold, atunder higher all types of insulation, but insulation where: temperatures theespecially heat keeps the metal dry. There are few objects with a temperature that remains constantly below or above the • the insulation contains salt leaches out; operation, temperature critical point. This is that because of variable • the insulation easily absorbs moisture penetrates of parts variations in parts of the object or or moisture different temperatures throughconnected the top layer; to the object. CUI can occur under all types of insulation, • the insulation contains foam containing but especially insulation where: remnant chloride and acid, which with moisture. • thereact insulation contains salt that leaches out; • the insulation easily absorbs moisture or moisture penetrates Insulation which absorbs thelayer; least moisture and dries the quickest through the top

offers the•lowest chance of corrosion occurring. Bear in mindchloride that and the insulation contains foam containing remnant cheaper insulation is notreact necessarily the most economical choice acid, which with moisture. viewed over the entire life cycle.

Insulation which absorbs the least moisture and dries the quickest offers the lowest chance of corrosion occurring. Bear in mind that cheaper insulation is not necessarily the most economical choice viewed over the entire life cycle.

2014

65 65

Rese

testing, in

earch,

nnovation

Philosophy of Testing

Testing Definition â&#x20AC;&#x201C; Is merely the physical or chemical procedure (or set of procedures) to determine some specific product properties. Evaluation (or grading) of test results is a very important adjunct to testing. Interpretation and use of the

Nt coNteN data will conclude the testing process.

Test methods are constantly being developed in varying degrees of sophistication. The ASTM, the Federal Test

Methods, NACE, ISO, FDA, EPA, and other organizations are probably the leaders in the development of test methods to provide reproducible results within prescribed limits.

2014 SEPTEMBER 2 68 68

Purpose of Testing

considered as a good one.

Service Life Prediction – Short term testing should provide information of the service

There is a tendency to develop new short-term test procedures

life of coatings for the wide range of environmental and

which could give better life prediction: reliability-based

operating conditions. However, outdoor long-term exposure

accelerated tests; tests to determine “times to failure” instead

tests and field tests have still remained traditional sources for

of “failure at given time” (survival theory).

obtaining estimates for service life prediction.

Specification Satisfaction Acceleration of degradation may be determined with various

– This is a very important objective of testing. A specification is

aging models (like Arrhenius Model). Knowledge of acceleration

nothing more than a purchase description which describes a

function along with cumulative probability distribution function

number of individual tests by which it is hoped that one can

of time to failure permits to predict coating service life.

predict the performance of the coatings in actual service. Unfortunately, some specs include unrealistic tests.

Comparison (Screening) –S creening is a comparative testing to select the best available coating for the given conditions. Coating

Failure Analysis – Failure analysis is successfully used to determine mode

manufacturers use this kind of testing to develop the

of failure, to correlate results of short-term and long-term

best formulations. Coating users employ this approach to

tests; to identify unknown coatings and their structure; to

distinguish differences between various coating system.

determine possible mechanism of protection and reasons

The need of this information is more easily understood

leading to failure.

when a coating selection must be made without the time

2014

are then ranked. If a ranking is similar, the accelerated test is

or opportunity to accumulate actual field experience. Such

Economical Concept of Testing

occasions may be the design of a new plant, or process,

Extensive testing program needs a great deal of effort, time

etc. Screening will give information which coating will give

and money, extensive number of chemicals, panels prepared

satisfactory relative performance and, just as important, will

and tested. Testing is expensive! Typical program to classify

indicate which coatings are unsuitable. It is very important to

coating system for Nuclear Industry (LOCA, Radiation,

design correctly the assessment testing criteria for screening

Decontamination, etc.) costs around $10,000. Slip Test for

testing program.

faying surfaces costs a few thousand dollars.

Prediction versus Comparison

Also, testing is time consuming! We cannot wait for

-T here is a contradiction between accelerated tests used

performance information for years. That is how accelerated

in industry and tests which can predict service life. Current

testing idea arrived. What is our price for acceleration?

accelerated aging tests were developed using the concept

Sometimes, very poor correlation with real life, misinterpretation

of a “comparison” test as opposed to “predictability” tests.

and misleading. If testing procedure is selected incorrectly,

In comparison tests various coating systems are subjected

this will do more than waste time and money. This may lead to

to the same accelerated and outdoor test environments. The

release unsuitable products.

coating systems in both the accelerated and outdoor tests 69 69

Reproducibility Several typical questions arise as result of testing: 1. Do the two series of measurements actually differ? 2. Is the difference in mean value statistically significant? 3. What is reproducibility of data? 4. Does the mean value obtained for a sample differ significantly from that of the population from which it was drawn? The answer may be obtained by use of statistics in testing. Such statistical methods as an analysis of variance, standard error of the mean, correlation analysis, etc. are becoming the very important part of each testing program. It is not enough to report only average of your testing data. You will be asked what is deviation of your mean (standard deviation). Another very important tool of testing is an experimental design. Benefits of statistical experimental design: significant increase of testing information with significant decrease of testing efforts (number of panels, materials, etc.) Testing Strategy Selection of the Right Tests â&#x20AC;&#x201C; Since the number and types of tests which can be used is exceedingly broad and diverse, the importance of proper test

Nt coNteN selection cannot be overemphasized. The following

important factors to be considered in the selection of test procedures for protective coatings:

A. How valid is the test? Are conditions selected for

testing (humidity, temperature, pressure, etc.) similar to those used in the field? For example, if coating

2014 SEPTEMBER 2 systems will work in water, how valid may be dry adhesion test versus wet adhesion test?

70 70

B. How important is the test?

Each testing panel consists of different areas: plane, edges,

C. A ll parameters involved in the specific test should be defined

scribe. Each area exhibits various types of degradation. How do

(coating and substrate thickness, application method, cure,

you evaluate correctly; what is the contribution of each area in

etc.)

the overall rating? What degradation factor is more important for the specific test and end-use outside application but not very

Standard Testing Package

important for underground pipe. Overall rating based on the

– t here is no “universal” coating as well as “universal” testing

weight factor is an acceptable way to solve this problem. Similar

method. The more realistic approach is to use set of testing

situation appears where we have to evaluate performance of

methods designed for each class of coatings and end

coatings exposed to test package. What is contribution of each

use. Examples of such sets are the various specifications.

specific test? The results of one specific test may weight more

Analysis of industry specifications and standards show that

heavily in the overall factor than another; under a different set of

many of them have some commonality by classifying those

conditions or use requirements, the relative importance of two

packages which are the keystones of any testing program.

different types of test could be different. And again, weighting

As usual, typical testing packages have been developed for

factor is a good solution for overall coating rating.

comparison testing. However, it is possible another design of testing packages based on the prediction theory. In this case,

Testing Data Retrieval

coating subjected to various tests consisted of various levels

– It is very important to represent the testing data obtained

of stresses. For example: salt fog test with various sodium

in a simple and easy-to-understand format that could be

chloride concentrations, and temperatures; humidity test at

successfully used by both, manufacturer and customer. SFL

various temperature and humidities.

Company developed the new Summary Report Format. Each report has compressed testing information covering

Grading and Interpretation of Testing Data

the most important performance characteristics. Next step

–G rading is an evaluation of coated panels exposed to different

in bringing our customers usable and accurate data that will

tests. There are many ASTM standard which describe the

help solve immediate problems concerning coatings selection

mode of coating degradation and the corresponding grading

is development of Product Performance Handbook., which is

procedures: rusting, blistering, chalking, cracking, erosion,

based on our summary reports.

etc. (refer to the failure chart in this manual). Some grading methods are quantitative (abrasion, gloss, Elcometer Adhesion, slip coefficient, water penetration, etc.); some qualitative

2014

Testing Methods

(blistering, rusting, cracking, chalking). All of those may be

Accelerated Weathering

rated on the basis of 10-point scale (10 – no failure; 0 – total

– Accelerated Weathering testers are widely used in industry.

failure). Grading by terms: “perfect”, “good”, “poor” is still very

They employ a variety of light sources to simulate sunlight and

popular although it is very suggestive. ASTM standard, which

the damage caused by sunlight. Most of them have humidity,

gave definitions what is perfect, good, very good, poor, etc.,

temperature and wetness control. They are commonly used to

may be very helpful in an effort to bring various points of view

characterize chalking, change in gloss, and change in color for

to the same scale. But grading is the first step in evaluation.

coating systems.

Next step is an interpretation of results.

71 71

'What does peel adhesion really mean? Is a high peel value the measure of a good anticorrosion coating?'

Nt coNteN

2014 SEPTEMBER 2 72 72

Over time it has become the most popular accelerated

Typical representatives of accelerated weathering testers are:

H. Immersion NACE Standard TM-01-74, Procedure

aging test because coating failures usually occur in a short

B) – Partial Immersion (2/3 to 3/4 of the coated area) in

time. Failures appear as undercutting at the scribe, rusting,

the corrosive medium at specified temperature. Volume-

Weather-Ometer with a Carbon Arc as a source of radiation.

and blistering. Reproducibility depends upon the following

to-surface ratio shall be 15 ml of test solution per square

Typical cycle: 102 minutes of light followed by 18 minutes of

variables that must be carefully controlled: uniformity of

inch of coating sample. Solution volume – 450-500 ml. Test

light and water spray.

the spray throughout the cabinet; angle of the panels;

Duration: 6 months. Typical test for tank lining.

A. Carbon Arc Weather-Ometer (ASTM G23) – Atlas

atomization pressure; humidity; pH; purity of salt solution; B. Xenon Arc Weather-Ometer (ASTM G26) – Atlas

condensate collection rate.

I. Hot Water Immersion

Weather-Ometer with Xenon Arc source of radiation. Typical cycle: 102 minutes of light followed by 18 minutes of light

B. W ater Fog Cabinet (ASTM D1735) – Atomized water at

and water spray. C. QUV (Florescent Ultraviolet and Condensation Apparatus, ASTM G53) – The following cycle is used

100°F. This test simulates indoors, high humidity or steam-

– Immersion testing is conducted on coatings that will be

laden atmosphere. The conditions in cabinet are favorable

subjected to immersion in service (tank lining, rail cars,

for water permeation, softening and swelling of coating.

storage tanks, etc.) Sometimes coatings are exposed

Failure appears as blistering, rusting, undercutting.

to various cargoes and the cumulative effect of various chemicals may be very dramatic. Coating film will absorb

(until others required): 8 hours UV at 50°C / 4 hours condensation at 60°C. UVB-313 or UVA-340 lamps are

C. Sulfuric Acid Fog Cabinet – Atomized 10% sulfuric acid

commonly used.

various chemicals to a degree characteristic for each generic

solution at ambient temperature. Simulates a wet, indoor

type of coating. Coating performance will depend upon

sulfuric acid atmosphere.

absorption and desorption of cargoes. The penetration of solution may be determined gravimetrically with absorption/

D. Correlation To Outside Weathering – Correlation depends on capacity of artificial light sources to simulate

J. Absorption / Description Method in Immersion Testing

D. A erated Brine Cabinet (Similar to ASTM D870) – Panels

sunlight. The graph illustrates the spectral energy

are partially immersed in a 5% synthetic sea salt solution

distribution as a function of the wavelength produced by

which is continuously aerated at ambient temperature.

a number of artificial light sources and compares these

Coatings are examined for blistering and corrosion.

desorption curves from which the diffusion coefficient is calculated. Physical Tests

energy outputs to terrestrial sunlight. The closer the energy distribution to sunlight, the more reliable and accurate

E. H igh Humidity Cabinet (ASTM D2247) – In this test,

Adhesion

the results of the experiment (Xenon Arc). QUV-B Lamp

specimens are exposed to 100% relative humidity at a

(formerly FS-40) emits larger amounts of shorter wave

100°F so that condensation forms on the test specimens.

industry. Since it is thought that corrosion does not proceed

lengths and causes samples to fail in shorter periods of

Mode of failure: blistering, rusting, undercutting.

to any extent as long as the coating adheres firmly to the substrate changes in the adhesion should relate to durability.

time, and often correlates less well than Xenon Arc Weather-

Nt Ometer.

– Adhesion tests are the most practical and popular in coating

F. Hydrochloric Acid Fume Cabinet – Mild (12% HCL) or

Adhesion depends upon many variables: environmental

strong (28% HCL) solution of hydrochloric acid is placed

conditions, coating and substrate thickness and their ratio,

Accelerated Corrosion Tests

in the cabinet and allowed to vaporize. Simulate a wet

cleanness of surface, surface profile, etc. Adhesion strength

– This group of accelerated testers is weekly used to test

hydrochloric acid atmosphere. As with the salt fog cabinet,

usually decreases when coatings are in a humid or wet

panels are evaluated for blistering, rusting, and undercutting.

environment and recovers to some extent after the coatings

coatings for corrosion protection.

A. Salt Fog Cabinet (ASTM B117) – Atomized 5% sodium

2014

chloride solution at 95°F. This test was originally designed to test the durability of coatings exposed to ocean spray.

are placed in a dry environment. The ability of coating to

G. Fresh Water Immersion (ASTM D870) – Panels are immersed in flowing tap water at ambient temperature.

maintain good adhesion properties under wet conditions is thought to be very important. There are several methods to evaluate adhesion. 73 73

Pull-Off or Tensile Method (ASTM D4541)

Impact Resistance (ASTM D2794)

water vapor passes through films of paint. The test specimen

– The most popular are the Elcometer and Pneumatic

– I s determined by a Gardner Impact Tester where a standard

(free film) is sealed to the open mouth of a cup or dish

Adhesion testers, where the adhesion strength is determined

weight is dropped on a test panel. A hemispherical steel

containing distilled water (Method A, wet cup method) or

by the force needed to remove the aluminum dolly glued to

indenter having a diameter of 0.5 inch is used. Impact

desiccant (Method B, dry cup method). The assembly is

the coating surface. Mode of failure is qualified in accordance

Resistance is reported as the number of inch-pounds

placed in a test chamber with a controlled atmosphere:

with the percent of adhesion and cohesive failures, and the

required to produce cracking or a delaminated diameter (at

Condition A, very low RH at 73°F; Condition B, 50% RH at

actual interfaces and layers involved.

specified impact load).

73°F; and Condition C, 90% RH at 100°F. The assembly is weighed at 24 hour intervals until successive readings reflect

Elcometer is fixed-aligning tester which measures tensile/

Flexibility (ASTM D522 or ASTM D1737)

a constant rate of moisture transfer through the film. The

shear adhesion; one error is introduced if the alignment is not

– I n the ASTM D522 the elongation of attached coatings is

weights are graphed against time which yields a line with a

normal to the surface. Pneumatic is self-aligning tester which

determined with conical mandrel apparatus. The panels are

slope equal to vapor loss for the test area in grams/day. From

measures pure tensile adhesion. Pneumatic tester is more

bent over a mandrel and the elongation is calculated from

this result several calculations can be made: Water Vapor

accurate and gives higher adhesion values.

the position (diameter) of the first visible cracking relative

Transmission (WVT); Permeability; Water Vapor Permeance

to the small end of the mandrel. In the ASTM D1737 the

(WVP).

Adhesion by Tape Test (ASTM D3359)

elongation is determined with cylindrical mandrel apparatus.

– Tape Tests are commonly used in the industry. They measure

The panels are bent over mandrels of various diameters. The

AC-Impedance

elongation is determined from the largest diameter mandrel

– The AC-Impedance technique is an electrochemical

peeling adhesion.

that produces visible cracking in coating. Method A – X-Cut Tape Test – is used for films with DFT equal or thicker than 5 mils. X-cut is made in the film to the substrate, pressure sensitive tape is applied over the cut and then removed, and adhesion is assessed qualitatively on the 0 (poor) to 5 (perfect) scale.

nondestructive method to evaluate corrosion rate and the protective properties of the coatings. This method hinges

Cathodic Disbondment (ASTM G8, ASTM G42, ASTM G95)

on the fact that electrochemical cell (coating-electrolyte-

– t his is an accelerated test for determining coating

model. By using AC-Impedance technique it is possible to

metallic substrate) can be represented by a purely electronic

performance when the system is under cathodic protection in

get information about corrosion rate beneath the coating and

an electrolyte (3% NaCL).

the penetration of water into the film. This information may be obtained without coating destruction. Electrochemical cell

Method B – Cross-Cut Tape Test – is used for films thinner The coating is artificially perforated before starting the test. The

consists of a working electrode (metallic substrate), platinum

electrical stress (voltage 1.5V) is produced by connecting the

auxiliary electrode and saturated calomel reference electrode.

test specimen to the negative terminal of a source of direct

Polarization resistance that is inversely proportional to

current and by connecting a platinum anode to the positive

corrosion rate and the capacitate associated with the water

terminal. Electrical instrumentation is provided for measuring

penetration were measured. Good correlation has been

Abrasion Resistance (ASTM D4060)

the current flowing in the cell. The electrical potential is also

found between AC-Impedance data and traditional tests (salt

– Is determined by the Taber Abrader Tester. Coated surface

measured. Test may be run at room or a constant elevated

fog, water fog).

than 5 mils. A lattice pattern with either 6 or 11 cuts in each direction is made in the film to the substrate, pressure sensitive tape is applied over the lattice and then removed, and adhesion is evaluated qualitative on a scale of zero to five.

Nt coNteN is abraded by rotating the panel under abrasive wheels.

temperature. Upon termination of test, the panels are evaluated

Abrasion resistance is calculated as loss in weight at a

for “zero” bond, reduced bond and total, using knife-adhesion

Internal Stresses

specified number of abrasion cycles, as loss in weight per

method.

– Internal Stresses in coatings play a very important role in

cycle, or as number of cycles required to remove a unit

their performance. Stresses arise in coatings as a result of

2014 SEPTEMBER 2 amount of coating thickness. Typical Conditions: CS-17 Abrasive Wheel; 1000 gram load; 1000 cycles.

74 74

Water Vapor Permeability (ASTM D1653)

–T his method covers the determination of the rate at which

their shrinkage or expansion, cross-linking, differences in

thermal expansion between coating and substrate. It has

2014

75 75

been shown that stresses depend upon temperature, humidity, water absorption, etc. If the internal stresses exceed the tensile strength of the film, cracks are formed. Also, stresses may reduce coating adhesion. Internal stresses may be determined quantitatively by two methods; strange gage method or cantilever method. Coatings are applied on one side of a flexible substrate. A coated panel will curve or bend due to forces exerted at the substrate-coating interface as a result of stress in the coating. The curvature (deflection) is measured under microscope (cantilever method) or by strain-gage. As elastic properties of substrate are known, the stress in coating can be calculated. It was shown that the coating adhesion varies inversely with the internal stresses. Both the internal stresses and adhesion for two-coat systems are dependent upon topcoat-to-primer DFT ratio. The high stress coating may be used in combination with properly selected low stress coating if applied at correct topcoat-to-primer DFT ratio. Internal stresses may be very dangerous and their knowledge can help to avoid some serious problems in coating performance. The stress profile of the coatings should be taken into consideration when selecting the components of coating system.

Cyclic Tests â&#x20AC;&#x201C; Although all weathering accelerated tests like WeatherOmeter or QUV have radiation and condensation cycles, light and darkness cycle, the tendency to use more sophisticated cycles for coatings testings with salt spray s

Nt coNteN a part of the cycle is becoming more popular. It is thought that cyclic tests may simulate the synergistic effects of

a wide variety of atmospheric and immersion corrosion conditions. Typical cycles: Alternate wetting and drying combined with solar radiation, periodic exposure to

chemicals, salt spray, alternate heating and quenching, freeze/thaw cycles, etc. Dynamic test conditions rather

2014 SEPTEMBER 2 than static are essential to best evaluate the performance of coatings. Recognition of this fundamental testing

76 76

2014

principle has led to the development of the innovative

Audysis) which is used to measure weight changes as a

test methods: KTA Envirotest (immersion in liquid; vapor

function of temperature and time. TGA provides information

phase; heat and UV); Prohesion Test (salt spray/drying);

about coating thermal stability, composition, decomposition

DOT Specifications (WOM/Salt Fog). Most of these tests

temperatures.

are relatively new and not standardized. SSPC is planning to conduct laboratory and field studies to evaluate the

TMA (Thermal Mechanical Analysis) is sued to measure

advantages of cyclic corrosion testing as performance

expansion, stress-strain relationship.

predictor. DMA (Dynamic Mechanical Analysis) measures mechanical Failure Analysis

properties under dynamic stress/strain load. This method

Purpose â&#x20AC;&#x201C; In order to improve coating systems it is

provides information about Tg, curing mechanism,

necessary to identify their failure. There are two reasons for

coefficient of thermal expansion, etc

failure: Natural failure expected as result of stresses during exposure under various conditions; failure as result of poor application (wrong DFT, contaminated surfaces, pinholes, porosity, etc.) In both cases the failure analysis may be very helpful. By using an advanced analytical equipment, it is possible to link changes in the coating microstructure to macrostructural performance changes; to identify components of coating; to identify surface contamination; to determine real thickness of various coatings, etc.

Thermal Analysis â&#x20AC;&#x201C;T hermal Analysis is a technique for characterizing materials by measuring and analyzing changes in their physical or chemical properties resulting from controlled and measured temperature changes. DSC (Differential Scanning Calorimetry), is most widely used for coating evaluations to measure the temperature and heat flows associated with transitions in materials as a function of time and temperature. Such measurements provide quantitative and qualitative information about endothermic or exothermic processes. DCS gives information about glass transition temperatures (Tg), heat of polymerization, degree of cure, etc. Another popular thermal analysis is TGA (Thermogravimetric 77 77

Laboratory Coating Testing Equipment Test Name

Procedure / Work Instruction #

Test Equipment

(Automotive) Abrasion Resistance (Scrape Abrasion)

Ford ES-AC3T-1A303-AA ISO 6722

(Automotive) Abrasion Resistance Sandpaper (Automotive) Accelerated Aging by Xenon Lamp or UV

Referenced Industry Standards

LEXWI-0034

outsourced

ES-T-329-A

Atlas Electrical Devices' Weather-O-Meter, Atlas UV-Con

ASTM G155, ASTM G154, ESB-M3G58-A, ESB-M3G59-A, Delphi M5725

(Automotive) Adhesive Solubility

ESB-M3G58-A, ESB-M3G59-A, ESBM3G32A

(Automotive) Bundling Performance, Env. Cycling

FRANWI-1361

Environmental Chamber

Ford ES-AC3T-1A303-AA, WSSM3G177B, SAE J2192

(Automotive) Bundling Performance, Heat Aging

FRANWI-1361

Oven

Ford ES-AC3T-1A303-AA SAE J2192

(Automotive) Bundling Performance, initial

FRANWI-1361

Ford ES-AC3T-1A303-AA

(Automotive) Bundling Performance, Material Compatibility

FRANWI-1361

Ford ES-AC3T-1A303-AA

(Automotive) Bundling Performance, Thermal Overload Thermal short-term ageing

FRANWI-1361

Nt coNteN Oven

(Automotive) Clip Retention

Ford ES-AC3T-1A303-AA BMW LV 312

WSS-M3G177B

(Automotive) Cold Flexibility

Environmental Chamber

Ford ES-AC3T-1A303-AA, SAE J2192, WSSM3G177B

Beckman AC Dielectric Strength Tester Model # PA7-502/102

ASTM D149, ASTM D69, ASTM D618, ASTM D1000

2014 SEPTEMBER 2 (Automotive) Dielectric Strength

78 78

LEXWI-0037

Test Name

Procedure / Work Instruction #

Test Equipment

(Automotive) Discoloration of Copper Rod

Referenced Industry Standards ASTM D69

(Automotive) Electrolytic Corrosion by the Wire Tensile Method

FRANWI-1363

MTS- Constant Rate of Extension Machine NA (CRE)

(Automotive) Flammability

LEXWI-0042

Shield/ Clamp/ Burner/Timer or combustion chamber

Ford ES-AC3T-1A303-AA ISO 3795, SAE J369-89 ASTM D568, FORD ESBM3G177A, ISO 3795, FMVSS302, ASTM D1000

Oven

Ford ES-AC3T-1A303-AA, SAE J2192, WSS-M99G172-A, ESBM3G177A, MSCH71-B (Type A), MSCH71-A (Type B)

Fog Test Chamber Haake Buchler Instrument Inc and Glossmeter

Ford ES-AC3T-1A303-AA SAE J1756

Automotive) Fluid Resistance (Automotive) Fogging

FRANWI-1348

((Automotive) Heat Aging

WSSM3G177B

(Automotive) Heat Resistance

MSCH69

(Automotive) High Temp Adhesion to Steel

ESBM3G32A

(Automotive) Indirect Measurement of Electrolytic Corrosion

LEXWI-0093

(Automotive) Migration Staining

Electrodes / Electrolytic Corrosion Box, DC voltage supply, multimeter, voltmeter

ASTM D 1000, PSTC-52

outsourced

FORD BU105-01

(Automotive) Moisture Permeability (Automotive) Mullen Burst

MS2929 LEXWI-0031

Model C Mullen Burst Tester

(Automotive) Noise Dampening

ASTM D774, ASTM D3786, ESBM3G32A Ford ES-AC3T-1A303-AA, BMW LV312-1

(Automotive) Odor Rating

RANWI-1353

(Automotive) Puncture Resistance

LEXWI-0077 and outsourced

Ford ES-AC3T-1A303-AA SAE J1351-93 MTS-Constant Rate of Extension Machine (CRE), test support platform, specimen holder, probe

ASTM D1000, ASTM D4833, Ford ESBM3G177A, MSCH71-B (Type A), MSCH71-A (Type B) Delphi EST329G

(Automotive) Reflectivity Properties

Delphi EST458

(Automotive) Tape compatibility

MSCH71-B (Type A), MSCH71-A (Type B)

(Automotive) Thermal Effectiveness Thermal Insulation

Ford ES-AC3T-1A303-AA SAE J2192

(Automotive) Water fastness of dye

ESBM3G58A, ESBM3G59A, ESBM3G32A

Nt (Automotive) Water Vapor Transmission Rate (WVTR)

Cups, humidity cabinet, balance

ASTM E96, ASTM D3833, FLTM-BU-1-1, PSTC-34

(Automotive) Water Vapor Transmission Rate (WVTR): MOCON Permatran 398

FRANWI-1379

PERMATRAN-W Model 398

ASTM E398

Application Testing: Box Sealing

LEXWI-0097

Environmental Chamber

Balance / Muffle Furnace

ASTM D5630

Brookfield Viscometer Synchro-lectric Model RVT

ASTM D2556

Ash Content

2014 Brookfield Viscometer

FRANWI-0798

79 79

Test Name

Procedure / Work Instruction #

Test Equipment

Referenced Industry Standards

Cantilever Bending Test

FRANWI-1342

Stiffness Tester

ASTM D1388, ASTM D5732

Differential Scanning Calorimetry (DSC), Crystallinity, Glass Transition Temperature

FRANWI-0772

TA Instruments DSC 2910 with cooling system (RCS), -40 to +400 °C

Durometer Hardness

FRANWI-1066

Shore Durometer Hardness Tester

ASTM D2240, ASTM D618

Dynamic Mechanical Analysis (DMA), Flow Properties as a function of shear rate, frequency, and temperature

FRANWI-0773, FRANWI-0777

TA Instruments AR 2000, TA Instruments ARES Rheometer RDA-III (2K STD), -100 to +300 °C

Hazemeter

FRANWI-0848

BYK Gardner haze-gard plus

ASTM Method D1003-92,ASTM Method D1044-90, Practice D618

Index of Refraction

FRANWI-1095

Abbe refractometer (Bausch and Lomb)

ASTM D 542

IR-Spectroscopy

FRANWI-0775

Perkin-Elmer Spectrum Two

Limiting Oxygen Index (LOI)

LEXWI-0029

JD Oxygen Index Flammability Tester with calibrated oxygen and nitrogen test gauges and Test Chimney

ASTM D2863, Manual

Optical Microscopy (with digital image acquisition and hot stage)

FRANWI-0779, FRANWI-0782, FRANWI-0771

Microscopes of various manufacturers

Oxidative-Induction Time of Polyolefins by Differential Scanning Calorimetry

FRANWI-0772

TA Instruments DSC 2910 with cooling system (RCS)

ASTM D3895

SEM (Scanning Electron Microscopy)

FRANWI-0778, FRANWI-0781

Amray Scanning Electron Microscope

Shear Adhesion, including Shear Adhesion Failure Temperature (SAFT)

FRANWI-0483

Rack or jig to hold panels, SAFT Oven

PSTC 107, ASTM 3654, ASTM 4498

Taber Abrasion Test

FRANWI-1374

Taber Abraser

ASTM D4060

Texture Analyzer

FRANWI-1197

TA.XT2 Texture Analyzer (5kg capacity, ASTM D2979 0.1 g sensitivity) from Texture Technologies

Thermogravimetric Analysis (TGA), Thermal Stability, Filler Content

FRANWI-0774

TA Instruments Thermogravimetric Analyzer 2950

Nt coNteN Volatile Content

FRANWI-0774

TA Instruments Thermogravimetric Analyzer 2950

ASTM D2369

Volume and Surface Resistivity

FRANWI-0391

High Voltage Supply (Keithly Model 240A), Electrometer (Keithly Model 610C)

ASTM D-257, ASTM D 374

Water PenetrationRate

FRANWI-1381

Cups, balance

PSTC-35, FLTM-BU-1-2, ASTM D3816

2014 SEPTEMBER 2 80 80

2014

81 81

For many years European countries have written National pipeline coating specifications e.g. Germany – DIN, France – AFNOR, UK – BSI etc. There have also been many company specifications, and in addition those produced by consultancies for specific projects. Over the last years there has been a definitive move to write European – CEN and ‘World’ - ISO standards. When the “Vienna Agreement” is applied this sometimes allows that the same document be used as a CEN and ISO standard, hence obviating the requirement for two similar documents. These CEN and ISO standards give every company, large or small, the opportunity to utilize modern pipeline coating standards. However, these CEN and ISO standards dictate minimum pipeline coating criteria, and can be lower in technical requirements than a corresponding company standard, and sometimes a National standard.

International standards and Nt coNteN specifications

2014 SEPTEMBER 2 82 82

2014

83 83

ISO 34-1, Rubber, vulcanized or thermoplastic — Determination of tear strength — Part 1: Trouser, angle and crescent test pieces ISO 37, Rubber, vulcanized or thermoplastic — Determination of tensile stress-strain properties ISO 62, Plastics — Determination of water absorption ISO 188, Rubber, vulcanized or thermoplastic — Accelerated ageing and heat resistance tests ISO 527-1, Plastics — Determination of tensile properties — Part 1: General principles ISO 527-2, Plastics — Determination of tensile properties — Part 2: Test conditions for moulding and extrusion plastics ISO 527-3, Plastics — Determination of tensile properties — Part 3: Test conditions for films and sheets ISO 868, Plastics and ebonite — Determination of indentation hardness by means of a durometer (Shore hardness) ISO 1431-1, Rubber, vulcanized or thermoplastic — Resistance to ozone cracking — Part 1: Static and dynamic strain testing

ISO 2178, Non-magnetic coatings on magnetic substrates — Measurement of coating thickness — Magnetic method

ISO 4625-1, Binders for paints and varnishes — Determination of softening point — Part 1: Ring-and-ball method

ISO 2781, Rubber, vulcanized or thermoplastic — Determination of density

ISO 5893, Rubber and plastics test equipment — Tensile, flexural and compression types (constant rate of traverse) — Specification

ISO 2808, Paints and varnishes — Determination of film thickness ISO 2811-1, Paints and varnishes — Determination of density — Part 1: Pyknometer method ISO 3251, Paints, varnishes and plastics — Determination of non-volatile-matter content ISO 3303-1, Rubber or plastics coated fabrics – Determination of bursting strength – Part 1: Steel-ball method ISO 3417, Rubber — Measurement of vulcanization characteristics with the oscillating disc curemeter ISO 3801, Textiles — Woven fabrics — Determination of mass per unit length and mass per unit area ISO 4591, Plastics — Film and sheeting — Determination of average thickness of a sample, and average thickness and yield of a roll, by gravimetric techniques (gravimetric thickness)

ISO 7619-1, Rubber, vulcanized or thermoplastic — Determination of indentation hardness - Part 1: Durometer method (Shore hardness) ISO 8501-1, Preparation of steel substrates before application of paints and related products — Visual assessment of surface cleanliness — Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings ISO 8501–3, Preparation of steel substrates before application of paints and related products. - Visual assessment of surface cleanliness – Part 3: Preparation grades of welds, edges and other areas with surface imperfections. ISO 8502-3, Preparation of steel substrates before application of paints and related products — Tests for the assessment of surface cleanliness — Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method)

ISO 8502-9, Preparation of steel substrates before application of paints and related products — Tests for the assessment of surface cleanliness — Part 9: Field method for conductometric determination of watersoluble salts ISO 8503-1, Preparation of steel substrates before application of paints and related products — Surface roughness characteristics of blast-cleaned steel substrates — Part 1: Specifications and definitions for ISO surface profile comparators for the assessment of abrasive blast-cleaned surfaces ISO 8503-2, Preparation of steel substrates before application of paints and related products — Surface roughness characteristics of blast-cleaned steel substrates — Part 2: Method for the grading of surface profile of abrasive blast-cleaned steel — Comparator procedure ISO 8503-4, Preparation of steel substrates before application of paints and related products — Surface roughness characteristics of blast-cleaned steel substrates — Part 4: Method for the calibration of ISO surface profile comparators and for the determination of surface profile — Stylus instrument procedure

Nt coNteN ISO 1523, Determination of flash point — Closed cup equilibrium method ISO 1817, Rubber, vulcanized — Determination of the effect of liquids

ISO 4593, Plastics — Film and sheeting — Determination of thickness by mechanical scanning ISO 4624, Paint and varnishes — Pull-off test for adhesion

ISO 8502-6, Preparation of steel substrates before application of paints and related products — Tests for the assessment of surface cleanliness — Part 6: Extraction of soluble contaminants for analysis — The Bresle method

ISO 8503-5, Preparation of steel substrates before application of paints and related products — Surface roughness characteristics of blast-cleaned steel substrates — Part 5: Replica tape method for the determination of the surface profile

2014 SEPTEMBER 2 84 84

ISO 8504-2, Preparation of steel substrates before application of paints and related products — Surface preparation methods — Part 2: Abrasive blast-cleaning ISO 8504-3, Preparation of steel substrates before application of paints and related products — Surface preparation methods — Part 3: Hand- and power-tool cleaning ISO 10474:2013, Steel and steel products — Inspection documents ISO 11124 (all parts), Preparation of steel substrates before application of paints and related products — Specifications for metallic blast-cleaning abrasives

ASTM D 92, Standard Test Method for Flash and Fire Points by Cleveland Open Cup Tester

ASTM D 2084, Standard Test Method for Rubber Property — Vulcanization Using Oscillating Disk Cure Meter

ISO 11357-6, Plastics — Differential scanning calorimetry (DSC) — Part 6: Determination of oxidation induction time (isothermal OIT) and oxidation induction temperature (dynamic OIT)

ASTM D 127, Standard Test Method for Drop Melting Point of Petroleum Wax, Including Petrolatum

ASTM D 4285, Standard Test Method for Indicating Oil or Water in Compressed Air

ISO 13623, Petroleum and natural gas industries — Pipeline transportation systems

ASTM D 149, Standard Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies

Determination of temperature and enthalpy of melting and crystallization

ISO 21809, Petroleum and natural gas industries — External coatings for buried submerged pipelines used in pipeline transportation systems — Part 1: Factory Applied Coatings

ASTM D 257, Standard Test Methods for DC Resistance or Conductance of Insulating Materials

ISO 11126 (all parts), Preparation of steel substrates before application of paints and related products — Specifications for nonmetallic blast-cleaning abrasives

Part 2: Fusion-bonded epoxy coatings

ASTM D 695, Standard Test Method for Compressive Properties of Rigid Plastics

Part 3: Fieldjoint Coatings (includes new chapter for ‘visco-elastic’coatings)

ASTM D 937, Standard Test Method for Cone Penetration of Petrolatum

ISO 11357-1, Plastics — Differential scanning calorimetry (DSC) — Part 1: General principles

Part 11: Rehabilitation Coatings

ASTM D 938, Standard Test Method for Congealing Point of Petroleum Waxes, Including Petrolatum

ISO 11357-2, Plastics — Differential scanning calorimetry (DSC) — Part 2: Determination of glass transition temperature and glass transition step height ISO 11357-3, Plastics — Differential scanning calorimetry (DSC) — Part 3:

ISO 80000-1:2009, Quantities and units — Part 1: General EN 10204:2004, Metallic products - Types of inspection documents ASTM D 70 [1], Standard Test Method for Density of Semi-Solid Bituminous Materials (Pycnometer Method)

ASTM D 4541, Standard Test Method for Pull-off Strength of Coatings Using Portable Adhesion Testers SSPC-SP1 [2], Surface preparation specification No.1 — Solvent cleaning SSPC CS 23.00, Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc and Their Alloys and Composites for the Corrosion Protection of Steel AWS C2.25/C2.25M [3], Specification for Thermal Spray Feedstock Solid and Composite Wire and Ceramic Rods

ASTM D 1141, Standard Practice for the Preparation of Substitute Ocean Water ASTM D 1321, Standard Test Method for Needle Penetration of Petroleum Waxes

[1] American Society for Testing and Materials, 100 Harbour Drive, West Conshohocken, PA 19428-2959, USA. [2] The Society for Protective Coatings, 40 24th Street, 6th Floor, Pittsburgh, PA 15222-4656, USA. [3] America Welding Society, 550 N.W. Le Jeune Road, Miami, Florida 33126, USA.

2014

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“Good specification writing can be described in two words: good communication”

Nt coNteN

2014 SEPTEMBER 2 86 86

Definition of a Specification

Types of Specifications

coated. This section also details the surface preparation and

By definition, a “specification” is a detailed precise presentation

There are three types of specifications: restricted, closed and

coating system for each item.

of a plan; a statement of legal particulars (as of contract terms).

open. This section of the specification should state the materials

A specification is a legal document.

Restricted Specification

(i.e., abrasive, coating, etc.) that will be used in the Coating

In the filed of engineering and construction, a specification is

Permits a choice of suppliers, usually three to four, for the

project. The materials can be described in three different ways:

that document which describes a particular scope of area or

bidder. This type of specification allows for competition among

by supplier, by generic type or by performance testing criteria.

work on a particular project. It is a description of exactly “what”

the suppliers.

When materials are described by the supplier, the specification designates the supplier(s) name and product that is the

is to be done, “how” is it to be done, and by “whom” is it to be done. If any of these questions are not answered in the

Closed Specification

utilized in the Coating project. When a supplier(s) is unknown,

specifications, misunderstandings and/or misinterpretations

Does not allow for “or equals”. A closed specification is often

the specification will state the generic type of material. If the

will arise. The purpose of a specification is to let bidders know

used when there is a special application, i.e., high temperature

supplier or generic type is unknown, a performance or testing

what is expected to reach your desired goal.

resistant coatings, or when personal experience tells you which

requirement is detailed in the specification for the material type.

product is best. Part 3

From the legal standpoint of a professional engineer, a specification is an integral part of the design project. All State

Open Specification

Execution

Boards in this country recognize specifications with the same

The most vague of the three types of specifications. An open

Delivery, storage, mixing, surface preparation, masking,

importance and validity as a design drawing. As an example

specification allows anyone to bid the job using any coatings

application of coating, touch-up staging and scaffolding are all

of the legality of a specification, the following are excerpts of

and coating system. An open bid often results in the low bid

facets of “EXECUTION”.

various state statutes on professional registration:

obtaining the contract – the work and products are often of

“State of New Jersey”

poor quality. Open specifications are often used in publicly

For surface preparation, the specification should describe

funded work.

the type of surface preparation to be utilized and the degree of cleanliness required for the surface to be coated. Industry

“…or “Licensed Professional Engineer and Land Surveyor”, as the case may be. Plans, specifications, plats, and reports

Items Included In A specification

standards from ISO, NACE and SSPC are generally referenced

issued by persons authorized under this chapter shall be

Part 1

to eliminate discrepancies in interpretation of the specification.

sealed with said seal, during the life of the licensee’s certificate,

General

but it shall be unlawful for anyone to stamp or seal any

this section includes the description or scope of work,

Masking details should be specified if there are concerns about

documents with said seal after the certificate of the licensee

exceptions and completion of prior work, job conditions (such

overspray on nameplates, flange faces, valve stems, rotating,

named thereon has expired or has been revoked, unless the

as allowable weather), required submittals, safety requirements,

sliding or wearing surfaces of pumps, engines, motors, etc.

certificate shall have been renewed or reissued.”

product delivery, etc.

The application of material section of the specification refers to

“State of Idaho”

Part 2

the method of coating application. Airless spray, conventional

“…issuance of a certificate or registration by the board shall…

Products or Materials

spray, roller or brushing are common methods of application.

and responsibilities of a registered professional engineer…

In agreement with the “type” of specification, this section

Statements regarding the scheduling of application, minimum

seal and signature shall be placed on allspecifications, reports,

will describe generally or specifically the required coating

delays after blast preparation, drying and cure times, number

plats, drawings, plans, design information and calculations,

materials. Quite often, a Paint Schedule will organize and group

and thickness of coats, etc. are critical items of information for

whenever presented to a client or any public or governmental

together the surfaces to be coated. The Coating schedule is

the contractor and the inspector.

agency.

an extension of the scope of work and lists the items to be

2014

87 87

Everything should be made as simple as possible, but not simpler

Nt coNteN - Albert Einstein -

2014 SEPTEMBER 2 88 88

The staging and scaffolding used for the Coating work should

this section of the specification to identify them and decide in

not be removed before the work has been accepted by the

advance how the work will be paid for.

inspector or owner. Part 8 Part 4

Guarantee

Workmanship

Every client would like to have the contractor guarantee his

the performance of work in a specification states the level

coating system “forever”. Nevertheless, a contractor will only

of quality, workmanship, performance, etc. expected in the

guarantee that which has been specified. If you choose to

implementation of the Coating project. Items of importance

issue an open “specification” you can expect FEW guarantees.

include, but are not limited to, protection of adjacent work, job

Remember: Quality contractors and quality coating systems

conditions, preparation, application and inspection.

will ensure your satisfaction and “guarantees” for many years.

Part 5

Steps to Writing Good Specifications

Special Requirements

1. D ecide what type of specification you intend to write – restricted, closed or open.

This section is reserved for the description of special conditions, performance requirements, and/or allowable deviations from general wording in the remainder of the

2. I dentify your scope of work and write yourself a checklist of the work items. It is best to jot down the specification-

specification.

related work items as the project design progresses. Don’t Part 6

go by memory – always refer to your project drawing, work

Cleaning

assignments, and bid package scope of work.

State your specific instructions and requirements for clean-up by the contractor. These conditions will vary depending on the

3. D ecide if your project has special needs and requirements

construction state of adjacent areas. Overspray may not be

such as acid-resistant coatings, high temperature

of concern in some construction areas: in other areas of “de-

applications, underground or submersion suitability, food

bottleneck” construction, overspray and paint spots may be

production compatibility, etc.

very objectionable. 4. S tart with a complete, unedited specification and check, Part 7

select, and condense the master until all inconsistencies,

Touch-up

multiple choices, and extraneous or non-related instructions

Touch-up Coating can fall into two categories. The first

have been removed.

Nt category would be touch-up work that was necessary through no fault of the Coating contractor. The second category of

5. W hen specific products are appropriate for your

touch-up may be required because the Coating contractor

specification, check with the vendor(s) for your particular

applied certain coatings in advance of the proposed schedule.

application, then identify the products by name, number,

If either of the above conditions may exist on your project, use

manufacturer’s address and telephone number.

2014

89 89

Nt coNteN

2014 SEPTEMBER 2 90 90

The Coatings Inspectorâ&#x20AC;&#x2122;s Role

2014

The coatings inspector is responsible for verifying that the coating work performed by the supplier is in accordance with the specifications and supplier procedures when procedures are required. The inspector must not only be familiar with the specifications and procedures, but must have a working knowledge of the points of inspection and the various instruments that must be used to verify these points.

91 91

Developing the Inspection Plan The Inspection Plan is the detailed instructions to the inspector. It covers all activities to be performed by the inspector and must contain detailed instructions for complying with specification requirements.

Step 1 – Pre-Surface Preparation Inspection and Testing This step contains the instructions to the inspector as how

Step 3 – Inspection and Acceptance of the Prepared

to examine or test the surface to determine if it’s acceptable

Surface

and meets specification requirements for the work to be performed.

After the production foreman has assured himself the surface has been prepared per the Specification requirements, the

The Inspection Plan must contain instructions to the inspector

inspector immediately performs the specified test on the

for reported non-conforming, or unacceptable conditions, and

surface. The tests for a steel surface are normally:

obtaining corrective action. It is not sufficient for the inspector to report the condition and walk away. In addition to the

Degree of Surface Cleanliness

Inspection Plan, there must be pre-established mechanism

Per visual comparison to SSPC Standard, or other previously

for correcting defects and unacceptable items reported by

established standards, and the number of readings per 100

the inspector, the inspector cannot function alone. Also, the

square feet of prepared surface.

Inspection Plan must contain adequate instructions for reinspection and acceptance of the surface after correction of

Surface Profile

the defect.

During the surface preparation inspection step, judgement calls by the inspector are extremely important. For example,

Step 2 – Surface Preparation

there are no known accurate tests for profile measurements.

After acceptance of the surface for surface preparation, the

Most tests are comparisons to a known profiled plate or disc

inspector must be instructed how to assure the Specification

or Testex Press-O-Coating replica tape. The replica tape is

requirements are compiled with for the surface preparation

measured with a spring micrometer, is about the size of a

step. The criteria to be addressed prior to start of surface

small adhesion bandage and consists of an emulsion Coating

preparation are, in part, as follows:

of microscopic bubbles attached to a mylar Coating backing. Replica tape is available in course of profile measurements up

Nt coNteN a. Air supply to be free of oil and water

to 2.5 mils and X-coarse for measurements between 2.5 mils

b. Relative humidity

and 4.5 mils. Also, the degree of surface cleanliness is also

c. Dew point temperature

a comparison to a visual standard, plus a word description given by the standard.

Once the above listed conditions have been complied with and actual surface preparation begun, the Inspection plan

The Inspection Plan must instruct the inspector to make

must instruct the inspector as to the frequency to repeat the

judgement calls as near as possible, however, the person

above listed tests. The conditions must remain within the

responsible for qualification of the inspector must assure

specified list throughout the surface preparation process.

himself that the inspector has adequate, and proven

2014 SEPTEMBER 2 92 92

2014

experience to make these calls. At this point, inadequate

In the Inspection Process, it is extremely important that

training and experience of the inspector can be extremely

defects that cannot be corrected by application of the

expensive.

remaining coats be separated from those that can be corrected.

Step 4 – Approval of the Prepared Surface After the surface has been adequately inspected,

Compliance with Repair Procedures

nonconforming areas should be marked with grease free chalk

Repair Procedures (the previously established procedures for

and corrective action taken to correct the nonconforming

the correction of defects in the coating Coating) are part of the

surface which must then be re-inspected. Approval of the

production procedure, however, it is the responsibility of the

surface for coating application is best given in the form of a

inspector to assure that the Procedures are complied with.

written memo, or signed form, specifying the area approved.

Therefore, instructions must be included for both in-process inspection and repair inspection.

Step 5 – Testing During Application of Coating Materials During the coating process, the Inspection Plan should

Acceptance of the Completed Primer Coating

instruct the inspector to confirm the following as a minimum:

The Inspection Plan must adequately instruct the inspector

a. The coating material being applied is the proper material.

to determine with minimum delay that all Acceptance Criteria for the prime coat have been met, and the steps to be

b. T he material remains within the manufacturer’s recommended shelf life for liquid curing coatings

taken in final approval of the Coating. Again as with surface preparation, approval is best given by written memo or signed form.

c. T emperature of the coating material, and the pot life at that temperature.

Final Acceptance of the Coating System The Inspection Plan must contain the final Acceptance Criteria

d. Materials are properly thinned and strained if required

for the system, which includes: a. The cure time of the applied liquid curing coating system

e. Application equipment is as specified. f. A mbient and surface conditions are within limits prior to start of coating and remain within limits throughout the process. g. T he applied Coating shows proper flow without sags and runs, and in the proper wet Coating thickness range for

prior to testing. b. The dry Coating thickness range and the methods to be utilized to confirm the thickness. c. The appearance of the system and the standard for comparison.

liquid curing coatings d. All other criteria specific for the system. Step 6 – Test Cured Coating, First or Prime Coat The Inspection Plan should instruct the inspector in the details of the necessary inspection method and the degree or frequency of those tests to confirm the Acceptance Criteria for the prime coat. 93 93

Personnel and Personnel Qualifications

is made by production personnel that a certain requirements

Inspection of important protective coating and lining operation

cannot be met, the field inspector must be the eyes of the

Testing Procedures

is essential. Poor planning and poorly qualified personnel can

technical specialist or the person making the final decision.

Written Testing Procedures are essential for two reasons: 1. They establish a uniform process, but no testing equipment

create tremendous added cots, and are even responsible for poor quality in some extreme instances. For this reason, we

It is extremely difficult to be totally objective, non-biased, not

is totally accurate. Each instrument or tool has an accuracy

look closely at the personnel involved.

over-demanding or under-demanding. The inspector who

range and the readings must be interpreted. Therefore,

attempts to add his feeling or gain recognition for himself as

experience is essential.

Administrator – (Reviews Specifications, develops and

a “hard” inspector is as poor as the inspector who allows

administers the Inspection Program). This person is the key

everything to pass because he is afraid he will hurt someone’s

to the effectiveness and efficiency of the Inspection Program.

feelings.

2. They assure uniform results when followed by various inspectors performing the same test.

Experience in the application and technical aspects of coatings and in the Inspection Process is essential. The administrator

The Inspection Process

The most practical and effective Inspection Plans limit the

must be able to visualize implementation of each steps of

The Inspection Process is simply carrying out the Inspection

use of instruments to only those essential for the test to be

the application and inspection processes as he studies the

Plan utilizing specific tests and test instruments to confirm the

performed. The instruments selected for testing should be the

Specification and formalizes the Inspection Program to comply

Acceptance Criteria for each phase of the work complied with.

most reliable and practical of those available.

with the Specification requirements.

If the Inspection Plan is adequately prepared, the Inspection Process becomes a rather routine procedure. Problems and

The key points of the inspection process are:

One well-qualified administrator can develop and administer

questions develop when a condition or circumstance is not

a. The adequacy and practical approach of the Inspection

Inspection Plans for several inspectors working under his

covered in the Inspection Plan.

Plan.

direction. However, if the administrator is not adequately qualified by training and experience, both the Inspection

A third factor affecting the Inspection Process, in addition

Program developed and the inspection personnel attempting

to adequacy of the Inspection Plan and qualifications and

to follow the instructions of the program suffer. An extremely

experience of the inspector, is the working relationship of

important quality of the administrator is his ability to evaluate

all parties involved. To produce an environment for the best

claims by production that certain requirements cannot be

working relationship, the production personnel should be

complied with, or Acceptance Criteria cannot be obtained.

informed of the details of the Inspection Plan. The job foreman should have a copy of the plan and should always be aware

Field Inspector – Although following an Inspection Plan

of exactly what the inspector is to test for and what the

developed and administered by another, the field inspection

Acceptance Criteria are.

b. The ability of the inspector to administer the Inspection Plan and deal with personalities involved at the same time. c. The adequacy of the Testing Procedures and the inspector’s abilities to conduct the tests to obtain practical data. d. Stop Work Authority of the inspector. e. The availability of practical Repair Procedures for correction of each defect detected by the inspector.

plays an important role. Above all, the field inspector must have

Nt coNteN common sense and the ability to reason and interpret. The

No inspector is perfect, yet the inspector's decision must

Inspection Process, even when following the best developed

rule, otherwise, the essential “Inspector Authority” does not

Inspection Plan, is never cookbook work.

exist. The inspector must have what is known as Stop Work

f. Proper instruments with adequate calibration for performing testing work.

Authority. Stop Work Authority gives the inspector authority

The field inspector must be able to communicate as the

to stop work when conditions are found to be out of the

middleman between who controls the Inspection Plan and

established limits, or when quality falls below acceptable

the foreman or superintendent responsible for the work. He is

standards. If the inspector utilizes his Stop Work Authority

the judge between the person who states, “the work is to be

and is overruled by higher authority, the inspector records

done this way,” and the person who replies, “it is absolutely

all events, conditions and the name and title of the person

impossible to perform the work that way.” Often when a claim

overruling him.

2014 SEPTEMBER 2 94 94

Inspection of important protective coating and lining operation is essential.

2014

95 95

Coating Selection and Recommendations Selection of a coating or coating system is an important step in a corrosion prevention program. There are many questions that must be answered before a cost-effective recommendation

Nt coNteN can be made. The purpose of this section is not to select a

coating system, but to provide some of the questions that need answers and why?

2014 SEPTEMBER 2 96 96

Goals

under insulation or fireproofing, salt spray, to total immersion.

Before one can determine what coating system to recommend,

Temperature cycling and thermal shock can also play a

you must establish what goal or goals are to be achieved.

significant role in selecting a coating system.

Limiting Parameters Many times, there are factors that will limit options in selecting a cost effective coating system. Some of these limitations are:

There are generally four main reasons for application of a

Substrate

• Is blast cleaning permitted?

coating system:

The selection of a coating system will vary depending on

• Application temperatures (Caribbean summer at 120°F or

the substrate and its condition. Is the substrate carbon steel,

Alberta, Canada where even summer evenings can drop to

• Protection of the capital investment

galvanized metal, stainless steel or other alloy, concrete, wood,

40°F)

• Beautification / Aesthetics

an existing coating or other material?

• Product Purity

In new steel fabrication, where blast cleaning is allowed, there

topcoated with epoxy or urethane. Moisture cured urethane

• Environmental Protection

is a wide range of coatings that can be chosen and applied.

requires humidity to cure.)

The selection of coatings that can be used on galvanized

• Relative humidity (inorganic zinc requires 50% RH if it will be

• Can spray application be used? (Many high performance

Protection of the equipment is usually the first and most

surfaces, concrete or stainless steel is somewhat limited.

coating are designed to be spray applied. Special thinners

obvious goal. Sometimes a particular color and gloss is

When the new coating is to be applied when blast cleaning is

may be required for other methods of application)

required. In the case of tank linings or components in a food

not permitted, perhaps in a field application, the selection of a

processing plant, the need to provide a surface that will

surface tolerant coating is necessary.

• What are the local VOC regulations? (These regulations vary around the world) • Transportation after coating (What environment will the

maintain product purity is essential. Increasingly, containment areas must be designed to prevent hazardous spills from

Sometimes, the most difficult situation is when the coating

coated products be shipped through to the job site?

reaching the environment.

system must be applied over an existing coating. Now the

Shipping damage and the ease of repair)

condition of the existing coating must be investigated. Is there

• Recoatability (Shop priming and field top-coating raises the

One must also determine what is an acceptable service life

corrosion, pitting, undercutting, delamination, etc.? Does the

concern of re-coat times. This situation can even pertain

for maintenance or replacement. How does this affect coating

existing coating have satisfactory adhesion to the substrate?

to shop applications when top-coats are delayed due to

system selection?

Does it have sufficient adhesion to the substrate to support the

processing schedules)

stresses of the new coating system? Does the existing system • On an offshore platform in the North Atlantic, there may only be 10 days a year that are suitable for Coating maintenance. • Perhaps the life cycle of the facility is limited

• Are there any requirements for FDA, NSF, etc?

contain water? What is the existing system and what will be compatible over it?

Summary

Even if one gets all the right answers to the questions, often a

The success of any coating system is based on a well-

test patch is required. Many tests may be required to get the

investigated recommendation.

answers.

Nt Now that the goals have been established, we can begin to

Set goals or expectations.

identify the exposure, substrate, history, limiting conditions and

History

Know what the exposure is, in detail.

where the coating system will be applied.

If there was an existing coating system, what was it? How long

Determine the substrate and its condition.

has it been in service and was it satisfactory? If the original

Investigate case histories.

system worked, recommend it again if it is still available.

Identify the limiting parameters.

and environment the coating must resist. This can range

What systems have been successfully used by others?

Last but not least, stay current with the latest technology. It

from internal of a building, general weather, high humidity,

Join and participate in industry organizations. Read trade

changes ... and fast.

high temperature, chemical fumes, chemical splash and spill,

publications. They can provide great insight.

Exposure

The next step in coating selection is to determine the exposure

2014

97 97

In-Service Pipeline Rehabilitation

Liquid epoxies are applied withairless systems to a final nominalproduct thickness requirement of500 microns. Photos courtesy of the authors

Argentina has a large, high-pressure pipeline system that transports natural gasfrom production wells to its main cities. The primary trunk pipelines of thissystem are mainly 24 in., 30 in., and 36 in. in diameter; more than 30 years old,and coated with asphalt materials that have severely degraded over time. Importantly,there are no alternative lines to transport the gas, so these old pipelines cannot be takenout of service during rehabilitation. To minimize the impact of possible leaks and blowouts that would lead to supplyinterruptions, an aggressive rehabilitation plan using various techniques was developed. Different methods were used to identify the areas to be repairedâ&#x20AC;&#x201D;in-line inspectionsusing smart pigs (ILI), external and internal corrosion defects direct assessments (ECDA,ICDA), bell hole inspections, and hydraulic tests, among others. Once the defects havebeen detected and repairs have been completed, it is necessary to

Nt coNteN develop a step-by-steprehabilitation plan to prevent the generation of

new corrosion defects and toimprove the installed cathodic protection

current distribution.This article describes the experience gathered between 1996 and 2003 by TGS (Trans-portadora de Gas del Sur S.A.) from the

rehabilitation of the Argentinean transportationpipelines using cold-applied

polyethylene tapes for recoating. The different elementsused in this analysis are described, including determination of the areas to be repaired,type

2014 SEPTEMBER 2 of materials to be used, application performance, operating conditions, excavationsize, and practical test methods. 98 98

Background on Rehabilitation Programs

pipeline has to be analyzed to verify if, at the actual corrosion

1992, when Argentina’s natural gas transportation and

levelsof the pipes, an effective repair method can be used. At

distribution networks wereprivatized, it became necessary

least two situations can befound. In the first, the rehabilitation

to develop an effective program to evaluate systemsand

process requires replacement of short sections ofthe pipeline.

techniques for upgrading eachnetwork. TGS used high-

In the second situation, rather than replacing a large number

resolutionintelligent pigs to inspect over6,000 km of its primary

of short sec-tions, whole sections are replaced to limit overall

trunk trans-portation network (lines with diam-eters of 24 in.,

shutdown costs. Therefore, within therehabilitation tasks,

30 in. and 36 in.).Simultaneously, an aggressive reha-bilitation

pipeline replacement must be considered before analyzing any

plan was implemented tominimize the possibility of cata-

re-coating operation. Although there are basic costs structures

strophic failures in the primary gastransportation pipelines.

associated with newpipeline construction, installation costs

This planconsisted of replacing 356 km ofpipelines, installing

are generally increased up to 100% by replacingshort sections

935 pipe rein-forcements, recoating 300 km ofpipelines, and

(1,000 to 2,000 m). Therefore, the location of the short sections

upgrading cathodicprotection systems by installing135 new

and thecorresponding tie-ins must be analyzed thoroughly to

rectifiers.

minimize the associated costs,even if the decision of replacing an undamagedpipe section has yet to be made.

The stages of defining the optimum coating scheme for the pipeline rehabilitation andthe operational and safety restrictions

Performance of the Cathodic Protection System: Once the

for excavation of the lines included the follow-ing.

pipe sections have been replaced, thedistribution of the

• Determining the areas to be recoated

cathodic protection currentsmust be analyzed to avoid over

• Determining the safe rehabilitation operating pressure

protecting thenew coating. The current may need to be re-

• Analyzing the operating conditions of the areas to be repaired

duced in new sections but increased in the oldsections.

• Determining the coating type to be used

This situation leads to a separate, de-tailed evaluation of the

• Evaluating the application costs

damaged pipe sectionslocated between two new sections. To

• Conducting final tests

properlyrehabilitate them, it is necessary to install insu-lating joints and to balance the cathodic protec-tion current input

Developing the Rehabilitation Plan Determining the Areas To Be Recoated

accordingly.

2014

The first issue a gas pipeline operator must address when rehabilitating a pipeline iswhether to recoat or replace pipe. TGS used the following factors to make this determi-nation. •Remaining expected lifetime of the pipeline•Performance of the cathodic protection system•New construction and recoating costs•Operational costs related to replacement vs. recoating/repair•Climate conditions and restrictions associated with each taskRemaining Lifetime of the Pipeline:When a rehabilitation project is evaluated, the over-all integrity of the

Operational Cost vs Coating Type Pressure Reduction 5% 99 99

New Construction and Recoating Costs:

to be recoated while taking into account companyassets

Once theinitial evaluation has been done, a technical and

process are avail-able, including the following.

economic evaluation of the alternatives—recoating vs. pipe

• In-line inspection with smart pigs (ILI)

replacement—must be car-ried out. To define the costs

• Cathodic Protection Data Manager (CPDM)

related to the pipe replacement, the following topics should

• Corrosion rates analysis

beconsidered.

• Risk analysis

preservation, worker safety, and environmental care.Presently, many important methods to support the decision making

• Cost of the new pipe • Cost of laying the new pipeline

It is necessary to combine the results of several of these

•O perational costs related to the gastransportation shutdown

methods to optimize the ef-fectiveness of the assessment.

during the tie-in operations •E nvironmental impact, caused by the natural gas venting process, on thenearby pop-ulation, vegetation, and wildlife

The quality of the pipeline coating is visually verified

This task is done by using a common database that runsunder a GIS platform.With the support of this analysis, it is possible to identify thecritical areas that have a high concentration

•C ustomer impact

of external corrosiondefects (the main reason for pipeline

In our case, the evaluation of the cost of materials and

failures in Argentina). It isalso possible to identify areas for high

labor had already defined theconvenience of performing the

demand of cathodic pro-tection current (linked to low quality

rehabilitation process because the costs of purchasingand

and severely damaged coat-ings) and also to consider highly

laying a new pipeline are three times higher than such

populated areas and areas witha high environmental impact

rehabilitation.

and sensitivity.

Operational Costs Related to Replacement vs. Recoating/Repair:

Determining the Secure Rehabilitation Operating PressureBecause the operating restrictions do not allow the lines to betaken out of service,determining the secure

From the point of view ofthe operation of the gas transportation

operating pressurevalues becomes necessary to perform

system, the analysis is much more complex be-cause the

rehabilitation. To reach suchan objective, a remaining defects

operational costs increase both as a function of the pressure

analysis is done on the pipelineto determine the failure

reduction rateand the number of days involved in completing

pressure. Generally, these defects havefailure pressures over

the different tasks. There is a limit atwhich it becomes more

the maximum operating pressures (MAOP)because the limiting

convenient to replace the pipeline rather than recoat it.As

factors on the operating pressure are repairedimmediately.

will be shown later in this article, when considering cases

Nevertheless, it may be necessary to reduce the pressure

like the natural gas trans-portation network in Argentina, it

in accordance with theassociated risks for this type of task.

is very important to keep the flow reduction to theminimum

Consequently, many different internal procedureshave been

and to achieve the shortest possible rehabilitation times.

established in different companies to set different reduced

One of the challenges to consider during the design stage

values for therehabilitation operating pressures, according to

of a rehabilitation plan isto clearly identify the priority areas

International Standards.

Nt coNteN

2014 SEPTEMBER 2 100 100

2014

The thickness, adhesion, and electrical continuity of the coating is electrically verified.

101 101

Analyzing the Operating Conditions of the Areas To Be

Use of the DCVG test, which accurately determines the

Repaired

position and dimension of a coating failure.

Given the pipeline operational limitations discussed above, once the area to be rehabil-itated is determined, the operational possibilities for the programmed tasks must beanalyzed. For such analysis, the following factors must be considered. • Proximity to the compression stations • Existence of parallel sections (pipeline loops) • Proximity of customers’ lines • Proximity of producers’ lines Generally, the areas to be repaired are associated with the discharge side of the com-pressing stations because the higher operating temperatures increase the degradationprocess of the asphalt coatings. In some cases, it is necessary to take the compressionstation itself out of service to reduce the pressure, which has a very negative impact inthe transportation flow. It is possible to minimize this impact if pipeline loops are avail-able at the compression station discharge.To minimize these situations, certain periods of the year, known in the industry as“operating windows,” are selected. In these periods, the demand goes down for climaticreasons or because big consumers, such as thermo electrical plants, are temporarily outof service.Because of the important growth in natural gas demand in Argentina in recent years,it has become more difficult to find these kind of “windows,” making it even morecritical to reduce the duration of the rehabilitation time.The complex situation described above is exacerbated by the way the rehabilitationtasks have to be performed. Because the line is working under a

Nt coNteN reduced pressure (gen-erally 5% of the operating value), the

size of the excavation trenches must be reducedaccordingly to preserve the pipeline from additional stress. The working

methodologythat has been analyzed and implemented is based

on the executionof 25-meter-long trenches, leaving 20 meters of the terrain withoutexecution in the between. This methodology

requires moving theequipment in two directions: the first stage in

2014 SEPTEMBER 2 thedirection of flow,and afterwards, when the job is completed, in the opposite direction,digging the areas that had been used 102

as the pipeline’s support in thefirst stage.Given this problematic

from dust and insects, should be added to thislist. It must also

working system, it is essential to minimizethe execution time

be kept in mind that in the Patagonia Region, winds of about

and to select a coating system that optimizes theapplication

100 km/hare very common, making it very difficult to achieve

time.Determining the Coating Type To Be UsedA wide range of

a quality recoating standard, evenwhen wind-breaks are used.

coating materials is available on the market, but onlya few of

Under optimal ambient conditions on 30 in.-diameter pipe,

these have the characteristics necessary to achieve thedesired

production speeds ofabout 200 linear meters per day can be

application speed and the required quality level.The weather

achieved, with an average production rate ofabout 150 meters

must be factored into the working conditions.In Argentina,

per day. During application, other problems may appear from

all kinds of soils and weather conditions can be found,from

time to time, such as obstructionof the spray gun tips, which

semi-desert conditions with strong winds in Patagonia (south-

lead to additional delays in the job’s completion.

ern region), to high humidity and low depth phreatic layers in meetthe overall requirements included the following types.

Cold-Applied Plastic Laminated Tapes:

• Liquid epoxies

The coating scheme consists ofan inner corrosion protection

• Liquid polyurethanes

tape (6 in.- to 9 in.-wide rolls, 0.63 mmin thickness), spiral wrap

•C old-applied plastic laminated tapes

applied with enough tension, and a mini-mum 1 in. overlap

thePampas (central region). A short list of possible coatings that

over its corresponding primer.Over the inner tape, an external

Liquid Epoxies and Polyurethanes Coatings:

mechanical protection tape (6 in.-to 9 in.-wide rolls, 0.63 mm

Liquid epoxies (Fig. 1) and polyurethanes areapplied with airless

mechanical tape should start with its mid-widthplaced over the

systems to a final nominal product thickness requirement of

corrosion protection tape overlap. To achieve athicker outer

500microns.For our particular rehabilitation tasks, the following

wrap for rocky back fill areas, the overlap can beincreased to

series of restrictions were ana-lyzed for the application process.

50%.When temperatures are low, the tape rolls may need to

• Average relative ambient humidity (RH) over 85%

be warmedto improve application and to increase the process

• Average ambient temperature of 10 C, or below

speed.Before applying the tapes, the weld beads are protected

• Pipeline temperature of 3 degrees C over dew point

with a dif-ferent manually applied tape (4 in. wide x 25 m long x

•P ipeline temperature above 10 CIf there are interruptions to

0.75 mm thick).In those areas presenting generalized corrosion

2014

in thickness) is also spiral wrap appliedwith enough tension, again with a minimum 1 in. overlap. The be-ginning wrap of this

the recoating process, the sand- or grit-blasted pipes couldbe

or deep pitting, amastic adhesive is also applied to regularize

coated following the guidelines below.

the steel surface.Patching and repairs can also be done using

• If RH is over 80%, within 2 hours

a manually appliedtape (rolls 9 in. wide x 25 m long x 0.75 mm

• If RH is between 70 and 80%, within 3 hours

thick).

• If RH is equal or below 70%, within 4 hours If, after blast cleaning, the pipe has not been recoated within these periods, then itmust be re-blasted to meet surface preparation standards.Other restrictions, like contamination 103

Evaluation of the Application Costs

will have to fulfill the corresponding TGStechnical specification

Currently, the advantages or disadvantages of using cold-

we define the voltage values used for the holiday detectiontests

applied tapes for recoatingoperations are under discussion. This

performed on the different applied coatings.Once a selection has

discussion is based mainly on previous experi-ences with old

been rehabilitated, the quality of the coating application is veri-fied

pipelines coated with this type of material, where several cracks

using a DCVG (direct current voltage gradient). Using this method,

werecaused by stress corrosion (SCC). In Argentina, it was found

it is possible todetermine if any coating coverage failures or other

that the detected SCC phe-nomenon is not linked to cold-applied

hidden defects affecting the integrityof the applied coating are

tapes coated pipelines but rather to asphalt coat-ings. In general,

verified. These coating coverage problems include too littleoverlap

this phenomenon is linked to the overlap area. Below, we have

when applying the tape; metal/steel parts exposed to the soil;

detailed thetests performed to the applied system to verify the

and coating break-down during the back filling operations due to

quality of the final coating.Using tape coating, it is possible to

stones, tree branches, or any other sim-ilar penetrating elements).

execute a daily average of about 300 meters perday on a 30 in.-

The DCVG test (Fig. 5) enables us to accurately determine the

diameter pipeline, which leads to very important improvements

position and dimensionof any coating failure, thus allowing

from anoperational point of view. Considering a pressure reduction

immediate patching or repair of the damaged areas.

for each span or section of the isolated pipeline so that it conforms to the rehabilitation inspection plan.In the following chart,

of 5% of the operation pressure and a daily averageof 150 meters per day for liquid coatings, Fig. 2 shows the costs of the transportationflow reductions, for each type of recoating material. As an alternative solution, resources could be doubled to reduce the duration of therehabilitation task. In the case of rehabilitating a 30-inch-diameter, 30-kilometer-long pipeline using a liq-uid epoxy coating that requires a pressure reduction of 20% due to the concentration offailures, the cost to achieve the same economical performance as the tape coating wouldbe USD 16.02 per inch x linear meter, which is higher than a new pipeline cost of USD14.00 per inch x linear meter.Comparing both graphs, we can deduce that the additional cost to achieve the sameduration of the job practically duplicates the value of the rehabilitation operation.

Conclusions • I n cases where both application rates of at least 200 meters per day and operationpressure reductions under 15% are possible, in-service pipeline rehabilitation is morecost effective than pipe replacement.•For single-line natural gas transportation systems, the operational costs related to pressure reductions play the most significant role when the rehabilitation tasks areplanned. •T he productivity of the coating application plays a critical role in selecting the mosteffective type of coating; otherwise, recoating costs could compare negatively to pipereplacement costs. •T he ambient conditions in the rehabilitation areas are critical

Nt coNteN Final Tests/Verification of the Applied Coating

The quality of the coating is visually (Fig. 3) and electrically verified (Fig. 4). The thick-ness, adhesion, and dielectrical continuity

(holiday detection) are checked, together withall the necessary

parameters to be con-sidered in the coating selection process.

•L ong-term rehabilitation plans that prove to be more cost effective than pipe re-placement should be continuously

generated to maximize the product flow and main-tain maximum operating pressure of the transportation system at all times.

Editor’s Note: This article is based on a presentation given at the 16thPipeline ProtectionConference, Cyprus 2005,

2014 SEPTEMBER 2 tests, to confirm that the coating has been effectively applied

and hasoptimum quality.If an electric isolation test is required, it

104 104

and is published in the proceedings. It is re-published here withpermission of the organizers, the BHR Group.

About the Authors Osvaldo Dâ&#x20AC;&#x2122;Albuquerque, a coatings, corrosion, and cathodic protection specialist, is theregional manager for the Latin America Covalence Adhesives Corrosion ProtectionGroup, as well as a Junior Scientist at the R&D Centre Armed Forces-Argentina. He beganhis career with Raychem Corp. in 1981, where he held various positions, including op-erations manager and logistics manager. A NACE member, he received a degree in in-dustrial engineering from the University of Buenos Aires.

Sergio Rio is a natural gas pipeline integrity specialist with the Pipeline Integrity Department of Transportadora de Gas del Sur S.A., Argentina. A NACE and ASME member,he has been working in the pipeline industry since 1985. He received a degree in mechanicalengineering from La Plata University.

2014

105 105

Coatings and Cathodic Disbondment The True Story Erik Broesder, stopaq B.v., the Netherlands, provides an evaluation of coating ageing tests in relation to cathodic disbondment results for underground pipelines.

Abstract: Damage to pipe coating is almost unavoidable during

coatings” often reveal disbondment to a certain extent. Contrary

testing followed by peel-testing. Results obtained with cathodic

transportation and construction and damage or holidays in pipe

to this, Properly formulated visco-elastic polymer coating

disbondment testing do not make much sense if over time the

coatings may expose the pipe to possible corrosion. Cathodic

systems do not show any disbondment at all, due to the unique

coating spontaneously disbonds because of the coating’s ageing

protection systems are installed to act as a back-up for coating

self-healing effect of small defects.

processes. Stopaq visco-elastic coating systems have proved not to

imperfections. However, cathodic protection systems interact

Nt coNteN with the coating by chemical and physical phenomena, which

Testing for cathodic disbondment is always done on newly

be vulnerable to ageing in Hot Water Immersion tests; values

can lead to cathodic disbondment of the coating. Corrosion

applied coatings and are only tested for a short period of time,

obtained with peel testing after Hot Water Immersion at Tmax +

may occur underneath the disbonded coating, which is a risk for

e.g. 30 days. Lifetime expectancy of pipelines however are much

20°C for 100 days were similar to values obtained with non-aged

pipeline owners.

longer, typically 30 years or more. During its operating lifetime a

test specimens and the self-healing effect - a typical property of

coating will age and lose essential properties such as adhesive

Stopaq coating systems – still completed within the expected

strength. This can be simulated by Hot Water Immersion

period of time.

Testing for cathodic disbondment of all types of “conventional

2014 SEPTEMBER 2 106 106

2014

Introduction Oil and gas transport pipelines are mostly constructed of carbon steel, which mainly consists of iron. This is by far the favourite material for these kind of pipelines, because it has many advantages over other types of materials. However, carbon steel is vulnerable to several types corrosion, caused by all kind of influences from the environment and the product being transported. 107 107

Research at Stopaqâ&#x20AC;&#x2122;s R&D centre continuously leads to new products and applications.

Nt coNteN

2014 SEPTEMBER 2 108 108

Steel pipelines - Prevention of corrosion

Breaks or holidays in pipe coatings may expose the pipe

Testing of cathodic disbondment

The most common type of iron corrosion is atmospheric

to possible corrosion, since after a pipe has been installed

For testing of resistance to cathodic disbondment, a few dozen

corrosion. This is an electrochemical process in which a few

underground, the surrounding earth will be more or less

different standards are available, see e.g. NACE paper no. 07022

dozens of chemical reactions have been identified (1). In these

moisture-bearing and it constitutes an effective electrolyte, which

. They are published by several institutes all over the world, e.g.

reactions two other molecules are involved: water and oxygen.

will allow the transportation of ions. This is where the cathodic

ASTM (2), (4), (5), (6), CEN (Europe) (7), CSA (8), ISO (9), (10),

protection systems comes into action; it acts like a back-up for

and many others. Furthermore, several standards are modified

coating imperfections.

by oil and gas companies for specific applications.

To prevent corrosion, different types of measures can be taken. The two most used measures are:

Selecting an appropriate standard depends on a lot of variables.

1) Coating of the steel substrate and

Interaction of coatings and CP

They mainly differ in applied potential, temperature, electrolyte

2) Cathodic protection (with underground pipelines); these are

The CP-current causes several chemical reactions to occur at

used, dimension of the artificial damage, test duration, and - of

often used in combination with each other. But how does this

the bare steel. These chemical reactions can affect the properties

course – specific circumstances in the field. Besides that, many

all work?

of the coating surrounding the coating defect. The major

of the standards available are used to compare coatings mutually

chemical reaction is:

but do not state requirements on maximum allowed cathodic

The function of the coating is to prevent corrosion. This can only be achieved by preventing water and oxygen from reaching

disbondment. Contrary to this, ISO 21809-3 and EN 12068 2 H2O + 2 e -

2 OH- + H2(g)

the steel substrate. When these molecules are not present,

list requirements for several types of coatings. Furthermore, selecting an appropriate standard implies considerations about

corrosion of iron cannot happen. To achieve this the coatings

This chemical reaction causes interaction with the coating:

several aspects, e.g. :

should be impermeable for water and oxygen. Special attention

1) Formation of hydrogen gas bubbles near or under the edge of

− most of the standards have a test duration varying between

should also be given to the application of the coating. Improper application may leave parts of the steel surface uncovered and

the coating causing lifting of the coating, and 2) Formation of hydroxyl-ions causing leaching of the coating

when water and oxygen can reach the steel, e.g. through voids

and/or adhesive of the coating, thereby changing properties of

in the coating, corrosion will occur.

the coating that are essential for proper adhesion to steel.

Cathodic protection is a method in which the potential of

28 and 90 days. However, life expectancy of most pipelines in operation is longer than that; 30 years is rather short, examples of 50 years or even 70 years are known. − ASTM-G8 quote: “the test methods are intended for use with samples of coated pipe taken from commercial production.”

a system is forced towards less corrosive values, thereby

Over time this will lead to disbondment of the coating to a certain

Laboratory tests should thus be done on pipes as used at

reducing or preventing the electrochemical corrosion reactions

extent, which is called cathodic disbondment. The disbonded

construction site and not on laboratory samples like flat panels

from occurring. This is often accomplished by applying current

coating will act as an electrically insulating shield on top of

of steel…

from an external electrical power source (impressed current) or

the steel underneath and this part of the steel surface is not

sometimes by using a sacrificial anode.

protected by the CP-current because the current cannot reach

holidays may not result in corrosion.” What are we testing for

the steel; this is called cathodic shielding. Soils and electrolytes

then... Corrosion is a risk, disbondment is not…

Nt Coating defects and CP

can enter the void between the disbonded coating and the steel

Damage to pipe coating is almost unavoidable during

and may cause corrosion underneath the disbonded coating.

transportation and construction (2) due to the often heavy loads

− ASTM-G8 quote: “all dielectric type coatings now in common use will disbond to some degree.” Choosing an alternative coating may not solve the problem then. However, Stopaq is

involved, machinery and equipment used, and - sometimes

Corrosion is a risk for pipeline owners; they like to minimize risks

- bad handling and installation practices in the field. Some of

and, if any, like to have the risks “in control”. Therefore it is of

the coating defects encountered are poor surface cleaning,

major importance that they know to what extent a coating is

inclusions in the coating, poor application, mechanical damages,

resistant to cathodic disbondment.

2014

− ASTM-G8 quote: “Apparently loosened coating and cathodic

different…

damages caused by soil loading, and loss of adhesion over time (3).

109 109

Tests are carried out according to the selected test method, which prescribes 1) the scope, 2) significance and use, 3) apparatus used, 4) type of reagents, 5) materials used, 6) test specimen including dimensions and preparation, 7) the test method and 8) reporting. The aqueous chlorine molecules will diffuse towards the cathode, where another In all tests an artificial damage is made in the coating all the

chemical reaction will occur:

way to the bare steel; the dimension of this defect depends on

2 OH- + Cl2(aq)

ClO-+ Cl- + H2O

the standard used. The bare steel in the damage is brought into contact with the electrolyte, either by immersing the test

Chlorine and hypochlorite-ions are known for their oxidative properties towards

specimen into the electrolyte or by attaching a cell containing

various kinds of organic materials. Most coating materials contain a significant

the electrolyte over the damaged spot. An inert counter

percentage of organic materials and contact with these oxidizing agents may

electrode (anode) and a reference electrode are also immersed

lead to deterioration and loss of essential properties of the coating, thereby

in the electrolyte. The test specimen and the counter

worsening the results of cathodic disbondment testing. In real practice, the

electrode are connected to an adjustable power supply. The

anode of a cathodic protection system is placed far away from the object to be

power supply is switched on and adjusted until the potential

protected, often at least a few hundreds of meters. It is therefore very unlikely

measured between the reference electrode and the test

that the generated chlorine molecules will diffuse towards damaged spots on

specimen reaches the required value. Adjusting of the applied

the pipe; deterioration of the coating by chlorine/hypochlorite is also unlikely to

potential must be done frequently and the current must be

happen in real practice. Nevertheless, it can be assumed that results obtained

recorded also. Note that ISO 21809-3 recommends the use

with test methods using chloride salt solutions differ from situations with cathodic

of a potentiostat, such equipment being capable of controlling

disbondment in practice.

the applied voltage continuously and recording the current at

The test is terminated after the prescribed period of time. The test specimen

specified intervals.

is then disconnected and disbondment of the coating is visually inspected by

Immediately after switching on the power supply, chemical

making radial cuts in the coating surrounding the damaged spot, followed by

reactions will occur. At the damaged spot of the test

gentle lifting of the coating. The area of disbondment is measured and recorded.

Nt coNteN specimen, the same reaction takes place as in cathodic protection:

2 H2O + 2 e-

Requirements for maximum allowed disbondment as stated in e.g. ISO 21809-3

2 OH- + H2(g)

At the anode two counter reactions will occur:

2014 SEPTEMBER 2 2 H2O + 2 Cl110 110

4 e- + 4 H+ + O2(g)

2 e- + Cl2(aq)

varies per type of coating, e.g. hot applied bituminous tapes and petrolatum tapes ≤ 20 mm, polymeric tapes ≤ 15 mm, PE-backed heat shrinkable coating without primer (type 2A-1) ≤ 10 mm, , liquid epoxy ≤ 8 mm, liquid polyurethanes ≤ 8 mm, and elastomeric coatings ≤ 7 mm. 6. Stopaq Coating Systems Stopaq coating systems consist of at least two layers with different functions. The first layer is a corrosion preventing material that is applied directly onto the bare steel of the object to be coated, e.g. Stopaq Wrappingband (various types). The second layer is a flexible mechanical protective material applied on top of Stopaq Wrappingband, e.g. Stopaq High Impact Shield or Stopaq Outerwrap (various types). This material is applied with tension, thereby generating some pressure on the layer of Stopaq Wrappingband. Stopaq Wrappingband is based on pure polyisobutene, which has properties that are beneficial in coating applications: − Polyisobutene (and the Wrappingband compound made thereof) is a liquid with high viscosity and glass transition temperature of -67°C, giving it cold-flow properties, beneficial for 100% coverage of bare steel surfaces. − Very low permeability for water and oxygen; beneficial for preventing corrosion reactions of iron. − No reactive chemical groups; resulting in excellent chemical resistance and supreme resistance to ageing and weathering. − Adhesion by van der Waals-forces; resulting in excellent adhesion to various types of substrates like steel, PE, PP, FBE and others. Due to this, surface preparation is less critical than with all types of other coatings.

2014

111 111

also. Inspection after termination of the test shows cathodic

− PE tape with pressure sensitive adhesive (unknown type) tested

disbondment is 0 mm or - actually - a negative figure since the

@ 60°C: after 60 days 80% of adhesion / peel force was left

compound has covered the area of the initial defect also.

and after 120 days only 40% of adhesion / peel force was left.

Therefore, Stopaq coating systems distinguish in a positive way from “conventional coatings”. The result of cathodic disbondment

A test specimen coated with a Stopaq coating system

testing is 0 mm, caused by occurrence of self-healing effect.

comprising Wrappingband CZH and Outerwrap PVC was also

subjected to Hot Water Immersion testing. It was aged for 100

Ageing of coatings

days @ 90°C (=Tmax + 20°C) and subsequently adhesion / peel

All coatings are vulnerable to ageing, caused by a variety of

force was tested. The obtained value was the same as found

influences such as thermal stress (fluctuations in operational

with non-aged samples: 100%! Furthermore, occurrence of self-

temperatures), mechanical stress (vibrations), exposure to

healing was tested also after Hot Water Immersion 100 days @

ambient conditions (wet / dry cycles, freeze / thaw cycles). The

90°C. This was completed within the expected period of time for

effects caused are changes in compositions and loss of essential

this coating system.

properties. Conclusion: coating ageing related to cathodic Standards are available for evaluation of coating properties after

disbondment

ageing (9). A method that is often used is adhesion testing after

Coatings are subjected to Cathodic Disbondment tests to

Hot Water Immersion. A test specimen is placed in water for a

evaluate the risks for pipeline owners. These tests are often

determined period of time at an elevated temperature, often at

conducted with new applied coatings and the duration of such

or above maximum service temperature of the coating. After

tests is far less than the life expectancy of a pipeline. All coatings

this ageing period the adhesion is tested using an appropriate

are vulnerable to ageing and Hot Water Immersion testing is a

method.

way to simulate the behavior of coatings over time. However, results obtained with cathodic disbondment testing do not make

Results in cathodic disbondment testing of Stopaq coating

It is a well-known fact that with testing of several types of coating,

much sense if over time the coating spontaneously disbonds by

systems as described above differ significantly from “conventional

adhesion properties will have deteriorated significantly after Hot

ageing processes.

coatings”. In execution of the test, an artificial defect is made

Water Immersion testing (11). Below are some examples of peel

in the coating system. Due to the liquid nature of the Stopaq

test values, compared to initial values of non-aged samples

Stopaq coating systems comprising Wrappingband and a flexible

Wrappingband compound and the compressing action of the

(100%):

mechanical protective layer distinguish in a positive way from

flexible mechanical protective layer on top of it, self-healing of the

− FBE coating (unknown type) tested @ 95°C: after 60 days only

conventional types of coating. Cathodic disbondment of such

Nt coNteN defect will occur. The liquid-like compound of Wrappingband is

40% of adhesion / peel force was left and after 120 days only

coating systems is 0 mm, caused by the self-healing effect. After

pushed towards the defect, thereby sealing the opening within

29% of adhesion / peel force was left.

Hot Water Immersion test of 100 days at 90°C the adhesion

a short period of time. Completion of the self-healing effect

− 3 layer Heat Shrinkable Sleeve (unknown type) tested @ 80°C:

depends on temperature; at a temperature of 20°C self-healing of

after 60 days adhesion / peel force had increased to 124% was

a coating system comprising Wrappingband CZH and Outerwrap

left, but after 120 days only 56% of adhesion / peel force was

PVC takes less than a day, but at 70°C it is completed within an

left.

hour. After completion, the current consumed in the cathodic

− 2LPE pipeline coating (unknown type) tested @ 60°C: after 60

properties are not influenced and the self-healing effect is still present.

2014 SEPTEMBER 2 disbondment test will drop to zero, the chemical reactions

days the coating had fallen off (0% left) and same result was

will stop and the cathodic disbondment process is ceased

found after 120 days.

112 112

Literature 1. Roberge, Pierre R. Corrosion Basics - An Introduction (2nd ed.). Houston, Texas, USA : NACE International, 2006. 2. ASTM G8 - 96. Standard Test Methods for Cathodic Disbondment of Pipeline Coatings. West Conshohocken, PA, USA : ASTM International, 2003. 3. Argent, Dr. Colin, et al., et al. Macaw's Pipeline defects. Newcastle upon Tyne, UK : Yellow Pencil Marketing Co. Ltd., 2003. ISBN 0-9544295-0-8. 4. ASTM G42 - 96. Standard Test Method for Cathodic Disbonding of Pipeline Coatings Subjected to Elevated Temperatures. West Conshohocken, PA, USA : 2003. 5. ASTM G80 - 07. Standard Test Method for Specific Cathodic Disbonding of Pipeline Coatings. West

How a novel idea from Holland wraps the coating world permanently (above and below the water line)

Conshohocken, PA, USA : ASTM International, 2007. 6. ASTM G95 - 07. Standard Test Method for Cathodic Disbondment Test of Pipeline Coatings (Attached Cell Method). West Conshohocken, PA, USA : 2007. 7. CEN - European Committee for Standardization. EN 12068. Cathodic protection - External organic coatings for the protection of buried or immersed steel pipelines used in conjunction with cathodic protection - Tapes and shrinkable materials. Brussels, Belgium : 1998. 8. CSA - Canadian Standards Association. CSA 245.20 06. External fusion bond epoxy coating for steel pipe / External polyethylene coating for pipe. Mississauga, ON, Canada : 2006. 9. ISO 21809-3. Petroleum and natural gas industries -

Nt External coatings for buried or submerged pipelines used in pipeline transportation systems - Part 3: Field joint coatings. Geneva, Switzerland : 2008.

10. ISO 15711. Paints and varnishes - Determination of

resistance to cathodic disbonding of coatings exposed to sea water. Geneva, Switzerland : 2005.

11. Totte, D. Hot water immersion â&#x20AC;&#x201C; predicting long term

2014 coating performance. Vienna pipeline coatings conference 2010. [Presentation]. 2010.

113

Combating corrosion in india Seal For Life Industries, part of Berry Plastics Corporation

history which brings confidence to the Owner to select and

USA, is a Global company in the oil, gas and water markets

use the product to protect critical sections of their buried

for providing state of art products and solutions for combating

infrastructure.

corrosion on on-shore and off-shore pipelines. Seal For Life Industries own the following well known brands ANODEFLEX–

Seal For Life Industries been present in India for last 30 years

Polymeric long line impressed current flexible anode systems,

and has built a reputation of reliable partner for supplying,

STOPAQ – Self healing visco-elastic pipeline coating system,

upgrading and developing new products / solutions for

POLYKEN – cold applied tape coating systems, COVALENCE

combating soil side corrosion on critical segments of buried

– heat shrinkable coating systems and POWERCRETE –

on-shore, off-shore pipelines, above ground storage tanks,

liquid epoxy coating systems. Over the years, these products

LPG mounded bullets, buried vessels and plant piping in

have been used on global pipelines in the harshest climates

petrochemical plant and refineries. Seal For Life Industries

/ terrains and have set standards for the Industry. Each

products have been used on many projects in India which are

Nt coNteN

2014 SEPTEMBER 2 Brand has a unique position in the Industry and has a strong

114 114

unique and one its kind in the world.

The various brands of Seal For Life Industries in use for various applications in India are as follows:

Covalence

Introduced in early 1980’s

Girth Weld Joint Coating systems:

- Three layer radiation cross-linked radiation linked heat shrinkable girth weld field joint coating systems for Three layer Polyethylene, Polypropylene and Dual layer fusion bonded coated on-shore pipelines:

HTLP-80, HTLP-PP, DIRAX (for HDD) - Two layer radiation cross-linked radiation linked heat shrinkable girth weld field joint coating systems for Coal tar enamel, Three layer polyethylene, Polypropylene Concrete weight coated off-shore pipelines` with PU infill:

WPC65M, WPC100M, PPS120 Long radius bends coating systems: HTLP80 Sealing systems for cased crossings:

Wrap around fiber glass reinforced heat shrinkable casing end seals to accommodate a range of casing pipes for a particular carrier pipe:

CSEM-F Main Line Polyethylene and Polypropylene coating repair systems:

High performance heat activated permanent repair system for all type of damages during extrusion in the coating plant and transportation and laying:

PERP80 Patch system and PE melt sticks, PERP-PP Patch system and PP melt sticks

Anodeflex

Introduced in mid 1990’s

Long line Impressed current flexible anode systems:

Conductive polymer & MMO long line anodes with pre-packed coke breeze for protecting external surfaces of above ground storage tanks, LPG mounded bullets and plant piping.

Anodeflex-1500 & Anodelex-3000

Polyken

Introduced in late 1990’s

Cold applied primer based butyl rubber with polyethylene backing pipe coating systems:

In-situ rehabilitation coating systems and coating of plant piping / fire water piping for new infrastructure. The coating system is primer activated cold applied three layer butyl rubber based inner anti corrosion tape followed by two layer butyl rubber adhesive polyethylene tape.

942/955

Powercrete

Spray & brush applied novolac based high build liquid epoxy coating systems:

Nt Introduced in early 2000’s

External liquid epoxy based high performance coating systems for coating of irregular shaped buried infrastructure – valves, fittings, tees in compressor stations & terminals, coating of skin effect tubing for skin effect heated and insulated high temperature crude & high viscosity product pipelines including insulated station piping, bends and field joints.

R-95 & R150

Stopaq

Cold applied non-crosslinked,non-crystalline visco-elastic polymer based pipe coating systems::

State of the art new-generation coating systems for transmission pipelines, CNG city gas distribution pipelines, plant piping, field joints, rehabilitation of buried on-shore / off-shore pipelines, coating of irregular shaped buried infrastructure – valves, tees, flanges, casing filling compounds and sealing of chime area of tank bottoms

2014

Stopaq-CZH and associated systems 115 115

massive growth pipeline network India

India Energy Overview: India has a geographical area of 3.29 million square kilometers and has a population of 1200 million. To meet the energy demand of this huge population, a large network of natural gas, crude, product, LPG pipelines have been laid in the last 35 years. The share of natural gas in the countryâ&#x20AC;&#x2122;s primary energy mix is approximately 8 to10%. This share is quite low as compared to the global average of 24%, primarily due to the supply-side constraints. Indiaâ&#x20AC;&#x2122;s consumption of natural gas was around 50 billion cubic meter in 2013, which accounts for approximately only 2% of the world natural gas market. However to maintain future growth, Government of India has identified - Natural Gas as one the major fuel in the energy basket and hence the natural gas pipeline network is set to expand tremendously in the coming years. Further, Government of India to control pollution level in the country has embarked on an ambitious plan of operating public transport on CNG (compressed natural gas) and bringing to highly populated cities piped natural gas for domestic sector cooking and heating / cooling applications and hence coming years are also going to witness an explosive growth of pipe steel / plastic network in cities.

Nt coNteN

2014 SEPTEMBER 2 116 116

Overview of growth in transmission pipeline network in the last 10 years in India has been as follows:

Length in Kms. Type of Pipeline

2005

2006

2007

2008

2009

2010

2011

2012

2013

Crude (Onshore)

4587

5764

5790

6141

6834

6977

8986

Crude (Offshore)

477

681

702

722

727

799

Gas (Onshore)

5506

5634

6232

7042

8606

9907

10448

11751

13111

Gas (Offshore)

882

1095

1100

1222

1374

1467

Product (On shore)

8939

10160

11391

12759

12985

13211

13564

14038

Grand Total

20391

22157

25188

26166

29602

31921

32831

36494

38401

Comparison of overall & per-capita Oil & Gas consumption of India versus other emerging economies BRIC Countries in FY 2012 are as follows:

BRIC Countries

Oil

Natural Gas

Brazil

125.6

26.2

Russia

147.5

374.6

India

171.6

49.5

China

483.7

129.5

Brazil

649.9

135.8

Russia

1039.1

2639.5

India

144.9

41.4

Per-capita Oil & Gas Consumption (Kg oil equivalent)

Nt China

361.2

96.7

The above table shows that India is way behind the other BRIC countries in per-capita consumption of oil and gas and as India progresses in economic development, consumption of oil & gas will increase rapidly resulting in a massive growth of the pipeline network in India including trans-national on-shore / off-shore gas pipelines from various countries â&#x20AC;&#x201C; Turkmenistan, Bangladesh, Myanmar, Oman etc

2014

117 117

Seal For Life Industries India

Covalence Field Joint Coating Systems: The long journey of Seal For Life Industries in India started in 1980’s when India embarked on building a gas pipeline grid for transmission of gas coming from Off-shore Bombay High. Construction of 1750 Km long 18”~36” diameter HBJ pipeline by a Consortium of International and Indian contractors led by Spie-Capag, France, Toyo Engineering and Nippon Kokko Japan commenced in 1986 and was commissioned in 1990. This pipeline starts from Hazira in Gujarat to Bijapur in Madhya Pardesh. and Jagdishpur in Uttar Pardesh. It carries 18 million cubic metres of gas everyday to three power houses at Kawas (Gujarat), Anta (Rajasthan) and Auraiya (Uttar Pardesh.) and to six fertilizer plants at Bijapur, Sawai Madhopur,Jagdishpur, Shahjahanpur, Aonla and Babrala. Each of the fertilizer plants produces 1,350 tonnes of ammonia per day. The construction of this pipeline was a unique engineering feat and was completed at an estimated cost of over 560 million US$. The pipeline passes through 343.7 km long rocky area, 56.3 km long forest area, besides crossing 29 railway crossings and 75 big and small rivers. The HBJ pipeline is three layer polyethylene coated and all the girth field joints are coated with Covalence WPC80 for normal buried joints and DIRAX for HDD joints. More than 160,000 girth weld joints were coated during the construction period between 1986 and 1989. The pipeline has been operational for about 24 years and various intelligent pigging, cathodic protection, bell hole and stress corrosion cracking surveys have confirmed that pipeline is in good health and is expected to be in service for the next 35 years without any major rehabilitation of the pipeline or the external coating.

Nt coNteN However to maintain future growth, Government of India has identified - Natural Gas as one the major fuel in the energy

basket and hence the natural gas pipeline network is set to

expand tremendously in the coming years. Further, Government of India to control pollution level in the country has embarked on an ambitious plan of operating public transport on CNG

2014 SEPTEMBER 2 (compressed natural gas) and bringing to highly populated cities piped natural gas for domestic sector cooking and heating /

118 118

cooling applications and hence coming years are also going to

- Epoxy layer provides excellent cathodic disbondment

witness an explosive growth of pipe steel / plastic network in

resistance to the joint coating system.

cities. - Co-polymer hot melt adhesive provides a strong adhesive and The excellent on-construction and performance of Covalence

shear high resistance bond to the epoxy / main line coating

heat shrink sleeves and the technical field services provided

to resist soil stresses and pipeline thermal movements during

during construction for ensuring correct installation laid a strong

operational life.

foundation for Seal For Life Industries- India. - Radiation crosslinked polyethylene backing provides excellent After the successful commissioning of the HBJ pipeline, the next

mechanical résistance against impact loads and indentation.

big onshore pipeline project was the 22”~16”/10.75” 1443 Kms

Further the polyethylene backing is fully UV stabilized and

long Kandla Bhatinda product pipeline of Indian Oil Corporation

this is a very important requirement in India as the pipeline

Ltd. The pipeline was designed by Bechtel, USA and constructed

welded sections are sometimes exposed to UV radiations

by Consortium of International and Indian Contractors lead

for considerable time > 6 months prior to backfilling. The

by Skodaexport of Czechoslovakia. The pipeline construction

UV stabilized backing ensures that there is no degradation

started in 1993 and was commissioned in 1996 at a cost of 370

to the joint coating system properties during such long term

million US$. All the girth weld field joints – approximately 130,000

exposures.

numbers were protected by Covalence three layer heat shrinkable field joint coating system – HTLP60.

- HTLP joint coating system in combination with the epoxy layer provides excellent resistance to oxygen and moisture vapor

HTLP60 or 80 field joint system is a three layer field joint coating

transmission and match the functional performance of the main

system comprising of 150~200µ thick solvent free 100% solids

line coatings thereby providing a corrosion free steel surface at

epoxy first layer brush applied to abrasive blasted girth weld

the critical girth weld joint area.

joint at low-preheats:70~80 C which then chemically bonds to 0

the copolymer hot melt coated wraparound radiation cross-

After HBJ and Kandla Bhatinda, many pipelines projects have

linked heat shrinkable sleeves to provide a strong reliable field

been executed in the last twenty years which has increased the

joint coating system compatible to various type of main pipeline

transmission pipeline network by more than 20,000 Kms of pipe

coatings used in India – coal tar enamel, three layer polyethylene,

diameter ranging from 10.75’ to 48” and practically on every

single and double layer fusion bond epoxy. The main advantages

pipeline project, Covalance HTLP field joint coating systems

of the HTLP field joint coating systems are:

have been used. In the last 20 years, more than two million field

joint systems have been installed and many pipe verification digs

- Suitable for field joint coating of 3LPE / CTE / FBE or DFBE

have proven the field performance of the joint coating system

coated pipelines with design / operating temperatures upto

in protecting the critical pipeline infrastructure of various Oil and

85 C

Gas Companies of India – Indian Oil Ltd, Gail India Ltd, Reliance

Ltd, Hindustan Petroleum Corporation Ltd, Bharat Petroleum

- Due to low pre-heat installation temperature, costly induction

2014

Corporation Ltd, Oil India Ltd, ONGC Ltd, Carin India Ltd etc.

generators and coils are not required. Pre-heating is done using Propane / LPG gas torches.

119 119

Anodeflex 1500 is a strong copperwire cable, excellent for HDD

Nt coNteN

2014 SEPTEMBER 2 120 120

Some of the significant projects in India including the longest

Natural Gas Pipelines

LPG pipeline in the World – GAIL Jamnagar Loni pipeline –

S. NO.

PROJECT

OWNER

PIPE DIA

LENGTH

Dahej – Vijaipur Pipeline Phase – I

GAIL

42”

612 Km

Dahej – Vijaipur Pipeline Phase – II

GAIL

48”

610 Km

Anodeflex:

Vijaipur – Dadri Pipeline

GAIL

48”/ 36”/ 20”

594 Km

Long line polymeric anodes – Anodeflex 1500 were introduced

Dabol – Bangalore Pipeline

GAIL

36”/ 30”/ 24”/ 18”

1414 Km

in India in 1994 for protecting tank bottom plates for crude oil

East – West Pipeline

RELIANCE

48”

1460 Km

storage tanks from soil side corrosion. Prior to introduction of

Dahej – Uran Pipeline Project

GAIL

30”

504 Km

Anand – Rajkot Gas Pipeline

GSPL

24”

230 Km

Halol – Dahod Pipeline Project

GSPL

12”

103 Km

Mundra – Morbi Pipeline

GSPL

18”/ 12”

140 Km

various tank inspections, corrosion under the tank plates were

Mundra – Delhi Pipeline

HPCL

18”

1054 Km

detected. Indian Oil Corporation Ltd, after a rigorous analysis of

Mumbai – Manmad – Mangliya – Bijwasan Pipeline

BPCL

18”/ 16”/ 14”

1389 Km

various configurations of anode systems- deep ground beds,

Barauni – Kanpur Pipeline

IOCL

20”/ 12”

745 Km

discrete single angle drilled anodes, long line anodes installed

Chennai – Trichy – Madurai Pipeline

IOCL

14”/ 12”/ 10”

683 Km

under the tank bottoms selected the configuration of long

Chennai – Bangalore Pipeline

IOCL

14”/ 12.75”

290 Km

line anodes under the tank bottom to ensure uniform current

Mumbai – Pune – Solapur Pipeline

HPCL

14”

508 Km

distribution and polarization of the tank bottom between (-)0.85V t

Vizag – Vijayawada – Secunderabad Pipeline

HPCL

18”/ 16”/ 14”

572 Km

(-)1.2V “OFF” with respect to Cu/CuSo4 reference electrodes.

Kochi – Coimbatore – Karur Pipeline

PETRONET

18”

293 Km

The long line anodes selected was Anodeflex-1500. The

Mangalore – Hassan – Bangalore Pipeline

PETRONET

24”/ 20”

362 Km

Mundra Delhi Pipeline

HPCL

18”

1054 Km

Vadinar Bina Pipeline

BORL

24”

737 Km

1 Jamnagar Loni Pipeline (Longest LPG Pipeline in the World)

GAIL

16/14/12.75”

1270 Km

The unique design of Anodeflex-1500 offers the following

Vadinar Bina Pipeline

GAIL

12.75/10.75”

600 Km

advantages over other similar anode systems:

Panipat Jalandhar

IOCL

10.75”

270 Km

16”/14”/12.75”- 1270 kms long where Covalence HTLP joint coating systems have been used are:

Anodeflex-1500, Indian Oil Corporation Ltd, one of India’s largest refining company and operating large crude oil and product storage tanks of diameters ranging from 30 meters to 80 meters

Product Pipelines

were not cathodically protecting the tank bottoms and during

Crude Pipelines

Anodeflex 1500 is a long line flexible, cable-like anode, which is placed in continious close proximity to the structure. Key to the anode’s performance is the central, conductive polymer coated copper conductor packed with high perfermonce coke breeze

LPG Pipelines

and contained in the acid resistant fabric.

Nt - Negligible longitudnal voltage drops.

- Limited current output per unit length.

-L ong ciruit lengths hence no splices / joints under the tank bottom plate.

-C oke breeze increases the surface area and reduces the contact resistance to soil thereby reducing the overall circuit reststance

2014

and preventing excessive voltages to be applied to the anode.

The Anodeflex 1500 designs for tank bottoms are validated thru

various Clients in India – Indian Oil Corporation Ltd, Hindustan

computer algortihms to enure the selected depth and spacing

Petroleum Corporation Ltd, Cairn India Ltd etc.

of the anode strings will provide uniform current dstribution to

Anodeflex based impressed current cathodic protection systems

prevent under / over protection of the tank bottom plates.

are also being used are for protection of LPG Mounded Bullets

In the last 20 years for more than 100 tanks of various diameters

used for bulk storage of liquefied petroleum gas (LPG). Mounded

ranging from 30 to 80 meters, impressed current cathodic

storage is generally safer than other methods of storing the

protection system using Anodeflex-1500 have been installed for

highly inflammable LPG. Mounded LPG Bullets are large, buried, 121 121

horizontal cylindrical steel tanks with dished ends of size ranging between 3.5 to 8.5 diameter and lengths of 35 to 90 meters or more. Mounded bullets allow storage of large quantities of LPG, up to 2,000 MT. The separation distance between the vessels is approximately 2 meters. The close proximity of the vessels is a challenge for distributing cathodic protection currents. Anodeflex provides a unique solution for providing cathodic protection of these vessels as the anode strings are laid in close proximity to the vessels running parallel to the surface of the vessels along the circumferential periphery of each vessel separated by a distance of one meter.

Powercrete for HDD is often copied, never equalled

In the last 15 years more than 100 LPG mounded facilities having 2 to 6 vessels in each mound have been cathodically protected using Anodeflex all over India for various Clients like Indian Oil Corporation Ltd, Bharat Petroleum Corporation Ltd, GAIL India Ltd and Hindustan Petroleum Corporation Ltd. The buried plant piping in the new refineries and petrochemical plants in India are now being protected by impressed current cathodic protection systems to prevent external corrosion. Designing of cathodic protection system for such applications is a challenge due to varying diameters of pipelines – 4” to 96”, number of pipelines in the common corridor, foreign structures in the close vicinity – earthing networks, foundation bolts etc.which drain cathodic protection currents. The earlier cathodic protection designs were based on combination of deep ground beds and close distributed discrete anodes installed close to the pipelines being protected. These designs required a complex distribution of anode junction boxes with resistors, sub distribution anode

Nt coNteN junction boxes, large quantity of anode cables connecting each anode to the junction boxes. Earlier installations of plant piping

cathodic protection were based on these designs, however the complexity of controlling the cathodic protection current and

maintaining the system to ensure that the plant piping was not

under / over protected resulted in the Owners and Consultants looking for alternatives and the most versatile system for plant

2014 SEPTEMBER 2 piping cathodic protection: long line flexible anode system-

Anodeflex was selected. This system offers all the advantages

122 122

of a close continuous anode bed cathodic protection system

with a skin effect heat management system (SEHMS). This

design for complex piping in the plants and hence reduces

innovative system prevents the crude oil from turning into wax

considerably the protective current required to protect the buried

by ensuring that temperature inside the pipeline always remains

plant piping and also reduces the various equipments required in

higher than the wax appearance temperature (WAT) of 149°F.

the cathodic protection system – anode junction boxes, anode

The pipeline has an FBE anti-corrosion coating for the carrier pipe

cables, transformer units making the cathodic protection system

and Powercrete R-150 for the skin effect heat tubing followed

cost effective, efficient, easy to operate and maintain and most

by 75mm high density polyurethane foam and 4mm thick outer

importantly to maintain the pipe to soil protection level as per the

HDPE extruded jacket. A heat tube of diameter 1” is welded to

required CP design criteria’s.

the 24” diameter carrier pipe thru which a high temperature high voltage withstand electrical conductor has been installed. AC

The longest heated pipeline in the world

Power at about 1300V and 50 Hz frequency is applied between the electrical conductor and the heat tube and due to skin and proximity effect, the electrical current is pulled to the inner face of the heat tube thereby increasing the temperature of the heat tube due to resistance heating to 1050C which in turns heats

In India, Anodeflex is now increasingly being used for protecting

the carrier pipe by conduction and convection. As this pipeline is

the buried piping in refineries and petrochemical plants. More

insulated and buried for a distance of 600Kms – Cairn India Ltd

than 100 kms of Anodeflex has been used for this application and

and their Consultants – JP Kenny were very particular in selecting

some of the key projects are:

the coatings for the insulated pipeline to prevent any corrosion

- Gail India Ltd Petrochemical Complex at Pata-Uttar Pradesh

under insulation phenomenon during the operational life of the

- Bhramaputra Cracker and Polymer Complex Ltd- Assam

pipeline in case of damage to HDPE jacket. As such, after carefully

- ONGC Petro Chemical Additives Limited -Dahej, Gujarat

evaluation high temperature FBE was selected as anti corrosion

-M angalore Refinery & Petrochemicals Limited- Mangalore,

coating for the carrier pipeline and Powercrete R-150 as the anti

Karnataka

corrosion coating for the skin effect heat tube, carrier pipe field joints and all other irregular shaped components of the insulated

Powercrete:

pipeline – long radius bends, valves etc. Powercrete R-150 was

Powercrete range of 100% solids high build liquid epoxy coatings

sprayed on to the welded carrier pipe using hot air less spray

are being used on many projects in India for protecting the buried

machines in the coating plant of Jindal Saw Ltd located in Gujarat.

infrastructure at elevated temperatures and complex structures

More than 600,000 liters of Powercrete R-150 was supplied on

like valves, fittings, etc. Two notable projects where Powercrete

this prestigious project. The pipeline was constructed on EPC

R-150 have been used for protecting critical components are

basis by Larsen & Toubro Ltd.

Nt Cairn India Ltd – 24” diameter x 670 km skin effect heated

insulated pipeline carrying high viscosity crude from Barmer,

Reliance Industries Ltd started construction of one of India’s

Rajasthan to Jamnagar, Gujarat. This pipeline is the longest

largest natural gas pipeline -48”x1375 kms long from east coast

continuous heated pipeline in the world and the first such pipeline

– Kakinda, Andhra Pradesh to Baruch, Gujarat in 2006 and

in India and the Reliance East West – 48”x1400 Kms natural gas

completed the pipeline in a record time of three years in 2008

pipeline from Kakinada, Andhra Pradesh to Bharuch, Gujarat.

to carry 80MMSCMD. The Consultant for this large project was

Cairn India Ltd pipeline carrying high viscosity crude is equipped

Gulf Interstate, Houston USA and the pipeline was constructed

2014

123 123

150.000 liters of Powercrete for one single project 2014 SEPTEMBER 2

Nt coNteN 124 124

by team of International and Indian Pipeline Contractors –

applied coating technology of Polyken was selected. Till date

Stroytransgaz, Russia, CPP, China, Larsen and Toubro India and

more than 450 kms of operational pipelines have been re-coated

Punj Lloyd India. Powecrete R-150 liquid epoxy coating was

using Polyken’s 3ply / 2ply field applied primer activated coating

selected as the field / factory applied anti-corrosion coating for all

system.

the station piping of the 11 compressor stations installed along the pipeline. The factory coating was applied by PSL Ltd located in

Conclusion:

Gujarat and the field coating by trained applicators of the Pipeline

Seal For Life Industries has been a valuable company to the Oil

contractors. More than 150,000 liters of Powercrete R-150 was

& Gas sector of India by providing technological solutions and

supplied for this prestigious project.

products with high level of technical services for training and application of company products for corrosion protection of

Polyken:

buried infrastructure across the entire gamut of off-shore / on-

Polyken range of coatings have extensively been used in the Oil &

shore pipelines, storage tanks, plant piping etc. Over the last

Gas Segment for rehabilitation of coal tar coated pipelines in India

three decades, the Company has supplied products to almost

and coating large diameter water pipelines. The on-shore crude /

every single Oil & Gas Pipeline Project and has a significant

product oil pipelines laid in India prior to 1980’s were field applied

presence in the buried infrastructure of the on-shore upstream

coal tar coatings and the total length of this network is more than

and down-stream projects. Seal For Life Industries has evolved

3000 kms of pipe diameters ranging from 10.75” to 28”. Over

over the years and has illustrious past of technologies from

the years, the coating resistivity reduced to a level where it was

previous companies – Raychem & Tyco International. Seal For Life

not economical to protect the pipelines by adding supplementary

Industries part of Berry Plastics Engineered Material Division, USA

cathodic protection systems. The Pipeline Owners initially started

has re-engineered itself for providing new green technologies for

the rehabilitation with field applied coal tar followed by manually

corrosion protection of the buried infrastructure for design life in

applied coal tar tapes but known of these technologies were

excess 50 years. The Company under the leadership of Dr. Fritz

successful in reducing the requirement of cathodic protection

Doddema Executive Vice President, Global General Manager and

current to acceptable levels of current density <100µA/m2 nor

Managing Director is committed to bring new technologies to India

the quality of application of the coating was upto the requirement

and work with the Indian community of Oil & Gas professionals to

to enhance the residual life of the pipelines > 30 years. After

prevent corrosion of the critical infrastructure of India’s growing Oil

evaluation of various rehabilitation coating technologies and

& Gas assets.

ease of application on the operational pipelines, 3ply / 2 ply cold

2014

125 125

HIGH TEMPERATURE PIPELINES (>80Â°C) A REVIEW OF COATING TECHNOLOGIES Ahmed Moinuddin | Seal For Life Pakistan & Middle East

It is generally accepted that for pipeline operating temperatures upto 800C, 3 layer PE is the most suitable type of coating. For higher temperatures, 3 layer PP line coatings were introduced about 15 years ago. However, many oil and gas companies have experienced premature failures of PP at temperatures above 1000C on onshore pipelines.

Nt coNteN Several papers have been published in NACE which testify to the inherent

issues PP faces at high temperatures. Additional research has been done in the last 3 years on the expected lifetime of PP. Results of this research are presented in this document.

2014 SEPTEMBER 2 126 126

2014

127 127

prevent cracks

HEAT AGEING REQUIREMENT OF HIGH TEMPERATURE PIPE COATING For any coating to function long term, there are a host of physical, chemical, and electrical requirements a coating needs to fulfill. Paramount among these is the requirement that a coating should maintain maximum flexibility (elongation and tensile strength) over the life of the line at the operating temperature of the pipe and stay bonded to the steel. If any coating prematurely heat ages, hardens, and loses its flexibility, it becomes hard and brittle. This results in cracking and loss of adhesion (disbondment) to the steel as the pipe temperature cycles and expands / contracts – a phenomenon more severe at higher temperatures. THREE LAYER POLYPROPYLENE: When 3LPP was introduced 15 years ago, it was deemed to be a suitable coating for high temperature pipelines. Some improvements have been made by PP coating suppliers since then in an attempt to extend its service life at high temperature. But despite these improvements, pipeline companies have experienced a number of failures of PP coatings when exposed to temperatures above 1000C. Laboratory testing has also been conducted on the time-to-failure of 3LPP. These findings have been presented in NACE conferences and have raised serious questions about the temperature limits of PP coatings. Some of these papers are attached herewith for reference. Failures of 3LPP line coating have also been encountered by ENI Pakistan as well as OMV Pakistan.

Nt coNteN STANDARDS GOVERNING 3LPP COATINGS:

There are currently three international standards which cover 3 layer PP coatings.

• NF A 49-711 (French) • DIN 30678 (German)

• ISO 21809-01 (International)

2014 SEPTEMBER 2 128 128

These standards are however minimum requirements and each

The service life of the coatings as covered here is a function of the

pipeline company needs to supplement the standards with

operating temperatures to which they are exposed (cf. table 1

requirements unique to its own operating conditions. For instance the thermo oxidative degradation of line coating is higher in sandy soils with a richer oxygen content than in clay type dense soils which have low oxygen levels. Therefore in sandy soils (as is the case in the Sawan â&#x20AC;&#x201C; Latif pipeline) the effect of heat ageing is more acute and the expected lifetime of PP coatings is reduced dramatically. NF A 49 711 standard (French)

this represents a catastrophic clear failure of the coating. The failure time can then be extrapolated to determine the life of the coating to this catastrophic failure at lower than 1500C operating temperatures based on Arrhenius principals applicable to polyolefins. DIN 30678 standard (German): A review of the DIN30678 standard issued in October 1992, suggests that PP has service life limitations due to heat ageing. As per an extract of DIN30678:

100

given above.

in melt flow index after 2000hrs (83 days) at 1500C. This is not an

cracking and disbondment is a more suitable measure since

expected service life shall be extrapolated from the values

However the heat ageing test is limited to measurement of change

As per recent research (see NACE papers attached) time to

Minimum expected service life, in years

Where coatings are used at alternating temperatures, their

This standard issued in 1992 is for PP coatings upto 1100C.

adequate measure of coating life.

Operating in temperatures, in ÂşC

While the standard does have a heat ageing test, it is not severe enough to truly test the lifetime of the coating. Coatings which met the DN30678 standard have still failed prematurely in the field. Like the NFA 49-711 standard, it also lacks the time-to-crackingdisbondment test criteria which is a functional measure of the coatings life. 4.3 ISO21809-01 standard : The standard issued in October 2011, limits the use of PP to 1100C design temperature. The heat ageing requirements in this standard are also based on measurement of Melt Flow index only which is very weak. For a 1100C temperature only a 40 day test at 1500C is specified. This is inadequate for verifying a long service

Nt Experience has shown that the resistance of polypropylene to

oxidation also differs that of polyethylene, in that tends to become brittle when exposed to high temperatures. For this reason, the expected service life of polypropylene as a function of service temperature has been specified in clause 1.

2014

life as evidenced by the premature failures encountered in the field and the recent research. Time to cracking and disbondment is a more suitable measure of a coatings life. Like the NFA 49-711 and the DIN30678 standards, it also lacks the time-to-crackingdisbondment test criteria as a measure of the coatings life.

129 129

The standard states the following for PP coatings:

Coating classes The coating shall be capable of withstanding the temperature range required as shown in Table 1. The coating class shall be specified in the purchase order. Table 1- Coating classes and design temperatures ranges Coating class

Top layer material

LDPE

MDPE/HDPE PP

Design - 20 °C to temperature + 60 °C ranges

- 40 °C to + 80 °C

- 20 °C to + 110 °C

Borealis (36% owned by OMV) is a major manufacturer of PE and PP coating materials. In a recent Seminar in May 2011, the following is an extract of their presentation:

ISO21809-1: Polyolefin coatings (3-layer PE and 3-layer PP) Table 1- Coating classes and design temperatures ranges Coating class

Top layer material

LDPE

MDPE/HDPE PP

Design - 20 °C to temperature + 60 °C ranges

- 40 °C to + 80 °C

- 20 °C to + 110 °C

Nt coNteN - First real international coating standard is in Final Draft stage

- The standard is the achievable compromise in reflection of all countries input and requests

- The standard can only been seen as the MINIMUM level

- GOOD: Nomenclature, definitions and test methods are regulated

- Pipeline owners/engineering companies have to continue and specify

2014 SEPTEMBER 2 their project related additional requirements clearly

130 130

3LPP COATING FAILURES EXPERIENCED BY PIPELINE COMPANIES

LASMO OIL (ENI) PAKISTAN In 1998 ENI experienced premature failures of PP coating within 2 years of installation. The failures were: - Cracking of PP when exposed to the sun due to UV, where the pipe had been exposed. - Heat ageing of the PP due to the high temperature. This resulted in loss of tensile and elongation and eventually disbondment of coating

2014

3LPP coating exposed to sunlight has totally disintegrated due to UV degradation. This is a failure phenomenon mentioned in DIN30679 standard for PP coating.

Embrittled cracked 3LPP coating.. has allowed moisture / water to enter and come into contact with the steel under disbonded coating and spread around the crack causing crevice corrosion. 131 131

ADCO (ADNOC), ABU DHABI

On the basis of the testing the following was determined to be the

ADCO has experienced many failures cracking and disbondment)

expected service life of 3LPP coating:

of their PP coatings on high temperature gas pipelines which

Service Life Estimation for 3 LPP

they have also published in NACE conferences. In 2009 ADNOC launched a test program to establish the causes of the failures and to determine the expected life of PP coatings when exposed to high temperatures. The testing was carried out for ADNOC by

Arrhenius Equation

t ƒ =A exp ( Ea ) RT

T, °C

tf,yrs

150

0.25

140

0.51

R = gas constant= 8.314 J/mole-K

130

1.11

T = absolute in K = °C+273.16

120

2.51

Accelerated heat ageing tests were done on PP coated pipe by

Ea = activation energy = 107 KJ/mole

110

5.90

placing a piece of coated pipe in an oven at 1500C. Once a week

tf = time to crack

100

14.5

Polylab, Houston, USA.

the pipe was removed and examined for signs of cracking / failure. The PP coated pipes showed cracking failure in 90 days. A summary of the test results from the testing is given below.

Estimated cracking time for 3LPP

Cracking Time Prediction for 3LPP Time to Crack, Years

16.00 14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00

3LPP, before Air Aging, DFT= 22mm, 4 mm, 6 mm

100

110

120

130

Temperature, C

140

150

Ea=107 KJ/Mole

3LPP Pipeline Coatins Conclusion - Two Major Failure Modes - Cracking, Disbonding - PP Cracking - PP physical properties deteriorate due to Thermo-

Nt coNteN oxidative /degradation + Residual Stress, Proper stabilizer package is need to increase longevity of service life of 3LPP

UAE Sandy Soils - 33-48% Porosity, subject to Thermo-oxidatve Degradation

Cracking of borealis 3LPP, after 90 days aging in 150 °C air oven

3LPP Disbonding - High Residual Stress Concentration at CutBack, Use <30 Degree Cutback, Avold 90 Degree Cutback

2014 SEPTEMBER 2 As a result of the failure analysis and the extensive testing done

by ADNOC, they have decided to limit the use of 3LPP coating to maximum 100°C.

132 132

properties, chemical and stress cracking resistance including:

TEMPERATURE COATING

− Temperature resistance

This type of coating has a successful 30 years track record of

− Thermal shape integrity

operation at temperatures upto 1200C.

− Tensile strength − Modulus of elasticity

In Pakistan, the system has been used successfully for the past

− Chemical resistance

16 years by:

− Impact resistance

- OMV Pakistan

− Creep resistance

- ENI Pakistan

− Resistance to stress cracking

- OGDC

−UV resistance

- Occidental Petroleum - PSO The coating system consists of a Heat Shrinkable tape with:

physical and electrical properties for longer at elevated

- A highly radiation-crosslinked PE backing

temperatures compared to polypropylene.

- A high shear strength high temperature adhesive with a softening point of 1700C

The following test results demonstrate the superior performance

- Low moisture and oxygen permeation due to the high

of Heat Shrinkable crosslinked PE coatings over 3LPP. The PP top

crosslinked HDPE backing

coat loses its elongation to break (a measure of the flexibility of the

- Excellent soil stress resistance - not effected by pipe movement

coating) with time much faster than Crosslinked heat shrinkable

- Excellent UV resistance

PE coating.

- Very good heat ageing (25+ year life at 1200C) Heat Shrinkable crosslinked HDPE coatings have a projected life Crosslinking polyethylene radically improves many of its properties

of 40 years at 1100C as shown in the Arrhenius plot below.

such as high temperature heat ageing performance, mechanical Arrhenius Plot

150 °C Aging 1.1

2014

The improvement in the heat ageing characteristics of the HDPE due to crosslinking, allows it to better retain its mechanical,

Normalized Elongation at Break (EBt/EBo

Arrhenius law to predict life

HEAT SHRINKABLE CROSSLINKED HDPE HIGH

Log Time (Hours)

1 106

0.9

Predicted Coating Liferime 40 Years

0.8

104

0.7

103

0.6

Test Data

102

0.5

160°C

0.4 0

125°C

110°C

80°C

Aging time (weeks) PP Top Coat1

PP Top Coat2

Cross-linked PE backing

Reciprocal of absolute Temperature 133 133

COMPARISON OF 3LPP WITH CROSSLINKED HEAT SHRINKABLE HDPE COATING

PARAMETER

3LPP

CROSSLINKED HEAT SHRINKABLE HDPE

Heat ageing

Above 1000C, PP has a very limited life.

25+ yr life at 1200C

According to the latest research â&#x20AC;&#x201C; 5.9 yrs at 1100C and 2.5 yrs at 1200C UV resistance Track record

PP vulnerable to cracking on exposure to

Very good UV resistance. Can be left for several

UV.

years exposed to the sun

15 yrs. Failures documented for

30 yrs with excellent performance worldwide

temperatures >1000C

including Pakistan at temperatures upto 1200C (ENI, OMV, OGDC, OXY, PSO)

Life cycle costs

Very high, due to need to repair / recoat pipe when the PP coating fails due to premature ageing at temperatures >1000C. Pipe is not protectable with CP against corrosion if coating is disbonded. At higher temperatures corrosion rate is faster and can lead to catastrophic failure and very high repair / maintenance / replacement costs as well as lost revenue during pipeline downtime. Very low due to excellent heat ageing characteristics.

Coating application

Crescent Steel, Huffaz Pipe, Data Steel

capability in Pakistan

Crescent Steel, Huffaz Pipe, Data Steel and SNGPL(with addition of a simple tape payoff machine). Currently pipe is being coated at Huffaz Pipe for an ENI Kadanwari pipeline with temperature upto 1200C

Nt coNteN Joint coating system

Complex and expensive. The 3 layer shrink

Very simple. Same materials as the line coating is

sleeve system requires Induction coils and

installed on the joint. Installation can be done with

generators.

an LPG Gas Torch.

Ultimate shrink force technology

2014 SEPTEMBER 2 134 134

CONCLUSION:

APPENDICES

Given the current state of technology, use of 3 layer PP

NACE published articles

coating for onshore pipelines should be limited to 1000C

design temperature due to their limited service life at

higher temperatures. For design temperatures above

100 C, based on track record, technical superiority and 0

life-cycle costs, heat shrinkable crosslinked PE should be used.

NACE 2006 - Hidden problems with 3 layer Polypropylene coatings NACE 2010 - Failure Analysis of 3 layer polypropylene pipeline coatings

C BHRA 2009 - Residual Stresses in 3LPO external pipeline coatings â&#x20AC;&#x201C; disbondment and cracking Specifications ENI Pakistan specifications for Heat shrinkable high temperature coating

In case of applications over 100 C, irradiation beamed polyolefine as prefab coating is the best choice 0

2014

135 135

Seal For Life Industries; the synergy Seal For Life Industries encapsulates five established and leading brands in the area of dealing with corrosion prevention and control. We operate worldwide across many different industries and in many different markets – which is in no small measure thanks to the innovative capabilities of the five brands within our group, each of which has its own specific disciplines. These five specialists, who had already earned their own reputation independently within the market, are Polyken Tape Solutions, Powercrete Liquid Solutions, Stopaq Self Healing Corrosion and Sealant Systems, Anodeflex Cathodic Protection, and Covalence Heat Shrinkable Products. In addition, two new brands - Blockr and Sealtaq - are being introduced, which will make it possible to fulfil the needs of many more (and new) markets for our solutions and innovations. It’s precisely the complementary strength of our specialisms that enables us to speed in with a specific, tailor-made solution for any challenge, in any infrastructure, anywhere in the world. Above or under water, from salty marshlands to complex operations

Nt coNteN in the Arctic, Seal For Life Industries will prove our principle that 1 + 1 = 3. By maintaining an open line of contact between our

specialists, Seal For Life can react fast and effectively – and suggest custom-made approach for each particular project. But whichever combination of our specialisms is appropriate, Seal For Life is the constant factor!

2014 SEPTEMBER 2 136 136

1+1 = 3 principle is made a reality by Seal For Life Industries. Seal For Life is the constant factor!

2014

Cathodic Protection Joint Sealing

Factory Applied Pipeline Coating (FAST GRE)

Above Ground Flange

Fieldjoint Coating

Visco-elastic Single Wrap

Sealtaq Civil Solution

Liquid Pipeline Coating Technology

137 137

High Temperature Anticorrosion Coatings and its Life Time Predictions ABSTRACT Heat Shrink Sleeve (HSS) coatings technology is based on radiation cross-linking of Polyethylene and Polypropylene sheets in combination with multiple types of adhesive Chemistries. Heat Shrink sleeves have been and continue to be used for the corrosion protection of oil, gas, water and District heating pipelines. Heat Shrink sleeves have proven track record and performance as a corrosion coating for field joint coatings; pipeline specials; and used as sealing systems in district cooling and heating application. This paper addresses the laboratory studies of the long term thermal, oxidative and hydrolytic stability of radiation cross-linked polyolefin as used in Heat Shrink Sleeves. Studies are presented on the results of long term heat aging and predicted life expectancy based upon Arrhenius plots. Analytical such as oxidation induction time, dynamical mechanical analysis, peel adhesion and physical testing are discussed as test methods to validate and predict long term stability and projected life expectancy for in-service on operating pipelines. KEYWORDS: Arrhenius, Cathodic Disbondment, Accelerated Thermal Aging, Hot Water Immersion (HWI), Oxidation Induction

Nt coNteN Time (OIT), Dynamical Mechanical Analysis (DMA), Field Joint

Coating (FJC). Polyethylene (PE) and Polypropylene (PP), 2L Crosslinked PE (XPE) and 3L Cross-linked PP (XPP)

2014 SEPTEMBER 2 138 138

INTRODUCTION

When a liquid epoxy coating is combined with a 2-layer system,

than the operating temperature, the data is plotted as time to

High performance pipeline corrosion protection and insulative

the product is then referred to as a 3-layer HS field joint coating.

failure versus temperature and extrapolations are made to the

coatings have been developed to meet the demanding

In the latter case the liquid epoxy acts as a primary anticorrosion

operation temperature in order to predict the lifetime of coating.

requirements of pipelines operating over a wide range of field

layer. In addition, under circumstances of high stress and

Such a study was previously conducted by Raychem and a

conditions. Today there are, a variety of pipe coating technologies

directional drilling operations (HDD), a typical reinforced heat

lifetime of over 30 years at 120°C was predicted for XPE backing.

are commercially available and selection has evolved along

shrinkable product in a three layer version (configuration) is utilized,

Indeed, this theory is supported by the fact that no failures to date

geographical lines. Important factors determining the coating

to meet the demanding field application conditions.

were reported from the sleeves installed on oil pipelines operating

selection relies on the pipeline construction, Right-of-Way (ROW)

at 110°C over 20 years.

conditions, pipe transportation and handling, and operating

The heat shrinkable sleeves installation starts by treating the

conditions. As an example, coating damage is a real concern in

welded steel pipe surface with grit blast to a near white metal

regions where limited transportation infrastructure, rough pipe

(Sa21/2) with an anchor pattern close to 70 to 80 µ; other surface

handling, aggressive backfills and high populations are prevalent.

treatments involves power wire brushing. The next step is to

This creates the need for robust, multi-layer coating systems.

preheat the pipe surface to the indicated temperature according to the selection of heat shrinkable sleeve, but protecting the line

The steel pipeline are generally coated with polymeric materials

coating to avoid its disbondment or mechanical damage; the

such a 3-layer PE and, 3-layer PP Line Coating systems

sleeve is wrapped around the welded pipe joint, secured with a

(consisting of an epoxy layer as corrosion barrier, tie layer as an

closure patch and shrunk by mean or propane-butane torch or an

adhesive layer and an outer mechanical layer defined as Top

automatic shrinking machine.

Coat), polyurethane, single layer Fusion Bonded Epoxy, dual layer Fusion Bonded Epoxy and multilayer insulated systems etc.

An important property of a HSS that are designed for high

Figure 1 XLPE heat shrinkable line coating installed in 2000

temperature pipeline application is its ability to retain the

on a pipeline operating continuously at 110°Cin Pakistan

All these coatings are plant applied in a stationary or portable

properties at the maximum operation temperature preferably for

factories. The coating at the end of each pipe length is cut back

the lifetime of the pipeline coating. One of the most common

over a length of 150 mm ± 20 mm1. These pipes are then welded

failures observed with high temperature coatings is cracking and

together in the field at the ROW leaving a portion of bare steel

flaking from the pipe as a result of embrittlement of the coating.

exposed. The bare steel needs protection from corrosion. There

Mostly, embrittlement is a result of the aging or thermo-oxidative

are several field joint coating solutions for example, injected or

degradation or coating loss of adhesion caused by its degradation

sprayed coatings and Polyurethanes, cold applied PE tapes,

in due to moisture exposure.

welded PP or predominantly used HSS.

Both the backing and the adhesive of the sleeve are stabilized with

HSS have been commercially available since pipeline coatings

proper antioxidants in order to inhibit their thermo-oxidative aging.

applied in manufacturing plants became commonplace in the early

The stabilization of the backing is more crucial since the backing is

1960s.

exposed to oxygen more so than the adhesive. In order to test the

Before

After

effectiveness of stabilizers, oven aging tests are carried out and

These HSS coating systems primarily consist of a cross-linked

the changes in mechanical properties are measured to follow the

and stretched polyolefin backings. XPE and XPP backing sheets

course of degradation. This type of testing has been found useful

are then coated with different adhesive chemistries, i.e. butyl-

for comparing thermal stability of different coatings. Additionally,

based adhesive and hot melts, resulting in the 2-layer system.

accelerated tests are carried out at temperatures much higher

2014

139 139

Other coating failures involve loss of adhesion over time in

the samples that showed a lower lifetime at a certain service

Hardness

presence of wet environments. When designing a heat shrinkable

temperature had a reduced antioxidant concentration, indicated

To measure wrinkling resistance of the sleeve to soil compaction

coating a hot water immersion test, in addition to all other

by a shorter time in which a sample has achieved its oxidation.

and wet-dry cycles

specifications2, becomes a critical test to assess the life time of

The two layer (PE based HSS) and three layer (PP based HSS)

Lap Shear

coating. The adhesion of the coating as well as its viscoelastic

coatings described above, were tested for hot water immersion

To ensure that the sleeve can withstand soil stresses such as the

properties shall not change drastically from the original values.

exposed at various time intervals; 28, 50, 70 and 100 days for the

longitudinal shear deformation caused by temperature differences

case of the 2 layer (PE based HSS); and, 0, 70 and 100 days for

and circumferential (hoop) shear stresses exerted during wet/dry

Therefore adhesion testing of the coating after its exposure to

the three layer (PP based HSS) coatings. The testing temperature

cycles; or pipe and soil movements tangential to the pipe.

water for long term at high temperatures remains of interest.

set at the respective coating maximum design temperatures.

International standards applicable to field joint coatings for

Peel adhesion test to pipe surface were determined at end of the

Adhesion

buried or submerged pipelines have upgrade the requirements

exposure period and its adhesion value compared to those of the

It is dependent on proper surface preparation and a proper

for hot water immersion test on the 2 and 3 layer heat shrinkable

pipes which were not exposed.

application of the sleeve. Of lesser relevance as compared to

sleeves, to maintain a retention of the peel adhesion of the

The % adhesion retention was calculated for both systems, the

shear, since most in ground pipeline forces are in shear not in peel

coating to both the pipe surface and line coating to be at least

results exceeded 75% of the original adhesion values. Dynamical

mode. However peel is very easy to evaluate qualitatively and has

75% of the original values after the exposure period at the

analysis of the exposed samples were conducted; modulus

a long history in the industry.

maximum operating temperature limited to a 95°C. This of course

and tan delta values were recorded in order to assess that

is a severe test but it is an important way to predict the life time

no significant material changes for the adhesives viscoelastic

Impact Resistance

performance for the high temperature anticorrosion coating.

properties were observed after the exposure. This would in

This is a measure of the coatings resistance to back fill and

turn confirm the integrity of the heat shrinkable coating for a

bumping of pipe during pipeline burial.

coating requirements as stipulated on the field joint coating

This paper reviews HSS requirements as High Temperature Anti

continuous exposure at maximum design temperature.

Corrosion Coatings, results are presented for two type of HSS,

Penetration Resistance

a two layer polyethylene coating rated for 65̊C and a 3 layer

HEAT SHRINKABLE COATING REQUIREMENTS

To measure coating resistance to puncture by rocks and other

polypropylene coating rated for 90°C as maximum continues

In order to protect the metal pipelines structures which come

debris if the pipe is laid on such objects in the trench and/or

service temperatures.

in contact with harsh environments, like high humidity, water,

objects are forced into the coating during backfill, compaction and

Several laboratory studies of the long term thermal, oxidative

electrolytes, sandy and porous soil conditions, the field joint

in-service performance.

and hydrolytic stability are presented. Tensile and elongation at

coatings need to have specific requirements and properties for

break testing were carried out for various XPP backing sleeves,

corrosion protection of the field joint pipelines.

Electrical and Chemical Properties

in addition a polypropylene line coating (PP top coat) was

The most important properties of a corrosion protection coating

Dielectric Voltage Breakdown

considered as part of the study. The heat shrinkable backing and

are listed below

To ensure that the “jeeping” Holiday testing voltage used to detect

Nt coNteN polypropylene top coat samples were thermally aged at various

flaws in the coating does not penetrate the undamaged coating.

temperatures in order to build the Arrhenius plots and therefore

Mechanical Properties

to predict the cross-linked backings life time performance.

Tensile Strength and Elongation

Volume Resistivity

DMA was conducted for all the examples exposed at different

To ensure proper strength and flexibility during handling and/

High resistivity ensures that all current flow from the cathodic

time intervals and temperatures; changes in the cross linked

or pipe bending, pipelines have to be bent to conform to ROW

protection system reaches the pipe through the holidays and

density by means of determining the tan delta parameter were

and landscape contours at subzero temperatures or high desert

damaged areas to cathodically protect the bare steel exposed

recorded. Furthermore OIT was evaluated on several thermally

temperatures.

areas and is not wasted by passing through the undamaged

2014 SEPTEMBER 2 aged samples. The aim of the OIT study was to understand if 140 140

coating.

Moisture Vapor Transmission Resistance Measures coating ability to prevent water from reaching the steel surface, which causes corrosion, from being created at the pipe surface.

2014

141 141

Cathodic Disbondment

Thus, when it is heated to a temperature where the crystals have

thermal-aging results are generally extrapolated to use-temperature

Measures resistance of coating to delamination caused by

melted, the material behaves like a rubber.

conditions by using the Arrhenius methodology5. This method is

electrical currents from the cathodic protection system. This is a

based on the observation that the temperature dependence of the

very important consideration, especially majority of coated pipelines

Because the material will not flow on melting, it can be formed

are under cathodic protection.

into a new shape, for example by heating and stretching. On

rate of an individual chemical reaction is typically proportional to:

subsequent cooling, the molecular crystals reform and retain the

Exp (-Ea/RT) (1)

Hot Water Immersion

new shape, overwhelming the ability of the crosslinks to “pull” the

Exp= exponential

To ensure that the coating maintains its barrier properties when

material back to the pre-melted state. This shape memory property

Ea= Arrhenius Activation Energy

operating at elevated temperatures and in the presence of water.

of XPE was utilized in designing the heat shrinkable backing.

R= Ideal Gas Constant T= Absolute temperature in kelvin degrees

Benefits of crosslinking

Crosslinking PE improves a large number of its properties such as

Crosslinking is a means of modifying the molecular structure

high temperature properties, mechanical properties, chemical and

In general, the aging of a polymer can be described by a series

of polymers and generally is done in order to impart improved

stress cracking resistance

of chemical reactions, each assumed to have Arrhenius behavior.

properties. Crosslinking can be done either by conventional

Kinetic analysis of these reactions results in a steady stage rate

chemical means, such as silanes and peroxides, or by exposure

The properties of polyolefin, polyethylene and polypropylene and

expression with the Arrhenius temperature dependence, where Ea

to ionizing radiation from either radioactive sources, or electron

that improves with crosslinking are as follows:

represents the effective activation energy of the mix of reactions

accelerators. Raychem was the pioneer in developing electron

− Temperature resistance

underlying the degradation. If these series of reactions remains

beam irradiation of polymers and making commercial products

− Thermal shape integrity

unchanged throughout the temperature range, a linear relation

based on this advanced technology

− Solvent resistance

exist between the logarithm of the time to a certain amount of a

− Tensile strength

material property change and 1/T. Then the Ea is obtained from

Polyethylene showed improved properties when cross-linked under

− Modulus of elasticity

the slope of the line and it is assumed it remains constant at lower

electron beam radiation. Schematic 1 a illustrates the molecular

− Chemical resistance

(extrapolated) temperatures.

structure of polyethylene. It is a semi-crystalline thermoplastic

− Impact resistance

material with amorphous and crystalline domains. When irradiated

− Creep resistance

To carry out the life time prediction of the heat shrinkable XPP

by electron beam radiation, free radicals generated when the (C-H)

− Resistance to stress cracking

backings, two different compositions and a third sample of a

bonds are broken in the amorphous domains and subsequently

− Weathering resistance

PP top coat (none irradiated polyolefin) were collected. For the

a permanent crosslinking occurs, or intermolecular joining of

− Abrasion resistance

cross-linked materials, sheets about 8 by 11 inches were cut

adjacent molecular chains are formed. The crosslinking results

and placed in the oven @ 180°C for 30 minutes, this was done

in the covalent bond of polyethylene molecules, thus, forming a

LIFE TIME PREDICTION OF HEAT SHRINKABLE

to bring the material to its none stretch stage. For the PP line

three dimensional network. Schematic 1b illustrates the molecular

POLYPROPYLENE BACKINGS

coating, samples were removed for comparison testing. For aging

structure of polyethylene after exposure to radiation. Crosslinks,

The typical properties for the some polypropylene compositions are

purposes samples 4 by 5 inches in dimensions were cut from oven

shown as dots, are covalent bonds formed between the two

listed in Table 1.

recovered cross-linked HS backing compositions, A & B and also

carbon atoms

Because of the intended heat shrinkable coatings service

from the PP line coating material. For the XPP compositions the

temperatures such as 100, 110°C, it is important to predict the

4 x 5 inches sheets were placed in air circulation ovens (± 2°C

After crosslinking the material will not flow at any temperature.

material durability. A common approach for the heat shrinkable

stability) set at 150, 170, 190 and 210°C, whereas for the non-

When it is heated, the crystals disappear as before, but it will

backings involves accelerating the chemical reactions underlying

cross-linked PP top coat, the accelerated temperatures selected

no longer flow or change shape because crosslinks act as ties

the degradation through changes in the ultimate tensile properties

for evaluation were 130, 150 and 170°C. All the samples were

between molecules. The cross-linked structure however is elastic.

(elongation and tensile strength at break). These accelerated

aged for a specified number of hours at each temperature. After

Nt coNteN Nt coNteN

2014 SEPTEMBER 2014 SEPTEMBER 2 2 142 142

Property

Test Method

Test Conditions

Requirement

Typical Value

Tensile Strength

ASTM D 638

23°C, 50.8 mm/min

> 15 MPa

35 MPa

Elongation at Break

ASTM D 638

23°C, 50.8 mm/min

> 400 %

600 %

Heat Aging followed by Elongation at Break

ASTM D 638

150°C/ 21 days

> 200%

484 %

Heat Aging followed by Elongation at Break

ISO 21809-3: 2008

130°C/100 days

Max 25% change from the original value

25% change

Hardness

ASTM D 2240

23°C

> 55 Shore D

60 Shore D

Dielectric Strength

ASTM D 149

23°C

> 300 V/mil

813 V/mil

Volume Resistivity

ASTM D 257

23°C

> 1015 Ohm.cm

9 X1015 Ohm•cm

Water Absorption

ASTM D 570

95°C, 24 hrs

< 1%

0.3 %

Moisture Vapor Transmission Rate

ASTM F1249

38°C, 90% RH

< 0.08 g/100in2 in 24 hrs

0.07

Enviromental Stress Cracking

ASTM D1693

96.7

Condition B

30 days @ 10% Igepal Oil

No failures after 30 days

Pass

Table 1 Properties for Polypropylene Backing Compositions

Nt Nt

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each period of time and temperature, the sheets were removed from the oven and allowed to condition at room temperature. Dumbbells were cut using a die ISO 527 type II and the tensile strength and elongation at break properties were determined @ 23 Âą 2Â°C with a cross head speed of 100 mm/min employing an Instron Tensile Tester model 5565 equipped with a long travel extensometer. The end point for each test, at different temperatures, was equivalent to the time required for an elongation retention of more than 33% of the original value or retention of more than 200%.of ultimate elongation. Plots were prepared for the elongation at break as a function of exposure time for all temperatures. Samples A, B, XPP backings and C, PP top coat are respectively shown in Figure 2. A comparable slope among the curves for all testing temperatures in samples A, B and C is expected, if the activation energy is to behave constant and therefore assumption of the Arrhenius behavior is correct A regression analysis was used for all the samples to determine the relationship between the logarithm of exposure time and the elongation at break produced at a 33% change from the original value. The Arrhenius plot to predict the lifetime for the cross linked polypropylene backing compositions and polypropylene top coat is shown in Figure 5. Results and Discussion From the regression analysis carried for the XPP backings compositions A and B, an r2 close to 0.9 was observed at the temperatures of 150 and 170C; when moving to higher temperatures and in both samples, A and B, the regression was found close to 0.8 Typically in the industry a regression value superior to 0.8 is

Nt coNteN Nt coNteN considered favorable and accepted as a linear relation among the studied variables.

For the PP top coat, the regression coefficients were found between 0.85 and 0.90 at the 3 testing temperatures. With these results, we

estimated an Arrhenius behavior with a comparable activation energy (Ea) at the studied temperatures, and proceeded to plot the logarithm

2014 SEPTEMBER 2014 SEPTEMBER 2 2 of the times to produce the predetermined change in elongation as a function of the reciprocal of the absolute temperature (1/T in Ë&#x161;K).

144 144

Schematic 1 Polyethylene structure before (a) and after (b) irradiation with electron beam represent crosslinks; Represent the covalent bond between carbon chains after cross-linking

Figure 2 HSS Polypropylene Composition A

Figure 3 HSS Polypropylene Composition B

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2014 2014

Figure 4 Polypropylene Top Coat

Figure 5 Arrhenius Plots for PP HSS Backing vs. a PP Top Coat 145 145

Figure 6 Dynamical Mechanical Analysis

The results for the XPP composition A revealed a lifetime superior

process stabilizers used alone does not increase OIT in

to that of composition B, at both 100 and 110°C temperatures;

polyolefins but when combined with hinder phenol an increase

16 and 6 years at 100°C and 110°C for composition A and 9

in the OIT was observed when the hinder phenol concentration

and 4 years at 100 and 110°Cfor composition B. Whereas for

increased in combination with phosphides. In the presence of

the selected PP top coat a much reduced lifetime was observed

HALS (hinder amine light stabilizers) the OIT measured bears

at the same temperatures. Significant lifetime under these

no relation to the actual thermal stability of the polymer. So OIT

accelerated thermal degradation conditions were expected

cannot necessarily be used to predict the long term stability of a

between XPP compositions versus a PP top coat material. A

polyolefin system, but it can be a valuable tool when comparing

further investigation for the rheological and thermal properties

results of the same antioxidant package within a specific

for compositions A and B was conducted to understand the

polyolefin material. So based on this, we determined the OIT time

significant difference in predicted lifetime between both XPP

for the XPP samples of interest.

samples. To evaluate the OIT a TA DSC Q100 apparatus was utilized. The Rheological and Thermal Analysis for Cross-linked

thermally aged samples from the Arrhenius study at the various

Polypropylene Backings

temperatures were run in inert atmosphere of nitrogen from 45̊C up to 210°C using a 20°C /min ramp, once the samples reached

Rheological Determinations (DMA)

equilibrium at 210°C, oxygen was fed to the system and an

Rheological data can be used to measure the degree of cross-

isothermal run for 60 min was completed. Results are expressed

linking. The shear modulus is directly related to the cross-link

in min and are listed on Figure 7.

density. Cross-linking raises the modulus and increases the

Figure 7 Oxidation Induction Time @ 210 °C XLPP backing

elasticity, i.e. decreases the tan delta. The rheological testing has

Results and Discussion

to be performed at a temperature high enough where there is no

XPP sample composition A has the greater shear module @

influence of the glass transition, in the rubber plateau, and in the

180°Cvs. samples B, 7.389E+4 Pa vs. 2.692E+4Pa; in addition,

crystallinity region.

Tan δ @ 180°C value for sample A was found to be 0.3859 vs. 0.5207 for sample B. This clearly indicates a significant larger

Rheological measurements were conducted using a TA

cross-link density and therefore a greater lifetime if the right

Instrument DHR2. The samples were analyzed at an increasing

choice of an antioxidant package is selected to protect the

temperature of 4°C/min and at a constant frequency and strain

polymer from its thermal degradation

percent of 1 Hertz and 0.1% with an oscillating shear mode. The

Nt coNteN Nt coNteN shear module and tan delta values were calculated at 180°C and

The rate of OIT change from sample A to B was comparable

used to compare the properties of the two samples. The results

for those samples aged from 150 up to 210°C and which had

are plotted in Figure 6.

met the criteria on elongation at break greater than 200%.

The absolute value for sample A is lower in all temperatures in

Thermal Analysis

comparison to the one composition B. Although both samples

For the phenolic antioxidants a linear relationship exist between

have the same antioxidant package and even when the

the stabilizer and OIT, therefore OIT can be used as an analytical

concentration of antioxidants on sample B is greater than the one

Figure 8 Hot Water Immersion Set up as per ISO 21809-

method to measure the hinder phenol antioxidant concentration

for A, this does not explain the reduce lifetime @ 100 and 110°C

3:2008 Standard

in a polymer system. J.R. Paiquet et al reported that phosphide

in comparison to polypropylene composition A. An important

2014 SEPTEMBER 2014 SEPTEMBER 2 2 146 146

factor determining the lifetime can be explained by a greater cross-link density. HWI and DMA Testing for 2LPE and 3LPP Heat Shrinkable Coatings 2L PE and 3LPP HSS coatings were installed onto a cleaned steel surface on 4 inch diameter steel pipes following the specific guidelines for each of the products according to the manufacturing recommendations. All samples were let to condition at 23 ± 2°C. The 2LPE HSS coating samples were placed in a setup, see Figure 8, for HWI test as per ISO 2180932:2008 specification @ 65°C whereas for the 3LPP HSS coatings

Figure 9 Normalized peel adhesion to pipe surface @ 23°C, CHS-10 mm/min after HWI

the testing temperature was set @ 90°C. Two pipes for each

a) @ 65°C for 2 XPE Coating

b) @ 90°C for 3 XPP Coating

product were tested before immersion for adhesion to pipe substrate at 23°C and a crosshead speed of 10 mm/min using an Instron Tensile Tester model 4465. Two pipes for each product were exposed to the water immersion test for 28, 50, 70 and 100 days. At the end of each testing interval, samples were removed from the set up and let to condition to 23 ± 2°Cfor 3 hours as minimum. Peel adhesion test at 23°C and a crosshead speed of 10 mm/min followed after completion of the immersion period. The peel adhesion results expressed as N/cm were normalized (Pt /P0) by dividing the value at each time interval over the original adhesion result. The (Pt /P0) results in function of the immersion period were plotted and are presented in Figure 9a for the 2L XPE and in Figure 9b for 3L XPP heat shrinkable coatings. In addition, pictures for the pipe after peel adhesion before immersion and after 100 days of immersion are shown in

Nt Nt Figure 10a for 2L XPE coating and

Figure 10b for the 3L XPP shrinkable coating.

2014 2014

Figure 10 Peel adhesion to pipe surface @ 23°C, CHS-10 mm/min for 2L XPE coating a) Before hot water immersion

b) After 100 days hot water immersion @ 90°C 147 147

XPP coating the values seem to decrease in function of time. The

in addition to cross-linked polyolefin several sources of 3LPP line

peel adhesion mode of separation was found to remain cohesive in

coatings will be studied.

all sample intervals, although for practical purposes samples peeled at the end of 100 days after hot water immersion are only illustrated.

By designing a heat shrinkable PP backing with higher cross-link density and selecting the appropriate antioxidant package an

Figure 11 DMA Plot 2-Layer XPE

When testing adhesives and coatings for its rheological properties

extended life time can be anticipated. This has been confirmed in

a common quantity of interest is the loss tangent tan δ. The loss

XPP composition A vs. XPP composition B. As expected, cross-

tangent or tan δ is the ratio of loss and storage modules, meaning

linking provides a great tool to extend the lifetime of a polymer, of

the ratio of the viscous to the elastic component. Values greater than

course if the polymer is a good candidate for cross-linking.

the unity characterize the adhesive for its viscous behavior whereas

An appropriate heat shrinkable coating shall not only comply with

values less than the unity, the elastic nature predominate the coating

specific international standards, i.e. ISO 21809-32, where specific

behavior. Another property of interest is the shear module of the

requirements are set such as lap shear, impact, indentation

coating especially at temperatures above the glass transition and

resistance, cathodic disbondment, peel adhesion, installed sleeve

melting temperatures. Significant shear module changing can be

thermal aging etc. Furthermore a high temperature coating shall

explained when the adhesive degrades either by chain scission or

be tested to retain its adhesion over time in presence of wet

cross-linking mechanisms.

environments. Acceptable adhesion levels after water exposure should not change more than 25% from the original values.

The viscoelastic properties for both coatings were tested in the temperature range of interest. For 2L XPE between 70 and 150°C

Future work in planned to conduct Arrhenius studies on the installed

and for the 3L XPP coating in the range of 130 to 200°C. For either

HSS coatings and monitor the changes in cathodic disbondment

coating no significant changes in the shear module and in the tan δ

and HWI after accelerated thermal aging conditions.

values were observed after the samples were exposed for 100 days Figure 12 DMA Plot 3-Layer XPP

at 65°C for the 2L XPE and 90°C for the 3L XPP coatings.

REFERENCES 1.”External polyethylene and polypropylene coating for line pipe”,

Rheological measurements were conducted using a TA Instrument

CONCLUSIONS

DEP 31.40.30.31-Gen.

DHR2. Adhesive samples were removed from the installed pipes and

The Arrhenius plot is an appropriate test method to define a material

December 1994

analyzed at an increasing temperature of 4°C/min and at a constant

lifetime if the activation energy within the testing temperatures

2. Petroleum and Natural Gas Industries. External coating for buried

frequency, a strain percent of 1 Hertz and 0.1% with an oscillating

remains as constant as possible. In general in thermo oxidative

or submerged pipelines used in pipeline transportation systems Part

shear mode. The shear module and tan delta values from samples

environments the chemical reactions underlying the degradation

3. Field joint coating for ISO 21809-3 Standard: 2008-08-15-

unexposed and exposed were compared. The results are plotted in

for the polypropylene-elastomer blends involve oxygen dissolved

3. Petroleum and Natural Gas Industries. External coating for buried

Figure 11 for the 2L XPE and Figure 12 for the 3L XPP.

in the material. Accelerating these reactions by using elevated

or submerged pipelines used in pipeline transportation systems Part

temperatures (e.g. in air circulating ovens) can bring complications

3. Field joint coating draft for ISO/FDIS 21809-3 Standard: 2015-

Results and discussions

caused by diffusion limited oxidation. Diffusion-limited oxidation

07-24

The peel adhesion results for both 2 layer XPE coating and 3 L XPP

occurs when the rate of oxygen consumption within the material is

4. P. Cook, Radiation Physics Chem., 35, 7 (1990)

coatings expressed as normalized values (value at time of test over

greater than the rate at which it can be resupplied by diffusion from

5. Dakin, T. W. AIEE Trans. 1948, 67, 113-118

the results without exposure) were found consistently above 0.80.

the surrounding air. This could result in heterogeneously oxidized

6. J.R. Pauquet, R.V. Todesco, W.O. Drake, Limitations

In the case of the 2L XPE the peel adhesion values were found to

material thus altering the tensile properties. Future work will consider

and Applications of the Oxidative Induction Time (OIT), 42nd

increase with time after hot water immersion, whereas for the 3L

thermally aging the materials under a controlled oxygen environment,

INTERNATIONAL WIRE AND CABLE SYMPOSIUM

Nt coNteN Nt coNteN

2014 SEPTEMBER 2014 SEPTEMBER 2 2 148 148

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district heating & cooling superior sealing solutions

Nt coNteN

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eNt Nt

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district heating from plant to households

a smart system District heating is a system for distributing heat generated in a centralized location for residential and commercial heating requirements, such as space heating and water heating. In many processes, for example when electricity is generated or waste is burned, large parts of the energy are set free in the form of surplus heat. The fundamental idea behind modern district heating is to recycle this surplus heat which otherwise would be wasted â&#x20AC;&#x201C; from electricity production, from fuel- and biofuel-refining, and from different industrial processes. The recycled heat is used to heat water which is transported to the customer via a well-insulated network of pipes.

Nt coNteN Source: vattenfall.com

2014 SEPTEMBER 2 152 152

from the tap The hot water circulates between the heating plant and the customerâ&#x20AC;&#x2122;s premises in insulated, underground steel pipes. The pipes are laid in trenches, often with other infrastructure such as phone lines and power cables, and they suffer average heat losses of only five to ten percent. Customers use the water for heating through piped underfloor heating or radiators and for heating tap water.

home, sweet home 2014

153 153

the other way:

district cooling

re-use of energy • One very large chilling plant distributing to an area is a lot more energy efficient and cost effective than thousands of individual chillers / airconditioners. • Lower capital, energy, operation & maintenance costs • Increased energy efficiency • Reduced air pollution and CO2 emission • Flexibility in building operation • Lower space requirement for cooling equipment

Chilled water supply and return network Chilled water plant

Customers

Nt Customers

Smaller chilled water plant

Chilled water plant

2014 154 154

sustainable resource Many different energy sources are used for district heating production, including waste, biofuel, heat pumps, landfill gas, natural gas, propane/butane, electricity and fuel oil. Several different energy sources may be used simultaneously in the district heating plant, which makes for stable and flexible supply of heat to customers. District heating based on renewable energy sources has a positive environmental effect.

climate protection 155 155

For example Europe

energy strategy

Nt coNteN The European Union has set targets to reduce energy consumption by 20% and to reduce CO2 emissions by at least 20% (possibly 30%) by 2020.

More district heating will help Europe achieve its aims of being: • energy efficient and flexible in its energy choices

2014 SEPTEMBER 2 • less dependent on energy imports

• competitive and a leader in climate change

156 156

Seal For Life Seal For Life Industries is a total solution provider for joint and sealing techniques in district heating/cooling. The product range includes: joint casings & sealing heat-shrink sleeves (wrap-around and tubular), foaming hole closures, primary joint foam seal, end caps and sealants. Additional equipment like torches, scrapers, heat shields, etc. are part of the Seal For Life District Heating & Cooling product assortment. In addition, Seal For Life has also designed products based on innovative radiation chemistry and polymer technology for transmission pipelines and gas and water utilities. Millions of pre-insulated pipe joints have been sealed with Seal For Life products.

2014

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lW ea

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M PS

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Seal For Life shrinkforce & waterbarrier technology

S-D

Nt coNteN INT

O YJ A R

2014 SEPTEMBER 2 158 158

158

/I EC

A comprehensive

product range answers every application need

in a district heating and cooling network. Withstands ISO-489 soilstress al

e alS

-E

S RJ

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reliable installation No matter what level of performance a joint sealing system displays, if it cannot be installed correctly and consistently, it will most certainly fail. Installing Covalence heat shrink sleeve/Dualseal systems. is really very simple but it is still vital to ensure that every part of the sleeve receives a minimum amount of heat. We now incorporate a unique solution to this challenge by supplying our sleeves with dimpled backing. These dimples vanish permanently on receiving the correct amount of heat thus providing

Nt coNteN a visual guide to the installer, and, most importantly, post installation proof to the coating inspector. The outer backing layer is made from irradiated crosslinked high-density polyethylene (HDPE). It is expanded during the production phase. Heating manually via torch or automatically via SFL

patented Kelvin technology causes the sleeve to recover and generate a permanent hoop stress around the pipe.

2014 SEPTEMBER 2 160 160

Covalence Heat Shrink Sleeves: • HDPE backing provides a high shrink force, resulting in a high hoop stress, and a high mechanical strength. • Due to the partially crosslinked molecular chains, the backing can be heated beyond the crystalline melting point of the HDPE without any damage. This results in a safe and fast installation. • Even after many years of installation, the backing will not creep will not creep or lose it compressive hoop force. This results in long-term, high-quality performance. • No special stocking requirements are necessary. No shelf life limitation. Since products are crosslinked and expanded at elevated temperatures, they will not recover when lying in the sun during construction.

Nr 1 in Abrasion resistance

High shear hotmelt adhesive Visco-elastic sealant

2014

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Shrinkforce protection When our beloved alligator has a prey clamped in its jaws, he will never let go. His scales protect him from harsh attacks from all sides. The properties of this powerful beast are similar to the concepts of corrosion protection of Seal For Life’s Covalence Shrinkable Systems. The innovative shrink technology of Covalence protects critical infrastructural objects without losing elasticity. Covalence is one of our most powerful and proven technologies. Whether in combination with the visco-elastic corrosion prevention materials, hot-melt and mastic adhesives, total care shrink technology is the way to Seal For Life tight. It’s about making the surface preparation and the applicators’ job easy. Covalence – the first and still the best at heat shrink technology.

Seal For Life joint and technology overview Product

RayJoint

DualSeal RJS-E End Seals

DualSeal RJS-E Jacket Continuation

Type of Joint

Oversized casing Heat-shrinkable casing (non-crosslinked) All-in-one-joint (crosslinked)

•

• • •

Metal sheet casing

Product features and benefits Soil stress resistance 0,5% sand humidity (EN489)

Pass

HDPE backing (high shrink force = 3N/mm2)

•

Pass

Nt coNteN PCI/Dimpled backing

Tubular (T) / Wrap-around (W)

• High wall thickness adapted to the corresponding casing pipe thickness • Superior performance against soil stresses • Partially crosslinked HDPE backing with high shrink force • No additional outside sealing required • Pressure testable before foaming • Smart economics: superior performance for low installation cost

• •

• High performance sealing system consisting of 2 sealing zones • Visco-elastic sealant, barrier against moisture, excellent flow and fill • High shear resistance hotmelt adhesive • High mechanical resistance HDPE backing with high shrink force • Easy installation • Antislip zone • Unisleeves offer just-when-needed installation • Dimpled backing offers a permanent change indicator (PCI) resulting in reliable installations and full inspectability at any time after installation

• High performance sealing system consisting of 2 sealing zones • Visco-elastic sealant, barrier against moisture, excellent flow and fill • High shear resistance hotmelt adhesive • High mechanical resistance HDPE backing with high shrink force • Easy installation • Unisleeves offer just-when-needed installation • Dimpled backing offers a permanent change indicator (PCI) resulting in reliable installations and full inspectability at any time after installation

2014 SEPTEMBER 2 162 162

Product

EasySeal WPSM-PE End Seals

EasySeal TPSM-PE End Seals

• •

Pass

• •

Type of Joint

Oversized casing Heat-shrinkable casing (crosslinked and non-crosslinked) Metal sheet casing

Product features and benefits Soil stress resistance 8% sand humidity (EN489) HDPE backing

Nt PCI/Dimpled backing

Tubular (T) / Wrap-around (W)

Product features and benefits

• Visco-elastic sealant, barrier against moisture, excellent flow and fill • High mechanical resistance HDPE backing with high shrink force • Very easy installation • Unisleeves offer just-when-needed installation • Dimpled backing offers a permanent change indicator (PCI) resulting in reliable installations and full inspecability at any time after installation

2014

• Available for complete casing pipe diameter range from 90 to 800 mm • Individually packed in polybag to avoid contamination • High mechanical resistance HDPE backing with high shrink force • Very easy installation • Dimpled backing offers a permanent change indicator (PCI) resulting in reliable installations and full inspecability at any time after installation

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built-in performance Itâ&#x20AC;&#x2122;s a well-known fact that most failures on pre-insulated pipes occur in the joint area. This is due to expansion and contraction during construction [bv day/night temp-delta] and operation and can cause breakdown of the joint sealing systems. The current edition of the European norm for joints of pre-insulated pipes EN 489-2009 stipulates that joint sealing components withstand a minimum of 100 cycles when tested for soil stress resistance using sand with max 0.5% humidity. The adhesives (hotmelts and mastics) are developed and produced at Seal For Life. They are specifically designed for each application. The combination of backing and adhesives guarantees the quality of the total sealing system. The difference between the shrink temperature at the high crystalline melting point (125Â°C) of the Seal For Life District Heating backings and the lower softening points of the adhesives ensures that all irregularities in the joint area are ideally filled with adhesive.

Nt coNteN

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The heat-shrinkable backing of the Covalence district heating products contains HDPE as the main polymer. As a result the sleeves have a higher mechanical strength and create higher hoop stress, which during installation presses the adhesive more effectively into the irregular corners and stepdowns and sustains the compression long term. For standard applications DualSeal RJS-E is used. DualSeal RJS-E autonomously meets all requirements of EN 489-2009. DualSeal RJS-E sleeves contain a mastic area in the middle and hotmelt zones at the sides. The combination of the two adhesives provides a dual functionality: The specially designed hotmelt exhibits extremely high shear resistance for superb soil stress resistance. The mastic area of the sleeve ensures extremely high reliability of sealing under all kinds of jobsite conditions and creates an elastic zone in the casing/jacket transition which acts as a mini-compensator to accomodate relative casing movements. Both hotmelt and mastic adhesives have excellent low temperature flexibility and have excellent resistance against long term elevated temperature, long term water resistance and chemical substances present in the soil. For less demanding applications Covalence EasySeal products TPSM-PE and WPSM-PE are used when expected pipe movements and soil stresses are moderate. Selection is simple: â&#x20AC;˘ You determine the level of performance needed â&#x20AC;˘ We provide the solutions

2014

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CAS 166

SES 167

Anod 168

linear anode

AnodeFlex™ is an energy efficient, flexible long linear anode providing an impressed current for use in cathodic protection systems for buried pipelines, tanks and other steel structures. Placed alongside a pipe or other buried metal structure, AnodeFlex™ provides uniform cathodic protection over the full length of the protected structure. Anodeflex™ complies with DOT and other government regulations.

deflex

de technology 169

HDD project Anodeflex-1500

3LPE 1016mm HDD project in Beijing Surberb of Beijing Gas group. AFLX 1500 was used as the CP of HDD section. AFLX-1500 was put into a 10 inch small pipeline and in the small pipeline was drilled a lot of small holes. The 10 inch small pipeline with AFLX-1500 inside and was crossed parallel with the main pipeline. The distance is about 7-8 meter of the two pipelines. Then fill up the sludge into the 10 inch with AFLX-1500 pipeline after the 10 inch pipeline was crossed.

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un os de pa rw ce at m er ob in ile st al pi la p tio on el n in sh e or co e at o of il in & fs g ho ga s re pi pe di st lin ric es th e at bu in ild g in & g co & tu ol c rn on in -k g st ey ru ap ct ca io pl ic ns si a ng tio ns fil le p r

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3LPE pipeline in Beijing Suburb city, China

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Linear anode technology avoiding stray current at refineries under tankbottoms

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Linear anode technology to protect compressorstations

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Linear anode technology to protect underground assets in soils with high resistivity

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Linear anode technology for HDD and MicroTunneling

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Tank bottom protection

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Self-Healing Vis 184

STOPAQ

sco-Elastic Coatings 185

What to look for in a Visco Elastic Coating In the world of the big brands, the struggle between innovation and those that would copy goes on. Seldom does a day pass that the press does not report on disputes between innovators and those that allegedly copy to compete. We are all familiar with Apple vs. Samsung, Google vs. Microsoft, or Nokia vs. Research in Motion. A patent represents an exclusive right granted by a State to an inventor. In exchange for making the invention public (and solving a problem or making a contribution to society’s technological progress), the exclusive right allows the patentee, for a limited period, to prevent others from making, using, selling, or distributing the invention without permission. We are proud to manufacture unique and protected anti-corrosion (visco-elastic) solutions. So our motto is: do it right, do it once! We are proud to manufacture unique and patent protected corrosion prevention (visco-elastic) solutions.

Advantages of BASF’s Oppanol® A unique set of properties in a single product: • High bonding strength • Adheres to almost all substrates, e.g., pp, pe, fbe, and & epoxy • Does not cathodically disband • Extremely low permeability • No internal stress • Long-term stability • Non ageing

Do It Right, Do It Once! • Developing and producing non-toxic anti-corrosion and sealing products • Fast and easy to apply systems • Healthy & safe solutions • Non-polluting and no chemical waste • Protecting the environment, both sea and land • Providing a better working environment • Providing logistical advantages • Offering guaranteed solutions • Being the best at what we do • A reliable and trusted source • Continuous improvement of compositions

Nt coNteN

2014 SEPTEMBER 2 186 186

No cathodic disbondment

Does not disbond from blasted or re-rusted steel in a few minutes at ambient temperatures

Maintains flexibility until -67Â°C

Real self-healing in 5 minutes at 700C

Fluid-like properties may be sprayed

Highly chemical resistant

Approved by renowned companies

High impermeability to water and oxygen

Fully amorphous material, can be painted

Maintains fluid phase

Dripping point beyond 130Â°C - C2H

Will not spark at 22,5 kV of wrappingband

Can be applied underwater

No discoloration after water soak immersion test

2014 Cohesive fracture leaving compound in place on surface by pulling the netting out of the band

Injectable

187 187

Range of corrosion prevention, insulation and sealing products against ingress of water

188 188

es el in ip at er p w

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y re fin

flo or in

sp la sh -z on e ae & r

ar in m

STOPAQ® is a fully amorphous, non-polar polyisobutyelene based compound having excellent intrinsic corrosion preventative properties. It is impenetrable to water, oxygen and bacteria, the elements that commonly cause corrosion. Unlike conventional coating types, the STOPAQ® compound features a liquid-like behaviour to flow across and ensure a full wetting of the entire surface of substrate. STOPAQ® supplies a wide range of patented visco-elastic solutions to protect assets from corrosion and water ingress. STOPAQ Aquastop is a compound suited for sealing of wall, pipe- or cable inlets and hollow spaces, against gases, moisture, standing water and running groundwater leaks. STOPAQ Casing Filler is an injected casing filler material, it is far superior to any other coating system currently in the market. This system combines the excellent corrosion prevention properties with the visco-elastic behavior of STOPAQ.

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Fusion-Bonded Coating Repair before laying, Mexico

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Pipe Storage Cut Back Protection (EndCaps and VPCI inhibitor)

Statoil, Norway

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Fast Gre, Stock Saltillo, Mexico

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Above ground refinery coating

Client: Shell UK Location: Mossmoran, Scotland UK Object: Piping / structural Object dimensions: Various diameter Number of objects: throughout Existing coating: 3 layer, zinc phosphate primer, epoxy midcoat, PU topcoat Reason: Severe corrosion due to failure and weathering of existing Contractor: Wood Group, Cape Applied system dry area: STOPAQ CZH paste / CZH Wrappingband / PVC Surface preparation: St 2 / St 3, water jetting Temperatures: +5 to +25 ambient, +10 to +25 surface Â°C

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watch this case online!

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Mainline Pipeline Coatings to resist AC/DC and Stray Current interference

196 196

Shell Pernis, Botlek, Rotterdam, The Netherlands Coated by Ehri B.V.

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Difficult to coat geometries

Client: Gasunie, Location: The Netherlands Object: compressorstation

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Transition areas

Application of CZH Paste

200 200

Vilsteren Compressorstation, Gasunie, The Netherlands 201 201

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Rehab of a T-Joint by Wrappingband + Outerwrap

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GNPOC, SUDAN

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Gasunie Compressorstation Workum in Wrappingband + Outerwrap

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Saudi Aramco Krt4 Pipeline STOPAQ Wrappingband + Outerwrap

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Onshore riser

Location: Oman Object: Gulf Petrochemical Services

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Bergermeer, TAQA, The Netherlands

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Offshore laybarge FJC coating CWC Pipeline Wrappingband + Outerwrap

Contractor: Valentine Marine Client: Saudi Aramco

210 210

Technip, UK PP coated offshore pipeline

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Above ground flanges

Client: Gasunie Netherlands System of CZH Paste, Wrappingband CZH and Fiberglass Reinforced Shrinkable Sleeve (HI Shield HSR)

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Onshore Riser

Gasunie, The Netherlands 214 214

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Petrol station joints, bends, T-joints

Since 1994, over 4,000 Petrol Station Manhole Covers and Piping in the Netherlands KIWA BRL K911 (Building Regulation)

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el in

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Underground tank coating

Top Projekt, Croatia 218 218

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Stainless steel (RVS)

Wintershall Noordzee B.V.

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221

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Avoid galvanic corrosion and deterioration by friction at pipe saddles

JANAF Refinery KRK, Croatia 222 222

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el in

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Pipeline rehabilitation

BP Azerbaijan, BTC Pipeline 224 224

Oman Gas Company, 2005 225 225

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el in

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Gasketprotection of above ground flanges

RWE Energy, Germany 226 226

National Grid, U.K. 227 227

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Cable/wall penetration: water leakage stop and prevention up to 35 Â°C

ENEXIS, The Netherlands 228 228

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sp la sh -z on e ae & r

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Water ingress prevention at pipe/wall entries up to 50 Â°C

Fluxys N.V., Belgium 230 230

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el in

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er y

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sp la sh -z on e ae & r

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High dielectric strength casing filler as cathodic protection solution

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Polish Gas Company 233 233

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

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Casing End Seals (Sleeve)

North South Pipeline Gasunie, The Netherlands NACAP (currently A.HAK)

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Chime area protection of tank bottoms

Oil India Ltd. 236 236

237 237

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el in

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Repair of thermal spray aluminum

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Pinbrazing

Catweld/pinbrazing kit

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at er p

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er y

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Fieldjoint coating with shrink sleeve

Job done in 8 minutes for 48" fieldjoint coating

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North South Gasunie Pipeline, the Netherlands

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el in

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Manhole cover protection Patented since 1996

STOPAQ 4100 plus geotextile mechanical cover

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CITY OF HOUSTON

245 245

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Coating of condensating lines to avoid shutdowns

Pemex, Mexico 246 246

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el in

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Fieldjoint Coating of pre-insulated pipeline at subzero temperatures up to -52 Â°C

Moda Pipeline from China to Russia 248 248

249 249

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el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

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sp la sh -z on e ae & r

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Sound dampening and vibration control

Impact hammer

Plate 2 mm

Acceleration Pick up Plate 2 mm, with Stopaq tape

Plate 2 mm, with 2 mm sound absorption material

Stimulus 250 250

AccelerationPick up

Result

- Steel plate 2mm - Steel plate with Stopaq tape - Steel plate with commercial sound absorption sheet

tennet offshore windmill park powerstation

251 251

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el in

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er y

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Fieldjoint coating

40,000 joints 48", Gasunie, the Netherlands

252 252

Balgzand, BBL Pipeline 253 253

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el in

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Underground valve protection

Wrappingband + outerwrap + CZH paste for transition areas

254 254

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el in

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Low to medium voltage cable joint system

Enexis, the Netherlands 256 256

OIL WELL INTEGRITY SEALING, Wintershall Libya 257 257

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

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Nut & bolt assembly corrosion prevention solution

Client: Santos Contract Resources: Contract Resources Application date: July 2014 Project name: GLNG in Curtis Island on the Queenslandâ&#x20AC;&#x2122;s East Coast Project description: Nut and bolt corrosion protection for asset life and maintenance ease was the scope to the coating and installation contractors. Harsh marine and coastal environment with high temperatures, wind, rain and constant salt spray from the ocean.

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at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

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Spherical tee corrosion prevention solution

Client: Jemena Contractor: Carcon Excavations Application date: July 2011 Project name: Gosford TRS Project description: Offtake from the 500 mm Sydney to Newcastle trunk line to feed the Gosford NSW area. Jemena upgraded the station and, due to the size upgrade, a new by-pass size upgrade needed to be done and therefore a spherical tee was used. Traditionally, Jemena would have applied a petrolatum system for this application, however, in this instance STOPAQ was selected as the coating system of choice.

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el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

T-Joints Protection with Shrinkable Sleeves

Reliance India 262 262

263 263

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

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ar in

High Voltage Joint Sealing, Tennet

264 264

Wrappingband CZHT, Paste CZHT + Outerwrap HTPP 265 265

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n ns t-eitleyo cou mrse lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

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Power

Liquid pipe

266

Powercrete is a 2 - component liquid curing coating used for rehabilitation, directional drilling, girth weld protection, bends, fittings and odd shapes, offshore applications, patch and repair and potable water applications. Powercrete is designed to meet the requirements of the most demanding pipeline applications.

rcrete

pipeline coating 267

Liquid Pipeline Coating Technology

This 80 kilometre Cairn India pipeline was build to transport hydrocarbon material rich and high in wax content. Due to this, the pipeline was welded with a 1inch sect tube on the 24inch dia mainline carrying heat tracing wire to provide the ‘skin effect’ to which afterwards the pipeline was insulated to maintain 100°C to 120°C while in service.

268 268

Powercrete R-150 Skin-Effect heat traced pipeline solution

269 269

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el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

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Rehabilitation in the ditch Liquid Pipeline Coating Technology

270 270

271 271

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

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Liquid Pipeline Coating Technology

272 272

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at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Liquid Pipeline Coating Technology

274 274

PC-DD (black) and PC-J (brown) in a Tianjin Gas Net pipeline with 508 mm diameter for HDD, China 2008

275 275

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

36 inch ARO Coating Liquid Pipeline Coating Technology

KINDER MORGAN U.S.A.

276 276

277 277

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

External protection manual applied Liquid Pipeline Coating Technology

278 278

279 279

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Internal protection plant applied Liquid Pipeline Coating Technology

280 280

281 281

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Liquid Pipeline Coating Technology

282 282

283 283

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

H.D.D. - applications Liquid Pipeline Coating Technology

consolidated pipe birmingham, U.S.A

284 284

285 285

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

286

pipeline tape

Polyken pipeline tape coating systems provide pipeline protection with cold-applied and fused tape coating products for various climates and environments.

OLYKEN

tape technology 287

Double face tape field applied

288 288

289 289

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Bell-Hole Application

290 290

291 291

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Fireproofing tape

Application: Fireproofing Living Quarters Market: Energy, Construction, HVAC Product: Polyken 297 FR Application Description: Oil Platform Fire protection is very important on oil platforms due to volatile chemicals that are present. Rockwool insulation panels are used to provide both fire and thermal protection on Oil Platform in the living quarters. Thermal is also important because average temperature where the oil rig is stationed is -5C and winter temperatures can be -10 to -40C. Polyken 297FR is used as a seam tape on the fiberglass backed Rockwool. The 297 tape meets Federal Aviation fire regulations and has been certified to Russian Marine fire standards.

292 292

293 293

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Fireproofing tape

Application: Fireproofing Living Quarters Market: Energy, Construction, HVAC Product: Polyken 337 Application Description: Oil Platform HVAC ducts are encased in foil backed insulation for energy efficiency. Polyken 337 is used as a seam tape on the foil backed insulation. The 337 tape meets ASHRAE (American Society of Heating and Refrigeration Engineers) fire regulations and has been certified to Russian Marine fire standards.

294 294

295 295

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Rehabilitation in the ditch

296 296

297 297

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Bell-hole rehabilitation

298 298

299 299

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

'over the ditch' 300 300

301 301

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

New build pipelines

302 302

303 303

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Factory 'off-site' application

304 304

305 305

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Factory applied water pipelines

306 306

307 307

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Coval

HEAT shrin

308

Covalence heat shrink sleeves provide long term corrosion protection and strong mechanical strength performance for oil, gas and water pipelines. CovalenceÂŽ offers a broad range of field joint coating solutions based on an irradiated cross-linked polyolefin backing combined with a hot melt or mastic pressure sensitive adhesive.

lence

hrinkable coating 309

High voltage cable protection

Bell & Spigot Joints MPSM/MEPS

Mechanical Coupler CPSM (tubular)

Line Coating Repair PERP

Flange Coupler FCTS/FCWS(-F)

Wrap Around 2 Layer Shrink Sleeve WPC

Bends FLEXCLAD Blocking Tee BLOT

House Tap Tee HTTE

Wrap Around 3 Layer Shrink Sleeve HTLP Tubular Shrink Sleeve TPSM

310 310

Casing Ends CSEM(-F)

Directional Drilling Sleeve DIRAX

EasySeal

Wrap-around Tubular Pre-insulated Pipe Covalence Solutions

Flexclad

Flexible Shrink Tape Covalence Solutions

Rayjoint

Joint Casing Covalence Solutions

Raytrans Electro-shrinkable Covalence Solutions

311 311

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Rayclad 80

312 312

313 313

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Rayclad 120

OMV Pakistan 314 314

315 315

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el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

HTLP 80, direct sleeve application on top of WET (uncured) EPOXY

HTLP 80, EDISON ITALY, Ghizzoni 316 316

317 317

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

West-East Gas pipeline, Petrochina, Yangzi river HDD

318 318

319 319

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

High voltage cable protection

320 320

321 321

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Offshore Solutions

Insulated offshore pipeline

Offshore pipeline in India, Carrier pipe 12.75" â&#x20AC;&#x201C; Perma pipe / ONGC 322 322

323 323

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Offshore Solutions

324 324

Offshore polypropylene & CWC pipelines

325 325

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Onschore large pipe diameter fieldjoint coating

326 326

327 327

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Blue 60

328 328

329 329

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Onshore 3LPE FJC coating

330 330

331 331

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Gastorch application 332 332

Offshore sparktest 333 333

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Large diameter bell-spigot joints waterpipeline

334 334

335 335

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

336

Syner

non-aging tape

SynergyQ is a new single wrap pipeline coating system that exists of a polyethylene backing and an extremely high shear resistant corrosion prevention material. The system does not require any primer and can be applied with little tension. It will not get brittle, tear or break at low temperatures; it simply seals for life. It is the ultimate non-shielding tape system with an extreme moisture uptake resistance in the market today.

rgyq

tape solutions 337

Complete Linepipe & Field Joint Coating Solutions for Ductile Iron pipeline

338 338

339 339

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Full Service Automated Coating Application Equipment. Factory & Field application

340 340

341 341

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

EASY-

ELASTOME

342

No blasting needed

-QOTE

ERIC COATING SOLUTIONS 343

Pinbrazing insulation and corrosion prevention

344 344

345 345

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Rivet bolts protection

oosterschelde bridge, the netherlands 346 346

347 347

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Rope access application

Dutch northsea windmill park 348 348

1. SLF substrate cleaner (SPRAYCAN) 2. sfl easyqote 3. sfl wB topcoat (1-component DISPENSER)

349 349

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

350 350

351 351

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Above ground H-beams and other structural beams

352 352

353 353

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Spotrepair windmills

354 354

355 355

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Above ground structural steel

Formosa, Taiwan 356 356

357 357

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Structural support bases Inpex, Australia

Icthys Gas Plant 358 358

359 359

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

360

SEA

SEAL

SEALTAQ

LANT SOLUTIONS 361

Crossover Waterproofing by Sealtaq Universal Band

Highway A28 - exit assen tt circuit 362 362

363 363

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

364 364

365 365

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

366 366

367 367

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Roofing repair of hotelroofs

Johannesburg, South Africa 368 368

369 369

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Roofing repair on wooden roof

Sodwana Bay Lodge, South Africa 370 370

371 371

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

372

BLO

OCKR

OME SOLUTIONS 373

Solutions for home and marine

374 374

375 375

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

SFL se 376

turn-key

ervices

ey applications 377

Services

Turn-key Applications & Equipment

Mobile Field Pipeline Coating 378 378

Mobile pipeline coating

379 379

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

380 380

Offshore onsite trained & certified crews

381 381

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

STOPAQ 4100 putty STOPAQ Wrapping Band STOPAQ High Impact Shield

382 382

Endseals Casings

383 383

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

384 384

FAST; Field Applied STOPAQ Technology with PE/PP extrusion for mechanical protection

385 385

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

386 386

Inshore splashzone prevention system for jetty piles

387 387

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

388 388

Offshore Flange Maintenance, BlueWater Australia

389 389

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

3LPP Pipeline FieldJoint Coating

Polypropylene Flame Spray for HDDapplication applied to Stopaq Basecoat

390 390

391 391

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

For the maximum installation comfort & performance SFL Technologies and Services developed the very first intelligent assistant tool in Heat Shrink Sleeve installation. The intelligent KELVIN Direct Contact offers optimal and guaranteed installation comfort and performance reading the characteristics of the Sleeve materials applied. The KELVIN Direct Contact recognizes the softening point of the Sleeve adhesive layer as well as the duration of the liquid stage the adhesive is kept in, the so called bonding phase.

392 392

Uniform and consistent tool to shrink a shrinkable sleeve for joints

KELVIN I.R. 393 393

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

Subsea pipeline and structural repair

X-knot offshore, Woodside, Australia 394 394

watch this case online!

0.22

watch this case online! 0.22

395 395

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

396 396

397 397

at er p

el in

at m os ph er ca ic th pa od in ic ta bl p ho ro e m te s o e ct lu do io tio n -it ns te -y le o co ur m se lf pu lp & pa pe tra rp ns la po nt rta s in t io fra n

er y

re fin

flo or in

sp la sh -z on e ae & r

ar in

Services

Turn-key Applications & Equipment

PE repair, Croatia 398 398

Induction removal bitumen, PE, PP or epoxy coatings 399 399

at er p

el in

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Services

Turn-key Applications & Equipment

Internal welding sleeve

• Traditional methods for welding internally coated pipe without protection are not recommended as Corrosion would concentrate at the weld seams where the internal coating has burned off (Trouble Spot) and reduce the life of the pipe by as much as 75%. • The Cylindrical Corrosion Barrier sleeve is designed to isolate the portion of internally coated pipe that is destroyed by the heat from the welding process. • It returns the internal lining to a homogenous state protecting the steel from the corrosion that occurs when the girth weld area is left unprotected by the loss of the I.D. coating. • The sleeve has two sets of O-rings affixed into grooves machined around the outer circumference of the ends. • The O-rings are manufactured with compounds specifically designed to resist the process flow being transported in the pipeline. • The heat resistant material folds around the interior radius of the steel backing ring to completely isolate the band from the sleeve and provides heat protection during the welding process.

400 400

Internal Welding Sleeves

During Welding

es el in ip at er p w

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Cross Sectional Cut

Advantages â&#x20AC;˘ The Cylindrical Corrosion Barrier sleeve represents a long awaited technological advancement for internally coated pipeline installations. â&#x20AC;˘ The sleeve is the most simplistic and efficient method to provide positive corrosion protection in a traditionally troubled spot for all internally coated pipeline systems. â&#x20AC;˘ The installation crew can move forward knowing that a permanent solution to girth weld corrosion has been accomplished.

401 401

Services

Turn-key Applications & Equipment

402 402

On-site turn-key casing filler application services mobile self-supporting units

403 403

at er p

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Services

Turn-key Applications & Equipment

DCN Diving, Nacap/Van Oord Gasunie, Netherlands 404 404

Subsea caisson application of STOPAQ

405 405

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Services

Turn-key Applications & Equipment

Product range: • Semi-Conductive Water Blocking Tapes • Non-Conductive Water Blocking Tapes • Film Laminated Water Blocking Tapes • Binding, Bedding and Barrier Tapes • Woven Tapes • Water-blocking Woven Tapes • Foam Tapes • Marine Tapes • Water Blocking Yarns • Water Blocking Cable Fillers • Water Blocking Flat Binders

406 406

Cable and Wire Solutions

Outer sheath Non-conductive separation tape

Braided shield Inner sheath

Insulated wires 407 407

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Marking underground buried services Can be manufactured in any colour, size, text or language to suit the project 408 408

TERRAM Protectamesh HD TERRAM Utilitape is a brightly-coloured underground warning tape manufactured from polyethylene ďŹ lm and can be produced to your speciďŹ cations: printed with any text in any language, any colour and any size.

Underground warning mesh Utilitape underground warning net is brightly coloured, has a central strip that can be printed with a warning message for easy recognition during excavation and is manufactured and tested in compliance with BS EN12613:2009.

Detectable warning tape Wavelay is a detectable warning tape with embedded steel tracer wires that can be located using standard cable and pipe locators used with non-metallic pipes and un-energised cables. As a backup, the highly-visible, printed tape will also show within the spoil during any subsequent excavation.

Detectable mesh TERRAM Detectamesh is a high-strength, rot-resistant polypropylene mesh incorporating a traceable stainless steel wire or aluminium foil, and overprinted with a warning message in black. It can be located using standard cable and pipe locators used with non-metallic pipes and unenergised cables. The highly-visible mesh will show within the spoil during any subsequent excavation. TERRAM Detectamesh is laid at half depth in the trench above a pipe or a cable.

409 409

Services

Turn-key Applications & Equipment

THE GREEN COATING TRAILBLAZER 410 410

GREEN Â®

SCAR

411 411

Services

Turn-key Applications & Equipment

Clamp Repair Application Instruction

Application pplication Instruction Instruction

(foto) (foto) 32â&#x20AC;? Subsea Pipe, Indonesia

412

(foto) (foto

) 413

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Services

Clamp Repair Application Instruction

Turn-key Applications & Equipment

±135°

POLICLEAN DISC

[1]

5 min.

[2]

[3]

Pipe and clamp to be coated in a habitat with:

Prepare entire surface, incl. adjacent factory

Surface cleanliness check. Apply ±150mm

Paste SZ might be used to fill up irregular

•

Paste SZ (optionally)

applied coating, according ISO 8501-1 St2

Stopaq Wrappingband onto the surfaces of the

shapes and sharp edges at the extremity of the

•

Wrappingband CL (*or Wrappingband SZ)

/ St3 standard minimum. Wire brush, Monti

pipeline at the 3, 6, 9 and 12 o’clock position

clamp or existing pipeline coating. Use small

•

Subsea Intermediate Wrap

Bristle Blaster, Grid blasting, Grinding disc or

and press the material, continuously, firmly into

chunks of Paste SZ for ease of application.

•

Outerglass Shield XT Grey

similar tools are sufficient. Prepare the remaining

the pores of the substrates [1] . Remove the

pipeline coating surface by use of scotch bright,

Stopaq after approx. 5 minutes in an angle of

any loose/damaged pipeline material needs to

approx. 135° and a with a speed of 100mm/

be removed.

min [2]. Cohesive failure should occur and the remaining Stopaq material should cover ≥95% of the surface [3]. If this is less, further cleaning is required. Repeat cleaning and cleanliness check

≥10mm

≥100mm

≥10mm

until ≥95% of the surface remains covered. ≥100mm

Sections covered with remaining pipeline coating should be checked with the same method.

Apply Wrappingband CL by means of straight

Carry out a visual inspection to ensure

In case that the application shall be done

or spiral wrap over the pipe. Start touching

that the entire area has been covered with

under water, without habitat, Wrappingband

the concrete until touching the clamp with

Wrappingband CL.

SZ shall be used. Follow the same application

a minimum side-by-side overlap of 10mm,

procedure, but with a minimum side-by-side

circumferential overlap minimum 100mm. Apply

overlap of 50%.

without air or water inclusions and with tension. The entire pipe and clamp must be covered with at least 1 layer Wrappingband CL. 414

es el in ip at er p w

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flo or in

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e ar in m

≥100mm

≥100mm ≥10mm

[1]

[2]

[3]

Apply strips of Wrappingband CL over the

Continue until the entire circumference has been

Apply Wrappingband CL with the same

Apply Wrappingband CL by means of straight or

clamp. Start on the larger diameter of the

covered with Wrappingband CL.

procedure on the other side of the clamp.

spiral wrap over the clamp with a minimum

pipe and work towards the pipeline. Apply

side-by-side overlap of 10mm, circumferential

Wrappingband without air or water inclusions

overlap minimum 100mm. Apply without air or

and without any tension. Press the material

water inclusions and with tension.

firmly in the pores of the substrate. Overlap over previous applied Wrappingband minimum 10mm and minimum 100mm over the clamp and pipeline. ≥100mm

≥100mm

≥50%

Apply Wrappingband SZ over clamp and on

Apply Subsea Intermediate Wrap with the

Apply Subsea Intermediate Wrap spirally around

the pipe. Start touching the clamp and end

same procedure over the transition area as

the clamp and on the pipe. Start touching the

touching the concrete. Start with 2 straight

the Wrappingband CL, but with a minimum

clamp and end touching the concrete. Start with

wraps and continue with a minimum overlap of

overlap of 50% over the clamp. Apply without air

2 straight wraps and continue with a minimum

50%. Finish with 2 circumferential wraps. Apply

inclusions and without tension.

overlap of 50%. Finish with 2 circumferential wraps.

Wrappingband SZ with tension and without

Apply Subsea Intermediate Wrap with tension and

water inclusions.

without air inclusions. The last 300mm shall be applied without tension. Cut the end as a tie. 415

Services

Clamp Repair Application Instruction

Turn-key Applications & Equipment

General information about the application of Outerglass Shield XT. •

The pouches of Outerglass Shield XT shall be opened one at a time and just prior to application. Once a pouch is opened, the curing reaction with moisture present in air or water

≥50%

will start immediately. •

The Outerglass Shield XT shall be applied within the working time indicated, including application of compression foil and perforation.

•

Do not cover large surfaces at once, since Outerglass Shield XT needs to be compressed

Apply Outerglass Shield XT criss-cross around

Continue until the entire clamp has been

immediately after application with compression foil.

the clamp. Apply with tension and without air

covered with Outerglass Shield XT. Continuous

•

Always apply and perforate compression foil well within the curing time of Outerglass Shield XT.

entrapments. Minor folds do not cause any

wetting of Outerglass Shield XT.

•

In case overlapping existing Outerglass Shield XT, it shall only be applied on fully cured

problem as the compression foil will be applied

Keep respect to instructions. Do not cover the

Outerglass Shield XT and after the compression foil has been removed and the surface has

afterwards. Continuous wetting of Outerglass

entire clamp if the compression foil cannot be

slightly been abraded.

Shield XT.

applied and perforated well within curing time.

•

Continuous wetting of Outerglass Shield XT during application is required.

•

Consult Safety Data Sheet and Product Data Sheet for appropriate personal safety measures, personal protective gear, application conditions etc.

Remove compression foil after initial curing time.

In the unfortunate event that the coating gets damaged after application the coating can also be repaired locally using the same application procedure as for new dry/wet application. Coating repairs need to be applied over the full circumference of the pipe/SoS and applied on bare metal or existing pipeline coating, connection to the already applied Stopaq coating. Always start 300mm next to the damaged area.

416

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er y re fin

flo or in

sp la sh -z on e ae & r

e ar in m

â&#x2030;Ľ50%

Apply Outerglass Shield XT over the pipe

Apply compression foil with tension over the

Perforate the compression foil with a perforation

Resin might seep through the perforations in the

sections. Start touching the clamp and end

entire area. For ease of removal, apply minimum

roller. Only perforate the compression foil, do

compression foil while curing.

touching the concrete. Start with 2 straight

66% overlap (3 layers).

not perforate the Outerglass Shield XT, Subsea

wraps and continue with a minimum overlap

Keep respect to instructions. Do not cover

Intermediate Wrap or Wrappingband CL.

of 50%. Apply with tension and without air

the entire clamp and pipe sections if the

entrapments. Keep respect to instructions. Do

compression foil cannot be applied and

not cover the entire clamp and pipe sections

perforated well within curing time.

if the compression foil cannot be applied and perforated well within curing time.

417

HD Rockshield

Longitudinal wrapping

Latitudinal wrapping

Spiral wrapping

418

419

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SFL o testce NEDERLANDSE GASUNIE APPROVED TRAINING CENTRE

420

• Rope access • Soil stress resistance horizontal

• Subkha simulation conjunction with cathodic protection

• Jacket hammer soil stress resistance

• Impact test

• Cathodic protection testpark

• Rollerbox test

outdoor • Casings under railroad

• Sandbox test (ISO 489)

• Storage tank, harbour wall, jetty pile,

• QT-centre

compressorstation applications

and many more.

entre

421

422

Albert Einstein “If we knew what it was we were doing, it would not be called research, would it?”

Connected partner:

POL GURU

science over convention

HOW LONG DOES YOUR COATING LAST? Make the right choice tomorrow’s solution: > >

guaranteed

30 yrs. Choose asset appreciation by understanding your total cost of ownership!

visit www.poly.guru And use our selection tool based on polymer chemistry, metallurgy and environmental factors to make an objective comparison between different coating systems. Predict the lifetime of the asset and avoid early failure.

Why STOPAQ’s Technology? - Effective electrical insulator & moisture barrier - Immediate molecular bond to the substrate - Ability to resist holidays - Full retention of physical characteristics - Maintains constant specific electrical insulation - Non-toxic & easy and quick to apply without primers 423

Rehabilitation, Coating Repair or New Building Coating | Onshore or Offshore Coating | Subsea, Splash-zone or Above Ground Coating

One family, one world, one mission KB Singh Shamil Kudashev

Sander Hofstee Katrien Masschelein Scottie Smith

Bas Huizing

Dirk TottĂŠ

Frits Doddema Gurinder Sethi

Dinko Cudic

Adelaide Cappa

Stefan Krieken 424 424

Neil Gill

Erik Broesder

Sam Thomas

Osvaldo Dâ&#x20AC;&#x2122;Albuquerque

Lety Pelayo Elmar Chavet

Seal For Life Industries’ approach is to engineer solutions to last for the design life of the asset. Seal For Life engineers are ever ready to work with you to deliver the most cost and energy efficient sealing, insulation and anti-corrosion solution for your project. Our creed is “do more with less”, and our proven in-house technologies are designed to deliver safe, quick, consistent and risk-free applications. At SFL, we make it our responsibility to ensure a hassle-free engineering experience offering you a complete “Seal For Life” solution.

Ralph Summ Jeroen Kuipers Riyad Al-Hasan Fikry Barouky

Meet the Pro's Ahmed Moinuddin

Eddy Alaerts

Nathan Knight Emiel Lubbers

Dong KyuYoon Not in this photo: Joseph Rao

425 425

total care The Anodeflex system offers a better, more cost effective, and environmental friendly approach to pipe rehabilitation. It is typically installed in the same right of way as the pipe, adjacent to the pipe, with only minimal disturbance of the environment.

STOPAQ produces and supplies worldwide a broad range of innovative patent defended self-healing anticorrosion solutions. The self-healing systems with unique visco-elastic properties prevent corrosion of your valuable assets for life. STOPAQ systems are maintenance-free and seal completely and permanently any substrate against the ingress of water, oxygen, bacteria or AC/DC current.

On- & offshore

Nt coNteN & Internal Under & Above Ground

Subsea, Splashzone

2014 SEPTEMBER 2 426 426

E! R A C O T DARE

Polyken pipeline tape coating systems provide pipeline protection with cold-applied and fused tape coating products for various climates and environments. With a full range of multi-layered coating systems and a host of coating accessories, Polyken is ready to respond to customers anywhere around the globe.

Covalence heat shrink force technologies provide strong mechanical strength performance and corrosion protection for oil, gas and water transmission pipelines. With technology born of the atomic age, shrink sleeves are unique in their ability to perform safely and efficiently.

Powercrete is a solvent free epoxy coating used for rehabilitation, directional drilling, girth weld protection, bends, fittings and odd shapes, offshore applications, patch and repair and potable water applications. Powercrete epoxies are designed to meet the requirements of the most demanding pipeline applications.

2014

Liquid Pipeline Coating Technology

427 427

Nt coNteN

2014 SEPTEMBER 2 428 428

engineering & services Seal For Life offers a wide range of tech engineering and innovative services. Dedicated partners in the field of on- & offshore surface preparation, application, installation, monitoring complement the services: • Turnkey offshore J-tube Filling • Turnkey onshore Casing Filling • Coating Removal

people planet

2014

• Insulation of pipelines • Coating Condensating Lines without shutdowns • Offshore Jacket Leg Coating • Underwater Coating Training • Job Supervision • Specialized Labour for HDD- joints • Surface Preparation Services • Installation of cathodic protection systems • Cathodic protection consultancy • Corrosion monitoring

Services

Turn-key Applications & Equipment

KELV IN

GREEN ®

SCAR

GREEN ®

SCAR

429 429

TURN RUST INTO GOLD 430 430

Ask for our Cost Avoidance Case!

431 431

experience centre The Seal For Life Industriesâ&#x20AC;&#x2122; Experience Centre is located in Stadskanaal, a relatively small community in the Northern Netherlands. The Centre welcomes many visitors, including business partners, students, and governmental authorities who are provided with a thorough overview of what happens around pipes above and below ground, as well as above and under water. An interactive history describes obsolete methods, tested methods and innovative solutions to corrosion and sealing issues. Novel thinking and the constant quest for innovation are the leading principles that bind together all the partners of Seal For Life Industries.

Nt coNteN

2014 SEPTEMBER 2 432 432

experience online!

2014

433 433

Have you seen this before! The marketing communication of

at once. Therefore we made a new

Seal For Life Industries is different.

overall website and a corporate

We believe in a ‘people approach’.

movie. Therefore we will invest in augmented reality and other

Therefore we make advertisements

innovative promotions to have

with impact and stopping power.

ammunition to attack markets, to

Therefore we have an experience

convince people of our passion and

centre that convinces every visitor

vision.

Nt coNteN

2014 SEPTEMBER 2 434 434

CARE! DARE TO

unmatched toughness

CARE! DARE TO

protection

Even at the extremes

When our beloved alligator has prey clamped in its jaws, he never lets go. His scales protect him from harsh attacks from all sides. The properties of this powerful beast are similar to the concepts of corrosion protection of Seal For Life’s Covalence Shrinkable Systems. The innovative shrink technology of Covalence protects critical infrastructural objects without losing elasticity. Covalence is one of our most powerful and proven technologies. Whether in combination with the visco-elastic corrosion prevention materials, hot-melt and mastic adhesives, total care shrink technology is the way to Seal For Life tight. It’s about making the surface preparation and the applicators’ job easy. Covalence – the first and still the best at heat shrink technology.

You know our strength as an ARO to protect FBE. Did you know that Powercrete is also engineered for mainline coatings, girthwelds, bends and specials, and offshore? Proven toughness, broad temperature ranges, quick to cure - we have the performance to Seal For Life!

since 1956

job done!

original advert

However we have a new logo and a new extended family, Polyken Tape Coating is proven since 1956 and still has the same advantages.

CARE! DARE TO

Made in the U.S.A.

SEALFORLIFE.COM

• Extreme durability • Highest quality raw materials • Fastest dry • Easy consistent application • Superior adhesion • Excellent cathodic disbondment resistance • No pinholes

2014 WE130328_ADV_IJSBEER_216bx303h_DEF_V2.indd 1

11-09-13 08:59

WE140363_ADV_COVALENCE_IPE_DEF.indd 1

17-07-14 15:21

c100 m0 y30 k20 c0 m75 y100 k0 c55 m55 y0 k0 c0 m100 y87 k0 c20 m100 y50 k0 c85 m45 y0 k0 c0 m0 y0 k100

Patented underwater Anti-Corrosion Technology Applications: • Splashzone Jetty Pile Protection • Subsea Pipeline Repair • Offshore Jacket Leg Protection

features & benefits: • Adheres under water & offers extremely high specific electric resistance • Training in cooperation with Falck Nutec at Seal For Life’s Technology Centre • Quick & easy to apply by trained divers and approved application companies

w w w . s e a l f o r l i f e . c o m

435 435

c100 m0 y30 c0 m75 y100 c55 m55 y0 k c0 m100 y87 c20 m100 y5 c85 m45 y0 k c0 m0 y0 k10

patents

Nt coNteN Thanks to its innovative character, Seal For Life Industries has turned developments into solutions. This has resulted in patents being registered in many countries all over the world.

2014 SEPTEMBER 2 436

2014

Name Protection (Intellectual Property) Seal For Life Industries is strongly attached to its trademarks. The trademarks have therefore been registered worldwide in order to avoid unauthorised use. Our portfolio ranges from oil and gas to chemicals, plastics, performance products, agricultural products and fine chemicals. Since many years Seal For Lifeâ&#x20AC;&#x2122;s R&D department works closely together with the R&D departments of BASF in Ludwigshafen, Germany. This is the worldâ&#x20AC;&#x2122;s leading chemical company. With about 105,000 employees, 6 Verbund sites and close to 385 production sites worldwide BASF serve customers and partners in almost all countries of the world. Their research and development activities aim to convert market trends and scientific ideas quickly into successful innovations. Through new technologies BASF can tap into additional market opportunities - creating added value for their customers, for example in the automotive, construction, food and pharmaceutical industries. Especially in the field of visco-elastic products, SFL/Stopaq and BASF have a continuous, dynamic concept of cooperation and frequent meetings of (technical) minds. 437 437

SFLâ&#x20AC;&#x2122;S

CLIENTS We cherish our clients. They are our reference point.

Nt coNteN

2014 SEPTEMBER 2 438

Sample Global Client Listing

2014

439

when we promise, seal the world... We at Seal For Life Industries will never become purists or idealists. We are and will always be realists, with feet firmly planted on terra firma. However, our solutions are important to the world. We can help transport the worldâ&#x20AC;&#x2122;s energy commodities safely over land and sea. We can help provide safe infrastructure in urban and pristine rural areas.. We can help turn the tide when it comes to raising dikes and dams. We can be of great value with our products in the aviation industry. We have the solutions in the field of traditional anti-fouling. And there are endless opportunities for applications of our products in and around the home.

Nt coNteN It is precisely this coverage and the synergies between our products, and the combination of our technologies, which makes us an undeniable player in all these markets. At Seal For Life, we are a partner with a realistic view of people, planet and profit. 10 regions Europe, Russia & CIS, Africa, Middle East India & Pakistan, South East Asia North East Asia, Australia & New Zealand North America

2014 SEPTEMBER 2 440

6 manufacturing plants • Tijuana, Mexico • Franklin (KY), U.S.A. • Stadskanaal, the Netherlands • Westerlo, Belgium • Baroda, India • Dammam, Saudi Arabia

2014

10 technical sales support offices • Buenos Aires, Argentina • Franklin, U.S.A. • Stadskanaal, the Netherlands • Westerlo, Belgium • Manama, Bahrain • New Delhi, India • Beijing, China • Seoul, Korea • Moscow, Russia • Singapore, Singapore

Visit us at sealforlife.com 441

SFL headquarters

Nt coNteN

2014 SEPTEMBER 2 442 442

GUARANTEE CERTIFICATE Wintershall K13A 2101081007

Services

STOPAQ® Splash Zone System

Turn-key Applications & Equipment

This Guarantee applies to the STOPAQ® Splash Zone System consisting of STOPAQ® Wrappingband CZH for above the lowest tide waterline and STOPAQ® Subsea Compound, for below the lowtide line stated below with the mentioned batch numbers, provided however that such product is applied as part of a STOPAQ® Splash Zone System, which combines a STOPAQ® Outerwrap (PVC) & STOPAQ® Outerglass Shield XT24 for mechanical protection. For improved color and gloss retention, a UV-resistant topcoat is recommended. STOPAQ® Corrosion Prevention Product

Batch number

STOPAQ Wrappingband CZH 100 x 10 STOPAQ Subsea Compound 100 x 6 STOPAQ Outerglass Shield XT24 10 x 60

232610 / 182010 / 303409 172810 PR3781 / 52809-AUG09

We, STOPAQ Oil & Gas Services B.V., turn-key suppliers & installers of the STOPAQ® Corrosion Preventation Splash Zone System, guarantee that the STOPAQ® Splash Zone System provides protection against external corrosion of the submerged object that is covered by this STOPAQ® Corrosion Preventative Splash Zone System for a period of 30 years from the date of application (installation), provided that: 1. the STOPAQ® Corrosion Preventative System is applied (installed) on the submerged object by a STOPAQ® Certified Applicator (Installer) according to STOPAQ® Splash Zone Application Procedure Rev. 01/10 including batch records filled in a daily report logbook; and 2. a STOPAQ® Certified Inspector inspects the object and the coating according to STOPAQ® Inspection Procedure Rev. 01/10, prior to, during and after the STOPAQ® Splash Zone Corrosion Preventative System is applied (installed); and 3. the object is not immersed above at a maximum temperature of 35° Celsius. The application guarantee is in conformity with ISO12944. The application guarantee is valid for a period of 5 years subject to the proviso that 3-yearly inspections will be carried out in relation to the condition of the coating. This guarantee relates to the latest inspection on reference-subject, as referred to in: South Beam This Guarantee is void if any corrosion occurs as a consequence of circumstances beyond the control of STOPAQ®, including but not limited to: 1. internal corrosion; 2. external damages inflicted upon the STOPAQ® Corrosion Preventative System; 3. excessive quantities of hydrocarbon solvents and chemicals outside the range of PH4-12 present in the soil or water. This Guarantee is restricted to the material costs only of the STOPAQ® Corrosion Preventative System necessary for an eventual repair of the previous applied STOPAQ® Corrosion Preventative System and does not cover any incidental, indirect, special or consequential damages, or lost profits, savings or revenues of any kind, whether or not STOPAQ® has been advised of the possibility of such damages. This Guarantee shall be governed by Dutch Law. All disputes arising in connection with this Guarantee shall be exclusively settled by the district court of Groningen, The Netherlands.

STOPAQ B.V. Frits Doddema Chief Executive Officer

STOPAQ Oil & Gas Services B.V. | Gasselterstraat 20 | 9503 JB Stadskanaal | The Netherlands |

+31 (0)599 69 61 70 |

+31 (0)599 69 61 77 |

info@stopaq.com |

4LL[Z 0:6 Ä LSK QVPU[ JVH[PUN UVYTZ STOPAQ meets ISO21809 - 3

www.stopaq.com

EUROPE - AFRICA - RUSSIA - MIDDLE EAST - INDIA - CHINA - AUSTRALIA - CANADA - USA - MEXICO - SOUTH AMERICA

field joint coating norms

2014

443 443

drs. JF (Frits) Doddema Global MD & GM Seal For Life Industries

at your service, with among Others:

K.B. Singh Specifications Engineering Head

Sander Hofstee Global Turnkey Services

Jeroen Kuipers Offshore business development

Sam Thomas Polyken Pro and Engineering SFL Solutions

Stefan Krieken Innovations & manufacturing

Katrien Masschelein Technology Director HSS

Seal For Life: 112 years of innov

Abboud Mamish R&D Vice President

Leticia Pelayo Customer Service

Bob Buchanan SFL North America

Marcia Navarro R&D Covalence Director

Gurinder Sethi Director India

Ahmed Moinuddin Market Support Manager

Cindy Patton Tape Coatings USA

Nathan Knight Specification Counsel

Nt coNteN Emiel Lubbers Project & Proposal Management

Frank Muffels SFL Protection SEA

Chris Banton SFL Prevention SEA

Neil Gill SFL International Protection Covalence/Polyken

Kresimir Kekez Cathodic Protection Engineer

2014 SEPTEMBER 2 444 444

eld

. 8 min

in.

ation

Hole in one Pipe golf challenge

Experience Centre

Rope access

. 4 min

6 min. Diving tank: under water coating Complete pipe coating: FAST

Contribution to a sustainable world STOPAQ Water Leak

10 meter water pressure

R&D

View at the international zoo

Above ground coating at refineries Liquid Pipeline Coating Technology

da er

2014

5 min.

445 445

Doing more with less

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This is our contribution to a sustainable world! What is more? Develop, Manufacture & Protect more m2 of Visco-elastic, Tape, Shrinkable Products and kilometres of Polymeric Anodes. What is less? This in short: energy-efficiency Resulting in: • less manpower, • less skilled crews, less grit, less time, • less preheating, less layers, less testing onsite, • less commissioning cost, less scaffolding cost, • less mobilization cost, • less waste onsite, • less precautions, • less heavy personal protection gear, • less defects to repair.

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Seal For Life, proud to be memb

Seal For Life Industries, formerly Berry Plastics

Powercrete Liquid Epoxy Coatings, and since

Corrosion Protection Group, is a part of the

2012, the STOPAQ line of visco-elastic coatings.

Company’s Engineered Materials Division and

The combination of STOPAQ with Berry’s existing

has more than 50 years of solid performance

corrosion protection group allows for solutions

in protecting oil, gas, water, wastewater, and

unrivalled by competitors in the market space,

insulated pipelines, as well as other metal

Most importantly, the research strengths of the

structures around the world. Berry’s corrosion

combined companies will allow for new innovation

protection brands include Polyken Pipeline Tape

and new products utilizing the best features of all

Coatings, Covalence Heat Shrinkable Products,

products across the group.

AnodeFlex Long-Line Linear Anode for CP, and

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ber of the Berry Plastics family

About Berry Plastics

Berry Plastics recently acquired AVINTIV Inc. which will enhance their ability to capitalize

Berry Plastics Group, Inc. is a leading provider of value-added plastic consumer

on the rapidly growing global markets for hygiene and healthcare.

packaging and engineered materials delivering high-quality customized solutions to their customers with annual net sales of $5.0 billion in fiscal 2014, their products are

Berry Plastics’ successes have been made possible through the dedication of their

designed utilizing proprietary research and unique development and manufacturing

employees. Berry Plastics’ culture generates a solid commitment to teamwork and

technologies. These technologies foster the innovation of their products, which include

shared success and has allowed them to effectively integrate strategic acquisitions,

• open top and closed top packaging

create and maintain strong customer relationships, withstand changing economic

• polyethylene-based plastic films

conditions, and grow at rates in excess of their industry. With headquarters in Evansville,

• industrial tapes

Indiana, Berry Plastic serves over 13,000 customers, ranging from large multinational

• medical specialties

corporations to small local businesses. Berry Plastic’s common stock is traded on the

• flexible packaging

New York Stock Exchange under the ticker symbol BERY.

Nt • heat-shrinkable coatings • specialty laminates • FIBCs (bulk bags)

To augment our product offering, Berry has been one of the most active acquirers of plastic packaging businesses globally, having acquired more than 30 businesses since 1988.

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Apart from personal, not commercial, use it is not allowed to copy, multiply or publish in any way or adapt the information and/or design. Although Seal For Life Industries has exercised due care to ensure the correctness of the information, SFL does not accept any responsibility for it. All content is provided “as is” and “as available”.

Disclaimer

The visual material in this book is the property of SFL, or obtained directly from the relevant parties. SFL has done its utmost to trace the rightful owner of the images and to tailor the use of these images. If the rightful owner(s) has (and) have difficulty with the use of the images in this book, they can contact us.

Credits

Chief Editor: Frits Doddema Concepts & design: La Compagnie, marketing & media

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Think. Design. Protect.

Gasselterstraat 20 9503 JB Stadskanaal The Netherlands

T: +31 (0)599 69 61 70 F: +31 (0)599 69 61 77 E: info@sealforlife.com I: www.sealforlife.com