ate ee] Oe (71S Felecia atone alle PB VET Cig Age Bonded Eroxs (FRE): Four i FI EUGPreface ‘The prot began with the soggation tht many people need to know more about ‘ipocoatings in general and FRE contigs i pris. Thy needa pce at My ‘gal was fo provide that starting pint with base of abe informaton te he Sndertanding ofthe uses an process of FBE pipecstingmatrale aad thee face Inplpline comin niigation ‘When stating this projet I was under the impression thf wax knowledgeable out uson-borsed epoxy (BE) cotngs, ther application and ther we oon {eis that — thre i much move o kon. Worang om he bask ha given me he ‘pportunity to alk with many tue exper ani to scm he itso data seated {rough lite of working nthe st re 1 yas fu to find that many of oar cole hae reused FEE costings and published extensively sharing thet Knowle withthe est fu Tt was halle {0 pull ogether thei many nang nd es aed ate to develop cobs one ‘eps, Poel the best par ofthe work was the opportu expo the Mees wh Wide varity of expert tx ths duty With no facepion, everyone with ‘was generous with heir owl an the me ve attempted to provide te information an a numberof lees. A quick can ‘rough he figures and capsons sould provide he hs cnecps Another sy tes. fg the tales and bullets shoud give the next level of information. Healy, the et ‘se hnps eh ot the ideas ith ore deta. Each chapter x dasiged to sled sone ‘ed aver the asc even tough another chapter may goin nich eater deal ‘hat reson some gues or chars ay te the sei vo on chaps, "ve worked digenty to secratly bring together he fat anders Tee ae sill many gaps and suspect ea that wil proven wrung in the ature Welee Suggesons and challenges tha wil esl in inproverent ea future eon ‘Aton Ko September 2012Table of Contents Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Chapter 11 Acknowledgment Prefuce Introduction to Fusion-Bonded Epoxy Coating Systems Chemistry of FBE, Polyolefins, Primer, and Liquid Repair Systems FBE Stand-Alone, Dual, and Multilayer FBE External Pipeline Coatings Three-Layer FBE-Polyolefin Coatings Internal FBE Pipe Linings Custom and Pipeline-Rehabilitation Coatings Joint Coatings and Linings FBE Application Processes Quality Assurance in the FBE-Pipecoating Application Process: In-Plant, Tests, and Test Variance Pipe Handling and Installation Cath¢ Protection with FBE-Based Coating Systems 7 129 167 217 255 343 423 463pter 12 pter 13 yendix A jendix B jendix C enix D Table of Contents Specifications and Standards ‘Coating Failure, Analysis, and Prevention Standards, Procedures, and Test Methods Abbreviations, Acronyms, and Symbols in Corrosion-Related Terminology Definitions and Acronyms Detailed Artwork Credit Listing for Fusion-Bonded Epoxy (FBE): A Foundation for Pipeline Corrosion Protection Index 487 503 559 567 573 377 581on Three-Layer FBE-Polyolefin Coatings > Ryan tg emote owe owes palpate ponsase ‘pe tin ene ee oe ‘Sys Hime gin wc See r e ewe pane cope eer ATE Dept gene er a Repo a pat =e eee in oe raga Fee Poe + ast ei a pe + Ee yt er sli a sa a + Enon pope perce atari ee ee een! sn ele mr al cere Se ed imeem unter tes hhcaer echeee ore ta Fe hota che Ricerca Paar a Se ae waren en SSS {tere ime one pans ete fe eeein ae et ei te eine tm pe ‘Siting hs mat cede ne fstype onan monn eg tow |miaeocsSae saa gm On. 2-1 pipe hs Pe 09 alg et hon Should eSSipn coor ime meee these sh er os ‘Scns bing cons Adie Laer uy dm he ade et ce > oe at‘osm ns yo Se ‘ha ayy rie hag rm Pope — epinephrine avin EN/ar i yee te” Say HF sees noe aes ‘hy high he FE ose saa el ea oe rapes ates Pedi panne = pa meee Ee oe She ES oe eer rsket. a pet cd tp oe nh pov woule ener on Tem a 1 OO Feseurmiaa| Fos Se anger ema gh emp prtne sat tion ancy an itary ne peg edie Soca a opt pena roe Topeont yer : eer tl pn “hla inde perio theroe Sa eure ares Sap Eb ios Ge ae ae Gee ae new wees ser pageant sats yer eae SSSpblisartaeier po einen ate . “itmurerragen ‘hers emu itn ects ‘rand an pci ml ie nt mt eri Sd eee kre opener oe Fee APO‘i pert ter i in te et [Bj ae tpt ope spe far BFC TY a oly 7 CP SRT Sie af elcome noc ne otis Nema csp ce he ne ap op FCS ad SPCC SR sre bate em Se mg hy Fe cde pen wih mp a oon satan pchgeh Miwory tor preset prrmane psy ee “he wl po ong nd pe diol dt alc Bestar pyc pbs i ogra aa Sie ———— | ‘oecay Malayer ystems : : 7 frie Mette anna capac Se (i tema cet esl ce eon ‘cer unc pen Ter ara ap repr pe ‘clan fe £8 her Catron Ege orcmg Insulation — Polypropylene Systems Sect cee appa pene a pee a et Sesame te cis er oe SS ehereeeteaeaee gen Scere Soe eecin ear brie pacraecaremete ene Sk eaeesaereccenes ae ahe fom air yn ah SS Seat Cal ge ye a SS cian tr “Fra pe Te tg Ie sis of dnl sas cua tng Boring neon ps nay ne aes Seren tn0b yim they Sayre on Oc ge +a {Ride agen ora nay werk sini teh ge =a ir Tye demain eh pe Polypropylene Insulating Foam ‘Suita pcm a"Ther ser aden owing te Pens compare ter maths (pps badaca cha peer peeps + Teil wok in ign ting ig ad pa TeSemiran Shit eee tang ae ‘ered cen * Ee tnera Roomate mnie nase eyes bance + FES aldo Spite Casing The nic an foo oc ssc a Rte ee pny eli ose Fou tie Get bie eee ng our ye rome Sein mapeceteteatgrereee URW eater Rough ied alte ‘ent gh ig men oh pt pe sage Soci et ops gh tas a er pa Sky cere maee “Side ood insuntion and supers cr rence SorRough Finished one Wh Cotes Sects pmictnrcea omer sets nn mn A Dense ied Poropyeneree syste FORMANCE “hele pom agua oti ence pen Ripert aware each ny man oe + option agin LESSER tae pep eptiaton p Snare ce tren tena pa eas anc clin ncaa pad ge REPU re wr meme peat apnoea ce ee ‘lng ee FH po pf ne a een TET ca the ten nk as he mu: ee ‘Sesion pumice ce oo cae ap eea tc ten iy ht et Tees pace Ce nf Bibi pire ns pla a Mechanic Protection rome Loe on “nsf cc sed cent ac ye carcatg aed SSnloay tices ptecapintgmpamape Se Agaeci epi Sir 38 oT ep ‘ingracroebning ere! pe sr big de ef esa ta eles ingle yg Directional Bore: Gage Fete OS Beg singe ple no ped SE Se ae———— Pigmentation: tea Absorpionanton cepicannttn amen creretemiet ernie Bl Mgecreietarmobbere mec enwesnimn cope i | ares tao At df Oe wponre hess mom tet | SSE cae service Pedomance ‘aE coungs to cahdy Gesnaunly rang wndarcnn oad Some a ES epee en raed eicnmnrenaceecenenes ne aga aoe ssc ego Cahier dons on eo iendnest Spore Sacuyee nouns tt dna sod ncn poem the ‘et a hast gia he med ao nde Oe ‘tees pee ore pase ppontn pon t Sora Sls Meine! ope pc ee is 1 Gins ecot ae sn pa ety ‘segue rg cement ere ‘Recta tee ncn tithe PE cin the chp spe ay Se ean seen mig ‘Slee Sagem cea etter ports er Sige toe antec sips a tyr Se ‘Sheer foes bans parece ft cn fact ‘squeegee aver can ‘requirements (conmern sbuut shielding for 4_a— ae ce a ee sens ret Se cert ce es ate openly orang pee ca ta ‘Steep eee coring hd eo adn unde pars of [Sere Zee ayes neem eae es peter Sere SS Sateen Sa sro So woe oer ot pare oily ln th ly day sa eeeemet giesiioee eee SeanaMt pe tact, olen Me ain et og ae eet ger pit Sn pay Es wun see ent Renyecansraesocmeces eects eS Sees chp srs ope Serie Uie tentang in ppc pt wn a fection" ey me Fea autpnte podem Pet tin ems oe ‘Sree mp Agee pentagons‘inci une | dsm maw Fat me Serpe ue ye | Peed Tcgemeine | is) : 1 I fans nye en gu Fe REET cir, Se | te ot pn ep at eng SEN Seve et | fn aS pa ey a Sowacsmce pa | char yw ea se Al ‘Sree hr | sane nea ‘Fintan Sgt |S ae fb gene oP ‘eid whe a of ae Ronnies ees eS SETS cept wn 11 bserlVr na te pa > wo Bs F0,-9R00+— aprile we 300+ RH HOO se hchamapininEgan ks) 8 aovrcht oR ORO +R “ ‘online iscsi Serre es pla ag ean cones ‘ccs ae aaters, thems nin ol eg nine pas sel age pen nage como ne rooms, mi pain mpd ng Me le i ap ghimmesdgmente ort gree eaec cas SiS an Aun en pt or ree Se Frage int nea tan ee base pe ae (C2E aS pos Scce gs t e ESAS Te ae nae or ete po te umes aC dbase Euan ack pt Aceh ‘Spr tet eed Aer t npe ‘Selig nae ns gy pent reso mee athe APPLICATION ‘Theat may leh it ea i oe Dit Seely Pl Wwe eM eof a ape (ti te aap rm et he sn tam meh SRNL atta dung com 2 aE atta erepctei a ic poe SEAS US EAL leper een el dpe a (pl Pc ede ling py Srp 2 ca a es a yn ptr Hae ES ie ae ons Pom ne eo ‘etal eg woman aoc feat, Ante See serie Shame Seppe ccm bel ne ett ‘shryasinirtmeiog She be oon aber org ep 3-Layer Coating Application: ‘Chromate Treatmentpaar sa sr SSSRLSa Bley whee er h tsconi ns rebut agtay ote gay coi seugrdionrras re rascals omer Soest tate esac ain Uno ee SS pel rn at mcg sing i occa estoee. 40 Appation pepe pany Serer SE SAE fer pce cm0 it andr a Tore rec ‘eet pie he | So Fs ca Sees A S| Soe man o mill aml | ed pep arse feo suet dng em | esse nhc Bafa rallies Gorm | Shon ESS plop egy meri ——_] Mrmr of gun ale vay Stl up pore poi wi SSEIULETS dtp palace rn apd poe SUT aay el rbd Ofer ‘iS 08 rani! erecta ee a pow mane ‘Sal spn i ms cme the pp bul be ot neh re ‘PIE accor woth pre na tes ld tg ma portunity xed ‘ps anes ooh esp ay mesg 3-Layer Application: tins nanpmeat Se derma eat ‘Sinan pat ae he ey Tema ‘rn set HE Se en nk is ice ae heed- 2 Ecketpchp cpt ipso nna meg SS eee cinemas Se eS Sy oat al ee pin pce, Cae tenet" ber pars gi, RELI pee lr ee oe re epi ey gst apy dc ong wpe a eo Layer Coating Application Slate A Se pe ty Sy Uvigmnenedtenee ie ‘ln sight aan Se FE eating 16 Sw:FOE: Ste AptetonCrar Seabee armas Seeeeas ‘Foden pcion sran pp nd uty Gacy sere ‘stam mur ny tg ea sup oat papa aes Se cee eee eee lj Application| SECIS epeten {LSE eet opin the ns See "Cina inSain bar may gid, te hs al sn bmi aes sl coma nee opm eater Sen mci ee eon a CORSE at upon yasrine woe aren were se tel eta a eprom npc TERE ata tenpon ot ne gi Epi cs a Ep ip ser ew ppt op ee tne aed Seige ee trate SEERA Teton pttometpatesuctn te “rm extruder. This i parculay toe for fourayer systems poring Wick: cosengsPosten sutton eng te eo rmethe Ygt Scere Ty Peete Uy se fey erry pret Pa eae? ea pt see er an eas ed alten te eS Pu 3 = ie SEH MSTe pes ct wien seni Se Seeing es esl ence SPST as Meenas hang cn rol» omnmaan Seer tl apna ung niyo SEAIESAT OCW tind tony ae os Spray Aplin nose catelsnebtneme mica rere Se ee eee = ane SS NS cate SEES ia tetera crap thug rami ofthe powder plylein promis the iy 1 produce ie season aces ng tt pp np nt pr opens en Bear Cooling of he cote pipe ea Rica sep in ta ayer snes, beers bs erm; : | ; nection + Spegumenesteacemame nee nine uty esac ic hn ee Sake ep Se ees fogercimene Farin am Theil or gosh ws ae at eran ee ‘Sponge hw puan te a pone ‘Smtr pps matsp om Many ian es pric itn a a as 1 tet amin int O50 este PE 2 Maayan nl pense a mgs — may dn Sorsogon nto {font bck — bea nga eth Bint 2 pee eRe “Fy 2 stor fel gti es, Oe pinion ata,syetea Quench3-Layer: impectionema ae ee ‘caren sunny34Layer Girth-Weld: repair Options aEE ———— Peano pl et. Cee( BL Gt per hana e cs Rov tog eee ie Se eee aac a carat Sepang it a nd Cnn se Per at ae eC ad Rape Ae 1 earn Mae nes ‘esc i eB te pe a focapeine ieee aaa cay ae ss SP fmt tht ee ge etecea eT mm om omen SPR te anne 1 Ea cage encom etn Pi aa | a ‘Sin fe nace oe EL EG Rea yon gy Pa ei © Stuy up Ra ac Sh ae epsces nnn rg ae mt, Te Ne eta = SEy eee eta eae eran Fre 2 PET rumen eee ere eee joc cere ener 0 Cp eee cerns treeee ae Seomiaieemienate gm n Bigheaminans 2 om can Baar ema