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Transcript of Michael Magerstadt
Michael Magerstädt
4th Annual Slurry Pipeline Conference · Perth · 12-Nov-2014
CASE STUDY: OIL SANDS AND PHOSPHATES SLURRY TRANSPORT
DESIGN LIFE EXTENSION BY ELASTOMER LINING OF STEEL PIPES
Slide 2
AUTHORS
Michael Magerstädt
ROSEN Group
Obere Spichermatt 14
6370 Stans
Switzerland
Thorsten Räth, Larry K. Lai, Holger Rosenbleck-Schmidt
ROSEN Group
Am Seitenkanal 8
49811 Lingen
Germany
Please send correspondence relating to this presentation to:
Slide 3
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 4
UPDATE HIGH PERFORMANCE POLYURETHANE
ELASTOMERS
What is Polyurethane (PUR)?
Up to 8 components: Isocyanate, polol, crosslinkers,
hardeners, chain extenders, etc.
„the Polyurethane“ does not exist –> millions of
permutations possible
Typical applications:
Soft foam (seats, matttresses)
Hard foam (insulation material)
TPU (injection moulded, automotive,
houshold appliances)
Elastomers (pipeline inspection tools, buffer,
rollers, etc.)
Adhesives and coatings
Slide 5
Experimental results from abrasion, adhesion, and tear resistance tests at independent laboratories demonstrate that these materials are ideally suited for internal protection of steel pipes.
very high abrasion resistance very high tear strength
UPDATES HIGH PERFORMANCE
POLYURETHANE ELASTOMERS
Slide 6
UPDATE HIGH PERFORMANCE POLYURETHANE
ELASTOMERS
Extensive tests have been performed determining key properties
• All tests on RoCoat were carried out by independent laboratories or
by operators
• Abrasion tests ASTM G 75; ASTM B611; DIN EN ISO 53516;
EN ISO 598; ASTM D4060/7;
• Adhesion tests EN10290; ASTM D 4541
• Flexibility, bending, gouge tests CSA Z245.20-10, Clause 12.11;
CSA Z245.20-10 , Section 12.15 ;
• Cold wall effect: Atlas Cell Test
• Slurry Jet Test
• Hot water immersion adhesion test ASTM D 870; EN 10290
• Various other tests
Slide 7
UPDATE HIGH PERFORMANCE POLYURETHANE
ELASTOMERS Adhesion to Steel – most essential for interior coatings
Slide 8
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 9
CASE OIL SAND TAILINGS
20‘000 hrs. of operation without rotation; still 20 mm coating @6 o‘clock
carbon steel needs to be rotated after 2500-3000 hrs
Tailings including rocks up to 5“ diameter
Coating thickness: 1“
Flow velocity approx. 5 m/s
Temperature 55-65 °C, no thermal insulation on pipe
Outside temperature down to -40 °C in winter
Line cleaning with water 95° C at regular intervals
Slide 10
CASE OIL SANDS TAILNGS
hydrotransport lines:
- similar life times as tailings; in some cases longer since bitumen acts as lubricant -
Slide 11
CASE OIL SANDS TAILNGS
Tailings lines and pipe storage yard and field test array
Slide 12
CASE OIL SANDS TAILNGS
Cold wall effect….
Slide 13
CASE OIL SANDS TAILINGS
Cold wall effect: Atlas Cell test
Tinternal (coating) = 50°C
Texternal (Stahl) = -20°C ΔT = 70°C, 17 Weeks
Results: no disbondment, cracks,
holes etc.
Slide 14
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 15
CASE OIL SANDS / EROSION-CORROSION
Erosion-Corrosion in Oil Sands Tailings
- Straight pipe after an elbow behind a pump
- High turbulence, high oxygen content
- At this location, steel pipe with chromium
carbide overlay (CCO) needs to be rotated
every 2’500 to 3’000 hours of operation
- First rotation of high performance elastomer
spool at 11‘000 hours with 5 mm elastomer
left at the 6 o‘clock position
Wear measurements taken during shutdown
Slide 16
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 17
CASE PHOSPHATE SLURRY STATION PIPING
Phosphate Slurry:
• pump station piping
• high turbulence
• flanged connections, customer-specific
• 12 mm coating
• selected areas 15 mm coating
• in operation for 18 months now
• Excellent performance
Slide 18
CASE PHOSPHATE SLURRY STATION PIPING
Slide 19
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 20
HIGH PERFORMANCE POLYURETHANE
ELASTOMERS VS. HDP LINERS
Low-erosion slurry lines / erosion-corrosion conditions
• HDPE Liners are not chemically bound to the interior wall of the steel pipe.
• They require a minimum thickness to have enough structural strength to prevent
liner collapse in low pressure situations.
• Material cost per kg is lower for HDPE than for high performance
polyurethane elastomers; but a much thinner layer is required:
• For an 18“ steel pipe ID, minimum structural thickness of an HDPE liner
has to be 13 mm.
• For the same pipe ID, a High Performance PUR Elastomer
coating thickness of 3-5 mm is sufficient.
• At similar or lower total cost as HDPE:
• longer design life due to higher wear resistance;
• higher safety against penetration of erosive components;
• No danger of liner collapse;
• Installation cost significantly lower due to field welding process.
Slide 21
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 22
FIELD JOINING
RECAP: Welded Joints: Single-weld syetem
Features
Just one filet weld per pipe joint to be performed in field
No in-field backfilling, no filling holes
Factory-prepared one-sided weld
No cutback
Firmly installed insulating layer under weld
Patent pending
Slide 23
FIELD JOINING
•Entire pipe sections joined by this system
are in continuous operation
•The welding process complies with ASME
Sec. IX.
•The field joints in field tests now in
Canada comply with ASME B31.11
•Pressure tested up to 250 bar (3‘000 PSI)
Slide 24
FIELD JOINING
left: weld joint – female end // right: expansion barrel
Slide 25
CONTENT
1. Update High Performance Polyurethane Elastomers
2. Case Oil Sands Tailings
3. Case Oil Sands / Erosion-Corrosion
4. Case Phosphate Slurry Station Piping
5. High Performance Polyurethane Elastomers vs. HDP Liners
6. Field Joining
7. Outlook
Slide 26
Intelligent RoCoat™ Allowing Remote Wear Measurement:
Unique, patent-pending system that measures wear of interior high performance elastomer coating
• No hole in the pipewall is required for data transmission.
• First system to go on stream in Alberta oil sands in January 2015
OUTLOOK
Slide 27
Intelligent RoCoat™ Allowing Remote Wear Measurement:
Unique, patent-pending system that measures wear of interior high performance elastomer coating
• Differentiation in the single-mm range
• Two readout modes:
• Firmly installed instrument at the
outside of the pipe with wireless
data transmitter and central
• Water – and dirt protected contact
points at the outside of the pipe for
attachment of portable readout
equipment by inspector
OUTLOOK
Slide 28
Intelligent RoCoat™ Allowing Remote Wear Measurement:
Unique, patent-pending system that measures wear of interior high performance elastomer coating
• No batteries or other energy source
inside the pipe
• number of individual sensors around the
pipe circumference can be selected to
fit the rotation requirements o the operator
(to assure that there is a sensor in or near
the 6 o°clock position after rotation)
OUTLOOK
www.rosen-group.com
THANK YOU FOR JOINING
THIS PRESENTATION.