February 2015

McDermott International, Inc.

© 2014 McDermott International, Inc. All rights reserved.

Role of Corrosion & Field Joint Coating System Selection Criteria in 

Submarine Pipelines Integrity

Nawin Singh

What is Covered?

Pipeline System

Pipeline External Corrosion & Impact

External Corrosion Coating Systems

Corrosion Coating Selection Criteria

Field Joint Coating Systems and Alternatives

Way‐forward

Conclusion

Why Pipelines and what they offer?

Lower cost 

More energy transportation capacity 

Feed different segments of the energy consumption

Safer & environment friendly mode of transportation

Negligible loss of product in transit

Pipeline External Corrosion 

When pipeline is either buried or submerged in water,corrosive environment constitute between metal surface andits environment. Corrosion is the damage of a substancewhich is usually a metal.

The rate of corrosion depends on various parametersincluding Pipeline Operating Temp. Surroundings e.g. water quality Soil quality & burial status Interference with other facility

Pipeline Incident Statistics 

Ground Movement, 3.3

External Corrosion26%

Internal Corrosion, 5.3

Materials Fault, 8.3

Human Error, 2.5

Other Natural Hazards0.3

Accidental TP damage, 33.5

Stress Cracking, 1.1

Malicious TP damage, 5

Incidental TP damage, 7.2

Construction Fault, 7.5

Source: Ref. 3 [ERM from CONCAWE – 1971-2010]

Pipeline Integrity & Corrosion Impacts

Cost of corrosion is upto 3%[2] of GDP for USA

For Oil and Gas Pipeline alone, it is approx. $7billion[2] peryear for USA

Corrosion rated as 2nd most common threat for pipelineintegrity [10‐26%[4] ]

Coating cost is only 5‐6%[19] of project cost but play veryimportant role in integrity.

Pipeline Corrosion Coating Developments

Coal Tar & Asphalt Enamel

Powder Epoxy

Two layer System

Multilayer polyolefin

[Source: www.brederoshaw.com]

Coating Type and Market Share

[Source: Ref. 10]

0

20

40

60

80

100

North America South America Middle East Europe North Africa Asia

FBE PE/PP Other

Industry Standards for External Coating

AFNORAFNOR

NF A49 706 (FBE)

NF A49 710 (3LPE)

NF A49 711(3LPP)

AWWAAWWA

AWWA C203 (CTE )

AWWA C213  (FBE)

BSBS

BS 4164  (CTE)

BS 4147  (AE)

CSZCSZ

CSA Z245.20  (FBE)

CSA Z245.21  (Olefins)

DINDIN

DIN 30670 (3LPE)

DIN 30678  (3LPP)

ISOISO

ISO 21809‐1  (3LPE & PP)

ISO 21809‐2  (FBE)

ISO 21809‐6 (2L FBE)

ISO 21809‐4 (2LPE)

Coating Selection Criteria

External Corrosion coating 

Economics

Adhesion

PerformanceEase of application

Environment

[Source: Ref. 15]

‐ Material‐ Application‐ Repair

‐ Cathodic Disbondment

‐ Holiday

‐ Mechanical Properties‐ Electrical Properties‐ Ageing/Design Life

‐ Application Rate‐ Compatibility with FJC‐ Easily repaired

‐ Past experience of End User‐ Local Regulation‐ Surroundings 

Coating Selection Criteria   [Ref. 6, 7, 13, 18]

Typical Properties Single Layer FBE 3LPE 3LPP

Service Condition Upto 80°C(110°C)

Upto 65°C  (80°C) Upto 110°C (140°C)

Typical Thickness 350m  ‐ 600m 2.2mm to 4.0mm

Impact Resistance[@23°C]

>1.5J/mm >7J/mm >10J/mm

Cathodic Disbonding[@approx. 23°c for 28days]

<8.5mm < 7mm < 5mm

Adhesion Strength[@23°C]

Rating 1 to 3 > 100N/cm > 250N/cm

Suitability for CWC application or HDD or similar

Suitable with additional layer

Suitable Suitable

Damaged during Handling Moderate Low Very Low

Cost [16] Comparatively lesser than PE

High Relatively Higher than PE

Coating Selection Criteria

0

5

10

15

20

25

FBE 3LPE 3LPPRank

ing considered

 on 1 to 3 Scale (b

ased

 on 3 as su

perio

r)

Current Generation Coating System

Ranking index ‐ Coating system

Normal Temp. Limit Max. Temp Limit Impact Resistance Adhesion

Disbondment Indentation Resistance Cost Performance

Field Joint Coating (FJC) System – Why?

Corrosion control

To supplement CP System

Mechanical protection

Design Codes specify e.g. DNV RP F102, ISO 21809‐3 FJC System Why?

Compatible FJC system

Fusion Bonded Epoxy (FBE) FBE 100% solid liquids, epoxy, epoxy‐urethane Heat‐shrink sleeves (HSS) Cold and hot‐applied tapes

Three layer polyethylene (3LPE) Three layer HSS Multilayer flame spray with PE

Three layer polypropylene (3LPP) Three layer HSS Multilayer flame spray with PP FBE, spray applied adhesive, co‐extruded PP

[Source: Ref. 1]

FJC System Selection

Technique

Compatibility

Pipelay geographical location

Environment

Complexity

Ease of repair

Cost

Field Joint Coating ‐ Possible Alternatives

Protective Network Coating System (PNC)

Solid Polyurethane

Other alternative for fast curing

Compensation with CP

Example:

[Source: Ref. 5]

System Injection Molded PP PNC

Pre‐heat Temperature 230°C 230°C

Cycle time on 24” joint 8‐10 minutes < 6 minutes

Operating Temp. rating ‐‐‐ 150°C

Level of applicator expertise High Low

Industry Compliance Yes Yes

Impact of Improvement in FJC System

[Source: Ref. 5, 16]

Pipeline Details 24” OD, 100KM long

Marine duration for one joint with conventional FJC 12 minutes (with 4 WS & 3 station for FJC)

Marine duration for one joint with alternative for FJC 8‐10 minutes (e.g. with 5 WS or PNC or other alternatives)

Saving per joint on marine duration 2.5 minutes

Total marine duration 341 Hrs / 14 Days

Saving on Marine Cost(assumed $400K/day)

5.6 MM $

Girth Weld Shrink Wraps $ 75 /meter2  [Ref. 16]

Total area (approx.) 4712 m2

Cost on account of FJC $ 354 K 

Cost for additional anode $ 225 K (lesser than FJC material cost*)

Saving It seem approx. 5 MM$ on account of marineduration can be realized per 100KM considering other aspect including specialized crew for FJC application

Way forward

External Corrosion Coating and Pipeline Integrity

Coating Failure mechanism and challenges

Coating Specification

Field Joint Coating Selection

EPCI contractor engagement

Interaction needs to be encouraged amongst the designengineer, coating material manufacturer, coating applicator,installation contractor and the end user to provide aneconomical solution and to enhance long term performanceof external coating system for pipeline integrity.

Conclusion

This presentation can be seen as the start of further discussion forthe Specification authors, Standardization bodies and subseaindustry as a whole to review

‐ The coating selection process in view of upcoming challengesin terms of high temperature pipeline, long lasting coatingsystem, minimizing or eliminating the failure

‐ Requirement and compatibility for field joint coating system

‐ Incorporating the ongoing innovation & researches

Question

What next of 3LPP for pipelines operating  more than 140deg C?

References

Sl No. References

1 [Online] / auth. A JPCL eBook ‐ Protecting and Maintaining Transmission Pipeline. ‐ Technology Publishing Company. ‐ January10, 2015. ‐ http://www.paintsquare.com/store/assets/JPCL_transpipe_ebook.pdf.

2 [Online] / auth. NACE International. ‐ Corrosion costs and preventive strategies in the United States. ‐ January 11, 2015. ‐http://www.nace.org/uploadedFiles/Publications/ccsupp.pdf.

3 [Online] / auth. Petitt Glenn // www.erm.com. ‐ January 10, 2015. ‐ http://www.erm.com/en/Analysis‐and‐Insight/Publications/ERM‐paper‐on‐cross‐country‐pipelines‐failure‐rates‐as‐presented‐at‐the‐IChemE‐Hazards‐XXIII‐Conference/.

4 8th EGIG ‐ report no. EGIG 11.R.0402 [Report] / auth. European Gas Pipeline Incident Data Group. ‐ Groningen : EGIG, 2011.

5 A New 3LPP Offshore Field Joint Coating [Conference] / auth. Mallozzi Meghan and Perez Mario // Corrosion Conference &Expo. ‐ USA : NACE International, 2010. ‐ Vol. Paper No. 10010.

6 External coatings for buried or submerged pipelines used in pipeline transportation systems ‐ Part 1: Polyolefin Coatings[Book] / auth. International Organization for Standardization. ‐ Switzerland : ISO, 2011. ‐ Vols. ISO 21809‐1.

7 External coatings for buried or submerged pipelines used in pipeline transportation systems ‐ Part 2: Fusion bonded epoxycoating [Book] / auth. International Organization for Standardization. ‐ Switzerland : ISO, 2007. ‐ Vols. ISO 21809‐2.

8 Fast Set Polyurethane Coatings ‐ High performance, cost effective alternatives for field joint coating [Report] / auth.Schertzer Richard. ‐ Canada : [s.n.].

9 International Experiences with Cathodic Protection of Offshore Pipelines and Flow lines [Report] / auth. TWI for PetroleumSafety Authority Norway. ‐ Norway : TWI Ltd., 2007.

References

Sl No. References

10 New Challenges and Developments in Pipeline Coatings [Article] / auth. Guan Shiwei William // North American Pipelines. ‐[s.l.] : www.napipelines.com. ‐ January/February 2010.

11 Offshore Pipeline Coating for Field Joints ‐ why? [Conference] / auth. Surkein Michael, Melot Denis and Eric Agel // Corrosion Conference & Expo. ‐ USA : NACE International, 2013. ‐ Vol. Paper no. 2258.

12 Performance of European cross‐country oil pipelines ‐ Statistical summary of reported spillages in 2012 and since 1971[Report] / auth. CONCAWE ‐ Conservation of clean air and water in Europe. ‐ Brussels : CONCAWE, 2013.

13 Plant‐applied external fusion bond epoxy coating for steel pipe [Book] / auth. CSA Group. ‐ Toronto : Canadian StandardsAssociation, 2010. ‐ Vol. CSA Standard Z2245.20.

14 Polypropylene Coatings for High Temperatures and Thermal Insulation of Pipelines [Conference] / auth. Turner Barry J. //Corrosion Conference & Expo. ‐ USA : Nace International, 2011. ‐ Vol. Paper no. 11030.

15 Review of Pipeline Coating Systems from an Operators Perspective [Conference] / auth. Thompson Ian and SaithalaJanardhan Rao // Corrosion Conference & Expo. ‐ USA : Nace International, 2013. ‐ Vol. Paper No. 2169.

16 Thick Film Coating Systems Technology Trends [Conference] / auth. Osborne Michael // PDA Annual Conference. ‐ Houston :PDA, 2014.

17 Trend in Pipe Coating Selection Process [Conference] / auth. Surkein Michael B. and LaFontaine John P. // InternationalOffshore and Polar Engineering Conference. ‐ Beijing : ISOPE, June 2010.

18 DIN German Standard for Polyethylene coatings on steel pipe and fittings – requirement and testing DIN 30670. ‐Germany : Deutsches Institute fur Nomung, 2012

19 www.bric.com [Online] / auth. Dasgupta Chanchal. ‐ January 12, 2015. ‐ http://www.bric.com/news/articles/new‐development‐in‐3lpe‐coating‐for‐pipeline‐protection.html.