PIPELINE COATING

PIPELINE COATINGS & ITS SELECTION

COATING REHABILITATION
NEW TECHNOLOGICAL DEVELOPMENTS IN
THE FIELD OF COATING
BY

RAJESH UPRETY

CHIEF PROJECTS MANAGER

IOCL

CROSS COUNTRY PIPELINE A

DIFFERENT PERCEPTION
JOURNEY OF PIPE :
STEEL PLANT
PIPE PLANT
COATING PLANT
STOCKYARD
CONSTRUCTION SITE
LAID INTO TRENCH
BACK FILLING

CROSS COUNTRY PIPELINE A

DIFFERENT PERCEPTION
JOURNEY OF PIPE :
PIPE CANNOT SPEAK, MUTE SUFFERER
SUBJECTED TO INTERNAL CYCLIC LOADING (BLOOD
PRESSURE)
SUBJECTED TO STATIC & DYNAMIC LOAD (TENSION &
WORRIES)
LAID ON UNEVEN TERRAIN (PIPE NEEDS TO BE DUCTILE &
COATING NEEDS TO BE FLEXIBLE)
PASSES DIFFERENT SOIL CONDITIONS
SUBJECTED TO CATHODIC PROTECTION (ELECTRIC SHOCK)

CROSS COUNTRY PIPELINE A

DIFFERENT PERCEPTION
JOURNEY OF PIPE :
IT IS THEREFORE, OUR SINCERE DUTY TO SELECT RIGHT
PIPE MATERIAL, MANUFACTURE QUALITY PIPES, SELECT
RIGHT TYPE OF COATING, APPLY IT PROPERLY, HANDLE IT
WITH CARE & PASSION AND LASTLY MAINTAIN IT
PROPERLY WITH PROPER & EFFECTIVE CATHODIC
PROTECTION & TIMELY REFURBISHMENT.
WE MUST, THEREFORE, PUT OURSELVES IN PLACE OF
THE PIPE TO UNDERSTAND THE PAIN OF PIPE.

PIPELINE COATINGS
PIPELINE COATINGS FOR NEW PIPELINES
Coal Tar Enamel Coating

3 Layer Polyethylene Coating

3 Layer Polypropylene Coating
Dual Fusion Bonded Epoxy

TYPES OF COATINGS - CLASSIFICATION

SOLID COATING (FBE, DFBE ETC.,)

LIQUID COATING (EPOXY, PU ETC.,)

TAPE COATING (COLD TAPE, VISCO ELASTIC TAPE, HOT
TAPE, 3 LPE ETC.,)

CRITICAL ISSUES FOR COATING OFTEN

NEGLECTED

INADEQUATE MANUFACTURERS TECHNICAL DATA SHEET

HIGH COATING THICKNESS
UV RESISTANCE OF COATINGS
MISCONCEPTIONS ABOUT COHESIVE FAILURE
PRE-HEATING BEFORE SHOT/ GRIT BLASTING SHOULD BE MADE
MANDATORY.
RANDOM CHECKING OF SURFACE PROFILE BY PRESS-O-FILM SHOULD
BE MADE MANDATORY.
RESIDUAL MAGNETISM

CRITICAL ISSUES FOR COATING OFTEN

NEGLECTED

CONTROL ON PROCESS PARAMETERS SUCH AS BARE PIPE TEMPERATURE,

NOZZLE PRESSURE, MILL SPEED ETC.,

WATER QUENCHING SHOULD BE UNIFORM (LIKE AN UMBRELLA)

FLUIDIZED BED SHOULD BE IN AN AC ROOM AND NOT NEAR THE
EPOXY APPLICATION BOOTH
LONG TERM PERFORMANCE TESTS (E.G., HOT WATER IMMERSION
TEST IN TAP WATER FOR 120 DAYS FOLLOWED BY PEEL TEST). ISO
21809 PART-3 HAS NOW INTRODUCED HOT WATER IMMERSION
TEST FOR 28 DAYS FOLLOWED BY PEEL TEST.
DOLLY TEST MUST BE INCLUDED IN THE SPECS

CRITICAL ISSUES FOR COATING OFTEN

NEGLECTED
APPLICATION WINDOW CALCULATIONS TO BE PROPERLY CARRIED
OUT.
MAJOR & MINOR COATING REPAIR TO BE APPROPRIATELY
DEFINED SO AS TO AVOID ANY AMBIGUITY.
CALIBRATION OF EQUIPMENTS SHOULD BE SERIOUSLY REVIEWED.
CONDUCTING RUBBER MUST BE USED IN HOLIDAY DETECTION
MACHINE.
COATING FAILURES TO BE ANALYSED AND DISCUSSED IN
APPROPRIATE FORUMS.

RECENT DEVELOPMENTS IN COATINGS

COATING SELECTION IS NEARLY ALWAYS

BASED ON TEST RESULTS ON NEW
SAMPLES NOT ON AGED COATINGS.
COATINGS NEED TO BE FIRST STRESSED
BY EXPOSURE TO A COMBINATION OF
HEAT, WATER AND TIME, AND THEN
SUBJECTED TO ADHESION TESTS.

SELECTION CRITERIA OF NEW PIPELINE COATING

(A HOLISTIC APPROACH)
REFURBISHMENT COATING SHOULD BE KEPT IN MIND. e.g., 3
LPE COATING IS VERY HARD TO REMOVE
DIAMETER OF PIPE
SOIL CONDITIONS LIKE ROCKY TERRAIN
ABRASION RESISTANCE/ MECHANICAL STRENGTH
JOINT COATING
CONSTRUCTION EXPERIENCE

BASIS OF SELECTION OF MAIN LINE COATING

CONSTRUCTION RELATED

Handling and transportation

Above ground storage
Bending
Stringing and lowering
Withstand high black body temperature and UV
exposure
Easy to repair

IN-SERVICE PERFORMANCE RELATED

Good adhesion to the pipe surface not just at 23oC but
at the max. operating temperature of the pipe, and for the
in-service life
Withstand shear forces at the max. operating temperature
of the pipe
Effective moisture and oxygen barrier
Effective electrical insulator
Low cathodic disbondment at holidays
Resist chemical, heat and UV degradation

ISSUES RELATED TO 3 LPE COATING PRACTICAL

EXPERIENCE
3 LPE with excellent insulating properties, although allows water to
permeate, shields CP current in case of a pin hole, leading to
disbondment.
As per DIN 30670 peel test to be carried out within 24 hrs, which is
not correct
In 3 LPE coating, white latex paint is used in the coating plant,
which is washed away in case the storage duration is long or in
case the latex paint is not applied properly, thus causing
degradation of outer layer and disbondment of coating.
In case of refurbishment it is almost impossible to remove 3 LPE
coating.
While selecting a type of coating , refurbishment of coating
related issues also to be kept in mind.
3 LPE does not have good abrasion and gouge resistance. As such it
is not ideally suited for HDD applications.
In case of HSAW pipes, DFBE coating is better as it covers the
intricate parts such as seam weld, girth weld etc., in a uniform
manner.

3- Layer PE

Adhesion
Loss

3- Layer PE

Adhesion
Loss

3-Layer PE: Corrosion in Girthweld Area

What is Dual-Layer FBE?

An anti-corrosion layer of FBE
Overcoated with a 2nd layer for special properties

Application of FBE
Cleaning of substrate by abrasive blast cleaning,
phosphoric acid pretreatment, (chromate)
Pre-heating by induction to 230C
Application by spray with multiple gun set-up

Coating bonds to substrate

Quenching after typically two minutes
QC and testing

DFBE Application
Primary Coat
Dust
Collector

Topcoat
Dust
Collector

Coating Booths

pipe
Electrostatic
guns

Fluid beds
Corrosion Coating

Topcoat

Properties of the Corrosion Protection Base Layer

Good adhesion to substrate

Sufficient flexibility
Compatible with the CP system
Good resistance to under creep of coating
Barrier to both oxygen and water
Suitable reactivity to be compatible / work with
subsequent layers

Properties of Protective Layer - 2nd Layer

Good adhesion to corrosion protection layer to form a
composite coating
Must complement corrosion protection layer
Needs to have sufficient flexibility
Damage resistant coatings must be capable of withstanding
different types of field damage
Coatings designed for use at high temperatures must give good
barrier properties and sufficient strength at service
temperature

Types of DFBE Coatings

Mechanical protection for damage resistance

High friction for concrete weight coating

UV resistance for storage resilience

Mechanical Protection Systems

What does MPS deliver?
Improved backfill damage resistance
Improved resistance to damage

How do we know this?

Simulation of laying condition back fill
Directional drill and dragged pipe simulation
Gouge test

Improved Backfill Damage Resistance

Evaluated using a stone drop test
- Modified ASTM G13

Crushed riverbed aggregate 25mm

7.5Kg per drop
Impact angle 45 degrees

Improved Damage Resistance

400 microns of standard FBE = holidays
300 microns of standard FBE and 300 microns of
mechanical protection system
using 10 drops = NO holidays

Gouge and Impact Testing of Damage Resistant DLFBE

and PE

Improved Gouge Resistance

Gouge Test
Weight loaded on an
engineered tip

Dragged over test piece

Assessed for penetration

Panel of Damage Resistant DLFBE after 50 kg

Gouge Test

Panel of 3LPE After 40 and 50 kg Gouge Test

50 Kg Gouge Test Results

Coating

Initial
Depth of
thickness Gouge

Coating
remaining

DFBE

950

625

325

3LPE

2625

2325

300

EXPECTATIONS OF REFURBISHMENT COATING

EASE OF APPLICATION & HANDLING

ADHESION
RESISTANCE TO CATHODIC DISBONDMENT
HIGH RESISTANCE TO INDENTATION/ PENETRATION
HIGH SOIL RESISTANCE
RESISTANCE TO BACTERIAL ATTACK
RESISTANCE TO BACKFILL
HIGH ABRASION RESISTANCE
MINIMUM SHIELDING OF CP CURRENT

EXPECTATIONS OF REFURBISHMENT
COATING

EASE OF INSPECTION DURING APPLICATION

FAST CURE TIME AND MINIMUM TIME TO BACKFILL
NO TENTING
EASY TO REMOVE
ENVIRONMENT FRIENDLY
UV RESISTANT
COMPATIBILITY WITH OTHER EXISTING COATINGS
ECONOMICAL

EXPECTATIONS OF REFURBISHMENT
COATING

RESISTANCE TO CREEP
HIGH IMPACT RESISTANCE
LOW MOISTURE PERMEABILITY
FLEXIBILITY
LONG LIFE
HARDNESS
TEMPERATURE RESISTANCE (SERVICE TEMPERATURE)

Determining Pipeline health

Survey is done every 5 years.
CAT (Current attenuation technique)
DCVG (Pin pointing defects)
CIPS
Combination of these to prioritize & finalize the
location and identify interferences etc.,
Bell Hole Survey

PIPE LINE COATINGS

3 LPE (2 to 3.5mm thk)

FBE (0.45mm thk)

3 LPP (2 to 3.5mm thk)

DFBE (0.7mm thk)

PIPELINE COATINGS

FACTORY APPLIED
COATING

TEMP RATING

PICTORIAL VIEW

MAXIMUM
TEMPERATURE RATING

Coal Tar Enamel

60C

3 Layer Polypropylene

140C

Dual Layer Fusion Bonded

Epoxy

110C

3 Layer Polyethylene

80C

COMPARISON OF 3LPE/DFBE PIPELINE COATINGS

THICKNESS

3LPE

DFBE

Anti Corrosion Layer

150

300-350 micron

Hot Melt Adhesive Layer

200

Outer Layer

1800 to 3800*

250-350**

(Mechanical Protection/ARO)

*In case of 3LPE coating the thickness of outer layer varies based on the following factors:- Water/Humidity barrier.
- Antirock system(rock shield) required or not.
- Special precaution required during storage, transportation, handling,trench bottom preparation, back filling etc
- -Laying & service conditions.
-- Environmental temperature.

** In case of FBE coating the outer layer thickness is fixed and all necessary precautions have to be taken into
consideration for preventing damage to the FBE coating which are OFFSET by providing higher thickness of 3LPE Coating.

COATINGS DURING CONSTRUCTION

DFBE

3LPP

Tuesday, July 02, 2013

3LPE

CTE

39

TYPE OF FIELD JOINT COATINGS

FIELD JOINT COATINGS
Three Layer Heat Shrink Sleeves
Liquid Epoxy Coatings
Liquid Tar Urethane Coatings
Liquid Urethane Coatings
Liquid Epoxy Urethane Coatings
Multi layer Cold Applied Tape Coatings
Visco Elastic Tape Coatings
FBE / Adhesive / PE or PP hot tape system

TYPE OF MAIN LINE COATINGS

3LPE

3LPP

FBE

Spray applied FBE powder

Flame Spray PE / PP

PROTECTIVE CURRENT DENSITY

FOR NEWLY COATED PIPES

SOIL RESISTIVITY
Ohm-meter

3LPE
A/m

FBE/DFBE
A/m

<10

50

70

10-100

25

50

>100

15

25

(*) SOURCE IS 8062-2006 (CATHODIC PROTECTION OF BURIED

PIPELINE/STRUCTURE FOR TRANSPORTATION OF NATURAL GAS, OIL
AND LIQUIDS CODE OF PRACTICE)

COATING RESISTIVITY
- COATING RESISTIVITY(FOR 3LPE COATING) > 1010 ohm-m

- COATING RESISTIVITY(FOR DFBE COATING) 10 ohm-m

- VOLUME RESISTIVITY( FOR DFBE AFTER AGING) > 10 ohm-cm
- VOLUME RESISTIVITY(FOR 3LPE COATING) >106 ohm-cm

COATING - PHILOSOPHY

THOUGH PIPELINE COATINGS ARE DESIGNED

TO REMAIN BONDED TO STEEL FOR DESIGN LIFE
OF PIPELINE --- IN REAL LIFE, COATINGS TENDS TO
FAIL PREMATURELY OR AFTER THE DESIGN LIFE
THE PIPELINE OPERATOR STILL WANTS TO OPERATE
THE PIPELINE AND WOULD REQUIRE RE-COATING

CONSEQUENSES
OF
CORROSION

PIPELINE COATINGS FAILURES

FAILURE OF COATINGS LEAD TO CORROSION

PIPE RUPTURE

SEVERE CORROSION

PIPE RUPTURE

FAILURE FROM THE SEAM

WHY DO COATINGS FAIL

?

WHY DO COATINGS FAIL ?

IMPROPER COATING SELECTION
IMPROPER COATING APPLICATION
LAYING DAMAGES
PREMATURE FAILURE OF COATING MATERIAL

IMPROPER CATHODIC PROTECTION

FAILURE OF COATINGS

WHEN COATINGS START TO FAIL WHAT STEPS

ARE TO BE TAKEN ?

CORRECTIVE MEASURES
ENHANCE CATHODIC PROTECTION
RECONDITION / RECOAT
REPLACE THE PIPE LINE

RECONDITION / RECOAT

VARIOUS TECHNOLOGIES OF RECOATING

COAL TAR OVER THE DITCH

HOT APPLIED COAL TAR TAPE
COLD APPLIED TAPE
VISCO ELASTIC TAPE
HIGH BUILD LIQUID EPOXY
LIQUID POLYURETHANE
MCU (MOISTURE CURE URETHANE)

Current Practices/Technologies
COAL TAR ENAMEL
BENEFITS
LOW COST
EASY TO APPLY

LIMITATIONS
LOW SOIL STRESS RESISTANCE
DIFFICULT TO MAINTAIN APPLICATION TEMPERATURE
UNEVEN FLOW OF MOLTEN CTE RESULTING IN
UNEVEN/INADEQUATE COATING THICKNESS PARTICULARLY AT
4 O CLOCK AND 8 OCLOCK POSITIONS
SUSCEPTIBLE TO SCC
HEALTH AND SAFETY CONCERNS

COAL TAR ENAMEL

COAL TAR ENAMEL

58

Current Practices/Technologies
Cold Applied Tape
BENEFITS

NO HEATING
EASY TO APPLY WITH WRAPPING MACHINE
HIGH PRODUCTIVITY
UNIFORM THICKNESS
LESS DEPENDENCE ON HUMAN SKILLS

LIMITATIONS

LOW ADHESION AND SUSCEPTIBLE TO DE-LAMINATION

SUSCEPTIBLE TO SCC
CATHODIC SHIELDING
TENTING EFFECT OBSERVED ON SAW PIPES

Current Practices/Technologies
Coal Tar Based Tapes-Hot applied
BENEFITS

LOW COST

LIMITATIONS

LOW ADHESION AND SUSCEPTIBLE TO DELAMINATION

SUSCEPTIBLE TO SCC
HEATING DURING APPLICATION POSES RISK TO PIPELINE AND
HUMAN LIFE
CATHODIC SHIELDING
TENTING AT WELD SEAM
LUMPING AND THINNING
HOLIDAYS, WRINKLING ETC.,
DIFFICULT TO APPLY
LOW PROGRESS

HOT APPLIED TAPE

61

Current Practices/Technologies
VISCO ELASTIC SELF HEALING COATING
BENEFITS

PERMANENT SOLUTION
IMPREGNATING STEEL
NO ADHESION PROBLEM
COLD APPLIED
NO CRACKS
SIMPLE AND EASY FOR APPLICATOR
ONLY ST 2/3 SURFACE PREPARATION NEEDED
ONE COMPONENT MATERIAL
TENSIONLESS APPLICATION
NO SPECIAL TOOLS NEEDED
REMAINS FLEXIBLE FOREVER
EASY TO MOULD
VERY FAST AND EASY TO APPLY

Current Practices/Technologies
VISCO ELASTIC COATING
BENEFITS
NO WASTE AND NON-TOXIC
HAS NO LIMITS FOR STORAGE SHELF LIFE OR APPLICATION TIME

LIMITATIONS
NO SOIL STRESS RESISTANCE HENCE CAN WRINKLE IN BLACK COTTON
SOIL
CLEANING CLAIM THAT COATING CAN BE DONE IN St-3 SURFACE,
HOWEVER, BASED ON OUR EXPERIENCE/ FEEDBACK BLASTING IS
NECESSARY
REMOVAL IS DIFFICULT

VISCO ELASTIC COATING

Current Practices/Technologies
LIQUID EPOXY COATING
BENEFITS

GOOD ADHESION AND CD RESISTANCE

GOOD SOIL RESISTANCE
GOOD PERFORMANCE IN WET CONDITIONS
NO KNOWN INSTANCES OF SCC
FAST APPLICATION AND LESS DEPENDENCE ON HUMAN SKILLS
NO TENTING EFFECT ON SAW PIPES EXCELLENT BONDING ON ALL
INTRICATE STRUCTURES

LIMITATIONS

LONGER CURE TIME COMPARED TO URETHANE, SLOW CURE BELOW 5

DEG C
INSECT AND DUST CONTROL TILL CURING IS ACHIEVED
PROPER PPE REQUIRED DURING APPLICATION/INSPECTION
LESS SURFACE IMPERFECTION TOLERANT

TYPICAL TEST PROPERTIES LIQUID EPOXY

Property

Typical Value

Specific Gravity

1.35 Mixed+_ 0.10

Color

Green

Mix ratio

2A:1B by volume.

Shelf Life

Min 6 Months.

Dry to Touch Time

24C 2 Hrs Max.

50C 30 minutes Max.

Viscosity in cps
Spray Grade

Part A: 60000-90000.
Part B : 9000-20000

Abrasion Resistance

0.5 g max loss

Impact Resistance

At Room Temp Joule Value =2.5

Min

Flexibility

20C 0.5 /PD Min.

Coating Rehabilitation

Current Practices/Technologies
PU COATING
BENEFITS

GOOD ADHESION AND CD RESISTANCE

GOOD SOIL RESISTANCE
FAST CURING AND LOW TEMPERATURE CURE
NO KNOWN INSTANCES OF SCC
HIGHER IMPACT RESISTANCE THAN LIQUID EPOXY SYSTEM
ADEQUATE MECHANICAL STRENGTH TO ABSORB SHOCK, HANDLING,
ABRASION
FAST APPLICATION AND LESS DEPENDENCE ON HUMAN SKILLS
AS COATING DOES NOT SHRINK, EXTREMELY GOOD FOR FIELD JOINTS & ON
WELD SEAMS.
UV RESISTANT BASIC PROPERTY OF PU.
AS TOUCH DRY TIME IS LESS, IT IS FAST PUT BACK INTO SERVICE
VERY DIFFICULT TO REMOVE

Current Practices/Technologies
PU COATING

LIMITATIONS

LESS RESISTANCE TO CD THAN LIQUID EPOXY SYSTEM

INSECT AND DUST CONTROL TILL CURING IS ACHIEVED
PROPER PPE REQUIRED DURING APPLICATION/ INSPECTION
LESS SURFACE IMPERFECTION TOLERANT
LOW POT LIFE OF PU
CARRYING SKID/ SPRAY EQUIPMENT IN ROW
REMOVAL OF PU COATING AT SITE FOR FURTHER REFURBISHMENT
LIMITED APPLICATORS PRESENT IN THE INDUSTRY
VERY DIFFICULT TO APPLY BY BRUSH

Automatic Spray Application

COMPARISON- PU & LQUID EPOXY

S.
No

TEST PROPERTIES

TEST
MET
HOD

PU

2 COMP
SOLVENT
FREE EPOXY

(1)

THICKNESS

ELCO
METE
R

2000
MICRONS

1000
MICRONS

(2)

ADHESION

D4541

1200 PSI

2500 PSI

(3)

HARDNESS

D2240

> 60 SHORE D

> 85 SHORE D

(4)

WATER PERMEABILITY

ASTM
E-96

(5)

ABRASION RESISTANCE
(1OOO GM LOAD, 1000
CYCLES)

D4060

0.3 gms/24
Hour/M2
Max.
Weight loss
< 0.05 gms
(H10 Wheel)

0.1 gms/24
Hour/M2
max.
Weight loss
< 0.05 gms
(H10 Wheel)

COMPARISON- PU & LQUID EPOXY

S.
No

TEST PROPERTIES

(6)

CATHODIC
DISBONDMENT
(28 days @ 250 C)

TEST
MET
HOD
G-8

PU

2 COMP
SOLVENT
FREE EPOXY
< 5 mm

< 4 mm

FUNCTIONAL PROPERTIES OF LQUID EPOXY COATING

ARE
FAR
SUPERIOR
TO
ELASTOMERIC
POLYURETHANE COATINGS.

Current Practices/Technologies
MCU COATING
BENEFITS

LONG TERM ADHESION

FAST CURING
EASY TO USE: ONE COMPONENT/AVOID MIXING FAILURES/NO RECOAT
WINDOW
APPLY IN ALL WEATHER CONDITIONS :
6 99% RH
APPLICATION TO DAMP SUBSTRATES
NO DEW POINT RESTRICTIONS
RESISTANT TO FOG, RAIN AND DEW

CURES EVEN AT -15 C

ALL YEAR ROUND AND NIGHT APPLICATION POSSIBLE
SURFACE TOLERANT :
BEST ADHESION ON MINIMAL PREPARED SURFACES
LOW STEEL ROUGHNESS REQUIRED: 25 M OR HAND AND POWER TOOL PREPARED
FLASH RUST TOLERANT

FINAL CONCLUSION
MAINLINE COATING

DUAL FBE

GOOD MECH
STRENGTH

REFURBISHMENT
COATING

LIQUID
EPOXY/ VISCO
ELASTIC TAPE
LIQUID
EPOXY/ HEAT
SHRINK
SLEEVES

NO TENTING

JOINT COATING

THANK FOR THE

PATIENT
HEARING !