Coating presentation tp bangkok 23 jan 2014

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Coating Overview

Audrey BERGERON Bangkok – January 23rd 2014

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About the instructor

Title Coating specialist

Region / Entity Asia Pacific / TPS

Business segment Subsea – Onshore Offshore

Education Meng./ Chemical Engineering

Contact [email protected]

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About Technip Singapore

• Shallow to deep water (3000 m)

• S-laying• Rigidd pipes (4” to 60 “)• Piggy-backed pipeline

installation• Pipe-in-pipe, CRA

OFFSHORE PIPELINE INSTALLATION

• Lifting up to 1200 tons• Installation of

platform, subsea structures, skids, modules, etc.

OFFSHORESTRUCTUREINSTALLATION,HEAVY LIFTING

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• Spools• Risers• Buckle Initiator Structures• PLEM• Manifolds• Skids• Crossing Structures• Installation Aids

FABRICATION SERVICES

• Full-time divers• Saturation to 300m• Pipelines, platform, SCM

de-commissioning / removal

DIVING, IMR, DECOMMIS-SIONING

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G1201 - 3rd Generation DP Pipelay Vessel incl. 1200MT Pedestal Crane

Summary

1. HSE moment

2. Reason for coating

3. Corrosion prevention - Generality

4. Surface preparation

5. Painting & coating

6. Pipe & field joint coating

7. Coating qualification – process and requirement

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3LPP/PE:

CS:

CUI:

CWC:

FBE:

FJC:

GSPU:

HP/HT:

HSS:

MLPP/PE:

PE:

PFP:

PP:

PU:

SPU:

SS:

TSA:

Three Layer PolyPropylene / PolyEthylene

Carbon Steel

Corrosion Under Insulation

Concrete Weight Coating

Fusion-Bonded Epoxy

Field Joint Coating

Glass Syntactic PolyUrethane

High Pressure/ High Temperature

Heat Shrinkable Sleeves

Multi-Layer PolyPropylene / PolyEthylene

PolyEthylene

Passive Fire Protection

PolyPropylene

PolyUrethane

Syntactic PolyUrethane

Stainless Steel

Thermal Spray Aluminum

Abbreviations

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Summary

1. HSE moment







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1. HSE moment

Find the difference:

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1. HSE moment

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Summary

1. HSE moment







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Why do we need coating? What kind of coating?

Corrosion protection

Anti corrosion paint

Passive Fire Protection (PFP)

Intumescent Epoxy

Cementitious coating

Fouling release

Anti fouling paint

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Mechanical protection

Polyolefin coatings

Negative buoyancy

Concrete weight coating

Prevent CUI(corrosion under insulation)

Metallizing (Thermal spray aluminum)

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Anti slip

Paint + natural aggregate

Insulation

PU foam

Aesthetic aspect

Polyurethane, Acrylic

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Summary

1. HSE moment







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3. Introduction to corrosion

According to NACE: “ Corrosion is a deterioration of a material because of reaction with its environment.”

Liquid water is in contact with metal AND

corrosive agent is present in the water

CORROSION =

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Corrosion impact:

o Safety: unsafe corroded structures / equipment

o Cost: For the US, the annual cost of corrosion worldwide is around 3% of GDP (US$ 250 Billion)

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Different types of corrosion

Uniform corrosion o Uniform loss of mass for external surfaces. Concerns

mainly carbon steel and cast iron. o Solution: corrosion allowance (3 to 6 mm), painting,

cathodic protection.

Galvanic corrosiono Creation of an electric current between 2 materials with

different potential. o Common cases: aluminum/stainless steel, carbon

steel/stainless steel. o Solution: isolation joints, cathodic protection, coating

Erosion corrosiono Erosion (abrasion): removal of metal by mechanical

action of liquids (or solids). Erosion-corrosion :removal of corrosion products by mechanical action of liquids ( or solids).

o Solution: improve flow by design of the piece, change for better material, corrosion allowance

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Different types of corrosion

Pitting corrosiono High chloride concentration leads to passivation layer

breakdown. o Affects stainless steel, aluminum, titaniumo Solution: increase molybdenum content in SS (CRA),

coating

Chloride stress corrosion crackingo Combined action of seawater and mechanical stresso 316 Austenitic stainless steels subject to CSCC if

chloride concentration > 50 ppm and temperature > 50

o Solution: coating, change material grade (316 SS to 22Cr or 25Cr)

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Corrosion preventionCorrosion prevention

Design

Coating

Chemical treatment

Cathodicprotection

Material selection

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How to prevent corrosion?

Design: avoid water retention, moisture / salts entrapment

Inhibitors: chemical added into a fluid to decrease corrosion rate

Material selection. Examples:o SS 304L very sensitive to CSCC in offshore environment. SS 316L, 22Cr

duplex or Inconel 625 are preferred.

o Carbon Steel can be selected for offshore structures, provided it is protected by coating and cathodic protection.

Cathodic protection: protection of the surface by another “sacrificial” metal (Zn, Al, Mg, …) who has a more electronegative potential.

Protective coating

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Summary

1. HSE moment







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Clean the surface from contaminant

Create roughness for coating adhesion.


objectives

Surface preparation: The key step to the coating success

dustgrease

mill scale

oil

Soluble salts

Former coating

contaminants

Long term stability to the coating

Did you know?75% of premature coating failures are caused by inadequate or improper surface preparation

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Substrate: carbon steel, stainless steel, Aluminum, galvanized steel …

Degree of cleanliness required (paint system type and thickness)

Geometry of the piece (area difficult to access with machines)

Place where surface is prepared (on site, applicator’s plant)

Selection of the method depends on:


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1. Prior to commencement

• check for fabrication or welding defaults: rough edges, cuts and welds shall be rounded to a 2mm radius to improve coating coverage and adhesion on the surface.

• remove weld spatters.


2. Solvent cleaning.

Degrease and remove oil, grease, soluble contaminants with solventcleaning (fresh water, emulsion cleaners, detergents, organic solvents,petroleum based solvents, alkaline cleaners). Does not removeChlorides, mill scale or other inorganic materials.

3. Abrasive blasting or other method

Remove chlorides and sulfates, create desired surface profile forprimer adhesion, create a uniform aspect.

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steel shot or grit (carbon steel surfaces),

aluminum oxide or garnet sand (stainless steel or carbon

steel surfaces).

Projection of abrasive particles to remove rust and other contaminant and create a rough surface

Abrasive blast cleaning


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Abrasive blasting equipment

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Surface preparation: other methods

Power tool cleaning (hand or mechanical). Example: rotary wire brush.

Water jetting. Only to remove previous coating, does not create roughness.

Pickling. Dipping of steel in an acid bath


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Substrate Type of system Cleanliness (ISO 8501-1 or SSPC)

Profile surface (ISO 8503)

Carbon steel – external surfaces

Typical paint system with DFT > 200µm

Sa 2 ½ eq. to SSPC SP10 50-75 µm

Carbon steel – internal surfaces

Internal coating (“lining”)

Sa 3 eq. to SSPC SP5 or Sa 2 ½

eq. to SSPC SP1050-75 µm

Stainless steel, Galvanized steel

Typical paint system Sweep blasting eq. to SSPC SP7 20-40 µm

- Carbon steel - Stainless steel

TSA - Sa 3 eq. to SSPC SP5- Sweep blasting eq. to SSPC SP7

70-120 µm

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Summary

1. HSE moment







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5.1 Corrosion protection coatings

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Definition Application Selection Protection mode Specification

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5.1. Corrosion protection coatings - Definition

PAINT= A+B

Binder (polymer)

Pigments + fillers

Solvent

Additives

Reactive + solvent

Component A

Component B

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5.1. Corrosion protection coatings - Definition

• 2 component- thermoset coatings• Excellent adhesion, chemical and water resistance• Shall be top-coated by UV-resistant topcoat

EPOXY

• 2 component • Resistant to UV, good gloss and color retentionPOLYURETHANE

• 2 component – min. zinc content 85% • Very high substrate adhesion – good chemical resistance• Max thickness 80 µm, subject to mud-cracking -careful with

repairs

INORGANIC ZINC

• Cure at ambient temp. or with help of heat• For heat resistance up to 600 , or foul releaseSILICONES

• 2 component coatings• Very good for immersion service• Suitable up to 230

PHENOLIC EPOXIES

• 2 component – used as linings – very resistant to chemicals and temp.

• High thickness (2 x 1000 µm)VINYL ESTER

•2 component – short pot life (45 min at 20 ) - Glass flake reinforced•Excellent resistance to abrasion, water and moisture – good for salt and fresh water environment and walkways

POLYESTER

Major paint used for corrosion protection purpose

Spray application : Air spray vs Airless spray

- Spray pattern easily adjusted

- High quality of finishes (automotive)

- Overspray causes high loss of coating

- Add solvent to improve atomization but leads to low thickness

Air spray

Airless spray

- Less overspray

- Heavier film built

- Better production rates

-Little control of coating quantity

- Speed makes it difficult for small pieces

5.1. Corrosion protection coatings – Application

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Brush application

Brush is only for

o Small areas not easily accessible by spray

o Repairs and touch-up

o Stripe coats, corner, edges, welds, bolting, flanges

o When environmental conditions prohibit the use of spray

Roller application

Do not use roller unless specific client approval

- Helps coating to have a good adhesion on substrate (for primers and underwater coatings)

- Good penetration into surfaces that cannot be properly cleaned

- Slow application (can be an advantage in some cases)

- Low DFT achieved

5.1. Corrosion protection coatings – Application

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Finish coat (polyurethane)

Intermediate coat (Epoxy based)

Zinc rich primer (inorganic zinc, zinc rich epoxy)Primer with inibitors (zinc phosphate)

1 – Barrier

2 – Galvanic

3 – Inhibition

• Impermeability to water vapor, oxygen and salts (Chloride), thick film, electric resistance pigmented epoxies (high solid content, mica flakes)

1. Barrier effect

• Primer contains a metallic pigment with a more electronegative potential inorganic zinc silicates and zinc rich organic primers (epoxies)

2. Galvanic effect

• Isolation of the substrate surface by addition of a metallic compound chemically bonded to the surface zinc phosphate pigment

3. Inhibition

5.1. Corrosion protection coatings – Protection mode

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Selection of coating depends on:

Atmospheric corrosivity of environment (marine C5M, industrial C5I, high C4, …)

Substrate (carbon steel, stainless steel, galvanized steel, aluminum, CRA, …)

Equipment operating temperature

Durability of the coating / installation

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5.1. Corrosion protection coatings - Selection

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5.1. Corrosion protection coatings – Specification

Frequently encountered coating systems – Onshore offshore systems

Substrate System DFT (µm)

CS operating below 120 (Uninsulated)

Zinc rich primer (epoxy or inorganic zinc)Epoxy high build Polyurethane topcoat

50-75150-20050

CS operating between 120 and 450 (Uninsulated)

Inorganic zinc primerAl pigmented siliconeAl pigmented silicone

50-752525

SS operating below 120 (Uninsulated)

Epoxy primer, zinc freeEpoxy high build Polyurethane topcoat

50150-20050

SS operating between 120 and 600 (Uninsulated)

Al pigmented siliconeAl pigmented silicone

2525

Insulated CS and SS operating below 200 Epoxy phenolicEpoxy phenolic

100100

Insulated CS and SS operating between 200 and 600

TSASealer (silicone)

25040

Bulk items (any substrate, any temperature, valves, piping, …)

Universal coating, inorganic copolymer (compatible with PU topcoat for color marking)

As per manufacturer

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Frequently encountered coating systems – Onshore offshore systemsInternal coatings (Carbon steel surfaces)

Application System DFT (µm)Potable water below 60 Solvent free epoxy

Solvent free epoxy300300

Crude oil, diesel, condensate, below 60 : bottom up to 1m + roof and upper 1m of wall

Abrasion resistant epoxyAbrasion resistant epoxy

150-180150-180

methanol, MEG below 80 Inorganic zinc primer 60

Process vessel below 120 Solvent free epoxy Novolac 300-600


Galvanized surfaces

Substrate System DFT (µm)Galvanized steel operating below 120 Epoxy primer, zinc free

High build epoxyPolyurethane

5010050

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Frequently encountered coating systems – Subsea systems


CS and SS in splash zone operating below 100

Abrasion resistant epoxy (glass flakes)Abrasion resistant epoxy (glass flakes)

300300

CS and SS immersed operating below 100

Abrasion resistant epoxy or high build epoxyAbrasion resistant epoxy or high build epoxy

175175


Antiskid surfaces

Substrate System DFT (µm)Carbon steel Epoxy primer

Ultra high build epoxy + non-skid aggregatesPolyurethane

50600-300060

Note: 1. Surface friction coefficient may need to be indicated. 2. Use of Aluminum oxide (and other non-ferrous irregular surfaces) is preferred

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Checks and Quality Controls

Before painting applicationo Operator and inspector Qualification certificates

o Instrumentation device calibration certificates

Surface preparationo Environmental conditions (Dew Point, surface T°C and Ambient T°C measurement),

o Abrasive contamination,

o Grade of cleanliness + surface roughness,

o Chloride content + dust level

Painting applicationo Wet and dry film thickness,

o Visual inspection

After painting applicationo Curing of inorganic zinc,

o Adhesion test

o Pinhole detection (only for immersed, underground and internal coatings)


5.2 Specific coatings

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Metallizing Passive Fire Protection Fouling-release coatings

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Thermal Spray Aluminum

Spraying of molten Aluminum wire by flame spray or arc spray

Good for immersion and CUI prevention.

Applied on Carbon steel or Stainless steel operating up to 600

- Excellent corrosion protection properties

- Excellent resistance to mechanical damages - Very high durability (up to 50 years)- Zero VOC.

- Porous: need to apply a sealer on top (epoxy or silicone).- Cost effective process - HSE rules must be strictly followed. - Critical surface preparation: high degree of cleanliness required

5.2 Specific coatings: Metallizing (TSA)

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TSA coating systems


CS and SS operating below 120

TSAEpoxy sealer compatible with TSA

25040

CS and SS operating above 120

TSASilicone sealer compatible with TSA

25040

Application examples

Bulk valves (all temperatures, CS and SS) Offshore or immersed structures Flare top

TSA applicators Norimax WASCO MTM Metalization

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Splitter column Turret component

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5.2 Specific coatings: Metallizing

Other Thermal Spray Coatings:

Zinc Al-Zn Stainless steel Inconel Copper Nickel Monel Hastelloy

Harder material Higher operating temperature gun

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Steel begins to lose strength as its temperature rises in a fire structural collapse.

PFP is designed to protect structures supporting high risk and valuable equipment.

Objective: prevent the substrate to rise in temperature during a fire to avoid steel to collapse:

o Jet fireo Hydrocarbon fire o Cellulosic fire

0

200

400

600

800

1000

1200

1400

0 30 60 90 120 150 180

Tem

per

atu

re °

C

Time (minutes)

Fire Curves

Cellulosic

Hydrocarbon

Jet Fire

Jet fire: Release of hydrocarbon fuel under pressure through a relatively small opening such as a crack or hole high levels of turbulence, “erosion” of the PFP coating.

Pool fire: Hydrocarbon fuel burning under atmospheric pressure.

5.2 Specific coatings: PFP

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- Provides corrosion protection

- Low DFT for 2h protection (2-10 mm)

- Low density

- Requires the use of skilled applicators

- Cost effective

Organic coatings: Intumescent epoxyThey are inert at ambient temperature but react when exposed totemperatures above about 200ºC. The reacted coating forms a thick carbonbased char. Applied with reinforcement mesh


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Spray application equipment

Source: PPG

Typical Plural Component Pump

Typical plural component mixing block and spray gun


Thickness of PFP is determined by:

o Size, shape of steel section to protect (beams, hollow section)o Critical failure temperatureo Duration of protection needed

Calculation of DFT with Hp/A value.

Low A

High Hp

Fast Heating

Low Hp

High A

Slow Heating

Source: PPG

Hp = heated perimeter exposed to fireA = cross-section area of steel element

The higher Hp/A value, the higher PFP thickness will be required.


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- Cheap, easy to install and repair

- Hard and durable

- Heavy

- Thickness around 25 mm for a 2h fire protection

- Poor flexibility

- Risk of hidden corrosion in reinforcement by water ingress

Inorganic coatings: CementitiousLightweight with nominal density around 500 kg/m3.Must be topcoated with a high water vapor permeabilitycoating. Must also be applied with mesh reinforcement.


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PFP systems


Fireproofed carbon steel surfaces

Zinc rich epoxy or inorganic zinc silicateIntumescent PFP epoxyPolyurethane

50As calculated50

Fireproofed stainless steel surfaces

Zinc free epoxy primerIntumescent PFP epoxyPolyurethane

50As calculated50

Fireproofed carbon steel surfaces

Zinc rich epoxy or inorganic zinc silicateHigh build epoxyCementitious PFP

50150As calculated

Fireproofed stainless steel surfaces

Zinc free epoxy primerHigh build epoxyCementitious PFP

50150As calculated

Objective: prevent formation of biofouling on vessels and structures (mussels, barnacles, algae, etc.).

2 mechanisms: fouling release coatings and antifouling coatings (biocide release).

Fouling release coatings:

- Silicones

- Fluoro-polymer

Prevent attachment of micro-organisms on the structure by creating a smooth finish with low surface tension.

5.2 Specific coatings: Fouling release coatings

Source: PPG

TBT-based coatings are prohibited

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5.2 Specific coatings: Fouling release coatings

Fouling release system


Any (riser, structure, hull, etc.) Epoxy primerFoul release coat (1 or 2 coats)Finish coat

50-100200-600100-150

Note: Fouling release systems depend on each coating manufacturer; all products of the system should be compatible with each other. The proposed system is for example only.

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5.2 Specific coatings: Shop primers

Thin film inorganic zinc primer applied on applicator’s plant for more accurate control of application process.

Typical application: steel plates for tank storage.

Purpose: Protect against corrosion and environment during transport and before erection.

Primer is applied automatically or not at 15-30 µm.

Source: TOTAL – GTS presentation

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Summary

1. HSE moment







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6.1 Pipe coating

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Selection Properties Standards Systems Subcontractors Futures challlenges

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6.1. Pipe coating - Selection

Pipeline protection = Combination of

Adequate protective coating,

Supplementary cathodic protection

Selection of the coating system depends on:

o Pipe material characteristics

o Service / design temperature

o Pipeline design thermal profile

o Maximum water depth

o Specific properties requirement (cathodic disbondment, elongation, strength, …)

o Laying method

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Properties for Corrosion protection coating

Main properties

o Strong adhesion to the pipe

o Corrosion properties

o Strong resistance to cathodicdisbondment

o Durability for design life of the pipe

o Good mechanical strength

6.1. Pipe coating - Properties

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Properties for Thermal insulation coating

Pipes are insulated to prevent hydrate formation, waxing and to satisfy separator arrival temperature.

Main properties

o Thermal conductivity

o Density

o Adhesion to base material

Properties for Weight coating

Main properties

o Density

o Compressive strength


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Types of pipe coatings

o Fusion Bonded Epoxy (FBE), Liquid epoxy

o 3-layer Polyethylene (3LPE) / Polypropylene (3LPP)

o MLPP Foam / syntactic

o GSPU, SPU

o Concrete Weight Coating (CWC)

Corrosion protection

Flow assurance

Negative buoyancy


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International standards in pipe coating: ISO 21809

3LPE/PP: ISO 21809 - 1

FBE: ISO 21809 - 2

CWC: ISO 21809 - 5

ISO 21809 replaces DIN (German), NF (French), CSA (Canadian)

Other standards or specifications

AWWA (American Water Works Association): AWWA C213-07 (FBE)

DNV-RP-F106 (FBE, 3LPP, 3LPE)

NACE RP0394-2002 (FBE)

DNV-OS-F101 (CWC)

NO STANDARD FOR INSULATION COATING

6.1. Pipe coating - Standards

Liquid coating

- Mainly used for buried pipe operating at elevated temperature, where 3LPE and 3LPP cannot be considered.

- Generally a high built coating applied by airless spray with DFT up to 3000 µm.

- Maximum service temperature can go up to 200 , depending on the type of resin (epoxy, epoxy novolac, phenolic epoxy, vinyl ester).

- Can be reinforced with glass flakes to improve moisture and mechanical resistance.

- Can be applied as an internal lining to protect against corrosive fluid. In this case, thickness up to 300 µm.

6.1. Pipe coating - Systems

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Fusion Bonded Epoxy (FBE)

Coating system description Single layer fusion bonded epoxy

Type of protection Corrosion protection

Typical coating thickness 350-500 µm

Design temperature 90

Water depth limit Unlimited

Major characteristics - Excellent long term corrosion resistance to steel, - Cathodic disbondment resistance (reduce cost of

cathodic protection) - Good chemical resistance.


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FBE coating process

Source: Bredero Shaw


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Three Layer Polypropylene (3LPP)

Coating system description FBE + PP Adhesive + Solid PP

Type of protection Corrosion protectionMechanical protection

Typical coating thickness 2- 4.5 mm

Design temperature 110 (up to 130 with high temperature FBE)


Major characteristics - High film thickness- Good PP flexibility mechanical protection to the

pipe.- Good impact strength


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3LPP coating process



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Three Layer Polyethylene (3LPE)

Coating system description

FBE + PE Adhesive + Solid PE

Type of protection Corrosion protectionMechanical protection

Typical coating thickness

2- 4.5 mm



Major characteristics - Cheaper than 3LPP, but does not have as good mechanical characteristics as 3LPP.

3LPE process is the same as 3LPP


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Multilayer PP (MLPP) – Foam MLPP


FBE + PP Adhesive + (Solid PP) + PP Foam + Solid PP

Type of protection Corrosion protection + Mechanical protection + Thermal insulation


Depends on thermal requirements


Water depth limit 600 m

Major characteristics K-value around 0.17 W/m.K, density 600-800 kg/m3

1. FBE2. 2. PP adhesive3. Solid PP4. PP foam5. Outer PP shield



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Multilayer (MLPP) – Glass syntactic MLPP


FBE + PP Adhesive + (Solid PP) + GSPP + Solid PP

Type of protection Corrosion protection + Mechanical protection + Thermal insulation





Major characteristics K-value around 0.16 W/m.K, density 650-700 kg/m3

Hydrostatic pressure resistance is reinforced by glass microspheres added into the PP matrix.


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Syntactic PU - polymer syntactic (sPU)


FBE + sPU

Type of protection Corrosion protection + Thermal insulation





Major characteristics - K-value around 0.12 W/m.K, density 600-700 kg/m3

- Thin wall + low polymer mechanical properties decrease compression resistance of the foam.


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Syntactic PU - Glass syntactic (GSPU)


FBE + GSPU

Type of protection Corrosion protection + Thermal insulation





Major characteristics - K-value around 0.16 W/m.K, density 800 kg/m3

- Hydrostatic pressure resistance reinforced by glass microspheres added into the PU matrix.

- Grade of glass influences the collapse pressure and theoretical maximum water depth.


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Injection moulding PU process



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Concrete Weight Coating (CWC)

Purpose: provide negative buoyancy and mechanical protection to the pipe.

Mixture of cement, iron ore and wire wrap

Main properties:o Density (1900-3700 kg/m3): varies iron ore

quantity.

o Compressive strength: depends on cement and water content.

o Thickness: depends on pipe diameter.

o Water absorption: ISO standard recommend a maximum of 5% vol.

Reinforcement o Rigid preformed cages

o Wire mesh fabric



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Concrete Weight coating

Type of protection Negative buoyancy + Mechanical protection

Typical coating thickness Depends on pipe diameter

Design temperature N/A


Major characteristics Density (1900-3700 kg/m3): varies with iron ore quantity.


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Impingement method



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Wrap-on method



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Elastomer coatings (Neoprene, EPDM, butyl rubber, etc.)

Mainly used for splash zone protection

Be careful of chamfering can cause failure of

the bond

Source: Yadana riser – F. Duesso

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APAC

Bredero Shaw

WASCO Energy

Americas

Bredero Shaw

CRC Evans

EMEA

Bredero Shaw

Eupec

Socotherm

Tenaris

6.1. Pipe coating - Subcontractors

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Operators - Gap analysis with ISO 21809-1: Microsoft Excel Worksheet

6.1. Pipe coating - Operators

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Microsoft Excel Worksheet

Operators - Gap analysis with ISO 21809-1:

ENI = based on ISO TOTAL SHELL and PETRONAS: more stringent on different tests

6.1. Pipe coating - Operators

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HT/HP- R&D programm in different pipe coating applicators and manufacturers

to test different materials like glass syntactic silicones

Arctic- Bredero Shaw involved in JIP for new material in arctic conditions

Flexible weight coating

Ultra deep waters – thermal insulation

6.1. Pipe coating – Future challenges

6.2 Field joint coating

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Definition Selection Standards Systems S-Lay installation Subcontractors

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Field joint definition: Part of pipe left bare for welding prior to installation

Purpose of FJC: anticorrosion or thermal insulation.

Field joint is the weak point in a pipe coating system.

Welded joints are highly sensitive to corrosion.

pipe

3LPP coating

Cut back length shall be predetermined and mainly depends on type of FJC.

Properties shall be the same as the parent coating (pipe coating).

FJC are mostly applied in field application shall be easy, fast and reliable.

FJC = FBE, HSS, Polyolefin tapes, IMPP, IMPU, PE, PP, liquid resins

FJC

6.2. Field joint coatings - Definition

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• density, thermal conductivity (if thermal insulation), coating breakdown factor

Line pipe working conditions

• mechanical protection expected (impact strength, abrasion, compressive strength, flexibility, water absorption, curing time)

Pipe laying environment

Parent coating

Parent coating FJC possibilities

FBE FBEHeat Shrinkable SleevesLiquid coating

Polyethylene HSSLiquid coatingPE flame spray

Polypropylene PP flame spray / tapesIMPUIMPPLiquid coating

Concrete coating HSS + HDPUF

6.2. Field joint coatings - Selection

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6.2. Field joint coatings - Standards

International standards in field joint coating: ISO 21809

ISO 21809 - 3

Other standards or specifications

DNV-RP-F102

NACE RP0303 - HSS

EN 12068 – tapes and HSS

NO STANDARD FOR INSULATION COATING

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FBE


FBE



350-500 µm

Design temperature 90 , modified epoxies can withstand higher temperatures


Major characteristics - The most widely used coating - Good chemical resistance- Very good corrosion protection - Very common and easy to find subcontractors- Low impact resistance

Overlap on parent coating

50 mm

6.2. Field joint coatings - Systems

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Heat Shrink Sleeves: 2-layers (mastic HSS)


Mastic adhesive + Polyolefin backing on St3 steel



2 mm

Design temperature Up to 100 (depending on product: PE or PP)


Major characteristics Manual application with gas torch

Example of HSS system PE: - KLNN Canusa- WPC 100M (Berry Plastic)PP: - GTS PP 100


100 mm


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Heat Shrink Sleeves: 3-layers (hot-melt HSS)


Liquid epoxy + hot-melt adhesive + Polyolefin backing on Sa 21/2 steel


Typical coating thickness 2 mm

Design temperature > 100 (depending on product: PE or PP)


Major characteristics Manual application with gas torch

Example of HSS system PE: - GTS 80 (Canusa)- HTLP80 (Berry Plastic)PP: - GTS PP (Canusa)


100 mm


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PP tape wrap


FBE + Adhesive PP + PP tape



3 mm



Major characteristics - Applied in spiral or wrapped by hand or by wrapsterwith the determined overlap (50% recommended).

- Only compatible with 3LPP pipeline coating

Example of tape wrap system

FBE: Scotchkote 226N (3M)Adhesive: Hifax EP 510/60m (Basell)PP tape: Hifax EP 510/60 (Basell)


70 mm


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Flame spray PP


FBE + Adhesive PP + PP powder



3 mm



Major characteristics Similar to tape wrap


70 mm


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Injection moulded polyurethane (IMPU)


FBE + Solid PU or PU primer + Solid PU

Type of protection Corrosion protection + thermal insulation


+4 mm

Design temperature Up to 130


Example of system FBE: Scotchkote 226N (3M)Solid PU: Hyperlast FJ302 (DOW)


70 mm


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Injection moulded polypropylene (IMPP)


FBE + PP adhesive + Moulded PP

Type of protection Corrosion protection + thermal insulation


4-10 mm

Design temperature Up to 110 (130 with high temp. FBE)


Example of system FBE: Scotchkote 226N (3M)Adhesive: BB 127E (Borealis) or Hifax EP5 10/60 (Basell)Solid PP: EA 165E (Borealis) or CA 197 (Basell)


70 mm


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6.2. Field joint coatings – S-lay installation

S-lay:

Firing line is horizontal

Pipeline is support by a stinger to avoid high bending stress.

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6.2. Field joint coatings – S-lay installation

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6.2. Field joint coatings – Subcontractors

BrederoShaw

Canusa CPS

PIH

OJS

FBE, IMPU, IMPP

HSS, liquid epoxy, tape wrap

FBE, flame spray PP & PE, HSS, IMPU, IMPP, PU foam infill

HDPUF, HSS

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Summary

1. HSE moment







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7. Coating qualification

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Painting Pipe and field joint coatings

7. Coating qualification - Painting

Norsok M501 rev.6

CS surfaces operating < 120

Ballast water tanks/ seawater filled vessels

Anti-slip for walkways, escape routes, lay down areas

Intumescent epoxy + cementitiousPFP

Splash zone and immersed surfaces

1

3B

4

5

7

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7. Coating qualification - Painting

Norsok M501 rev.6

Test (acc. to ISO 20340) Assessment method Acceptance criteria

Seawater immersion- 4200h- For system 3B, 7A, 7B, 7C and 1 when used in tidal or splash zone

ISO 4624- pull-off testISO 4628-3,4,5,6

5MPaNo defect

Ageing- 4200h- For system 1, 3B, 4, 5A, 5B, 7A

ISO 4624- pull-off testISO 4628

5MPaNo defect

Cathodic disbonding- 4 weeks- For system 3B, 7A, 7B, 7C, 1 whenused in splash or tidal zone

ISO 15711 Max. 20 mm

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Shell systems that need to be qualified as per DEP

TSA (DEP 30.48.40.31)

DFT checking

Ballast water tanks/ seawater filled vessels

Anti-slip for walkways, escape routes, lay down areas

Intumescent epoxy + cementitiousPFP

Splash zone and immersed surfaces

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Test Assessment method

Measurement Acceptance criteria

Visual examination ISO 14918 100% surface Uniform appearance, no defect or blisters

Coating thickness ISO 2808 Min. 5 Min. 250 µm

Coating adhesion ISO 4624 Min. 3 > 7 MPa

Overall quality Bend test (DEP) Min. 3 Minor cracks

Sealer Visual inspection 100% surface No open pores at the surface

Shell systems that need to be qualified as per DEP - TSA

Check every step of the ITP.

The process leads to qualification of:

o operators (blasters, sprayers),o equipment,o subcontractor coating procedure.

Example of PQT done for Prelude FLNG

Microsoft Word 7 - 2003 Documen

Adobe Acrobat Document

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7. Coating qualification – Pipe & FJC

Qualification of 3LPE and 3LPP as per ISO 21809-1: Adobe Acrobat Document

Properties 3LPE 3LPP

Continuity Zero defect Zero defect

Impact strength > 7 J/mm > 10 J/mm

Indentation at 23 Indentation at max temp.

< 0.2 mm< 0.4 mm

< 0.1 mm< 0.4 mm

Elongation at break > 400 % > 400 %

Peel strength at 23 Peel strength at max. Temp.

> 15 N/mm> 3 N/mm

> 25 N/mm> 4 N/mm

Cathodic disbondment 23 , 28 dCathodic disbondment 65 , 24 hCathodic disbondment max. temp., 28 d

< 7 mm< 7 mm< 15 mm

< 7 mm< 7 mm< 15 mm

Hot water immersion test (80 , 48h) Average < 2 mm and max. < 3 mm

Average < 2 mm and max. < 3 mm

Flexibilitty No cracking at 2° angle No cracking at 2° angle

Curing of epoxy As per manufacturer As per manufacturer

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Sources

Bibliography:

[1] NACE CIP 1 Manual

[2] Encyclopedie de la peinture: formuler, fabriquer, appliquer, tome 1

[3] ISO 8501-1

[4] ISO 21809-1 to 5

[5] PPG – PFP and Fouling release coating presentation

Websites:

[6] www.nace.com

[7] http://www.corrosion-doctors.org/Seawater/Fouling.htm

[8] www.brederoshaw.com

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Thank you

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Coating presentation tp bangkok 23 jan 2014

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