COATING SYSTEM FOR 3LPE EXTERNAL COATING AND

FBE INTERNAL LINING ON PIPES FOR OIL AND GAS APPLICATIONS.

* SYSTEM IDENTIFICATION: External coating.

1) System designation - 3 Layer polyethylene coating on

carbon steel pipes
2) Trade name - Smoothflow
3) Name of coating manufacturer - Scan India
4) Coating process - 3 layer sintering process
5) System structure - 3 layer
6) Structure components - 1) Fusion Bonded epoxy
2) Maleic anhydride grafted polymer adhesive.
3) Medium/High density Polyethylene.
7) Service temperature range - -45˚ C to 80˚ C
8) Total nominal coating thickness - 3 mm max.
9) Manufacturing standards - DIN 30670 / CSA Z245.21.02 system B2

* MANUFACTURERS DATA:

Primer (FBE)
1) Type of primer - Fusion Bonded epoxy
2) Physical form - Dry Powder
3) Manufacturer - Jotun Powder Coating Pvt. Ltd.
4) Product - Corro-Coat EPF 2002 HW
5) Density - 1.6 +/- 0.05 g/cc
6) Gel time - 20 – 27 Sec.
7) Particle size - 99.8% below 250 microns
8) Recommended film thickness - 80 – 150 microns
9) Color - Green, red
10) Cathodic disbondment radius - 3 – 5 mm radius average
11) Method of application - Electrostatic spray
12) Storage conditions - 25˚C with max 65% relative humidity
13) Shelf life - 12 months
14) Application temperature range - 180˚C to 220˚C
15) Pot life - 15-20 mins.

Adhesive
1) Type of adhesive - Maleic anhydride grafted polymer adhesive.
2) Physical form - Dry powder
3) Manufacturer - E I Dupond Pvt. Ltd.
4) Product - Fusabond EMB 158 D50
5) Density - 0.933 g/cc
6) Particle size - 99% below 300 microns
7) Method of application - Sintering
8) Recommended film thickness - 150 – 200 microns
 9) MFI - 1.7 g/10 min
10) Processing temperature - 180˚C - 220˚C
11) Storage Condition - below 25˚C with max 50% relative humidity.
12) Shelf life - 24 months.

* Polyethylene top coat

1) Type of adhesive - High density polyethylene
2) Physical form - Black pellets (pulverized to dry powder)
3) Manufacturer - Borouge
4) Product - Borcoat HE 3450
5) Density - 0.942 g/cc (bare polymer)
6) Color - Black
7) Particle size - 99% less than 250 microns
8) Method of application - Sintering
9) Maximum film thickness - 2700 microns
10) M F I - 2.0g/10 min
11) Tensile Strength - 26 M pa
12) Elongation at failure - 600%
13) Carbon black Content - 2%
14) E.S.C.R. - 5000 h
15) Hardness (shore D) - 60
16) Processing temperature - 180˚C - 220˚C
17) Storage Condition - below 50˚C away from light
18) Shelf life - 24 months

* SYSTEM IDENTIFICATION: Internal lining.

1) System Designation - Fusion bonded epoxy lining on

the internal surface of carbon steel pipes.
2) Trade Name - -
3) Name of Coating manufacturer - Scan India
4) Coating process - Sintering process
5) System Structure - Single layer FBE.
6) Service temperature range - -45˚ C to 80˚ C
7) Total nominal lining thickness - 500 microns max.
8) Manufacturing Standards - API RP 5L7.

* MANUFACTURERS DATA:

Internal FBE lining

1) Type of material - Fusion bonded epoxy
2) Physical form - Dry powder
3) Manufacturer - 3M Ltd.
4) Product - Scotchkote 134
5) Density - 1.51 g/cc
6) Gel time - 40 – 120 Sec.
 7) Particle size - 99.8% below 250 microns
8) Recommended film thickness - 450 microns
9) Color - Forest green.
10) Method of application - Sinter spray
11) Application temperature range - 200˚C to 220˚C

* MANUFACTURING PROCEDURE:

1. The pipes to be coated are checked for any signs of oil or grease contamination. If these are
found then the pipes are washed with a mild detergent in water.
2. The pipes are then put on the pipe rocks outside the blasting unit. The pipe is fed by kick in
units on to the axial roller conveyors which move the pipe helically towards the blasting
chamber.
3. The pipe is heated by flame heaters to 150˚C to remove moisture, then it is fed to the blasting
chamber, inside the blasting chamber, the pipe is blasted with a combination of Steel grit &
shot with the help of airless blasting turbines. This gives the required cleanliness (SA 2.5 – 3)
as well as the specified anchor pattern.
4. The blasted pipe in then subjected to phosphate pre treatment which is sprayed on the pipe.
After allowing the necessary reaction time, the pipe is rinsed with high pressure water to
ensure removal of excess chemicals from the pipe surface. Warm air is then blown on the pipe
for it to dry.
5. Inspection of the blasted & chemically treated pipe is carried out. Any weld splatter or
irregularities are removed by chiseling or grinding. If is has a surface area larger than 25 cm²,
it is reblasted.
6. The pipe is then moved to the internal blasting station where airless blasting turbines mounted
on a lance are used to blast the pipes internally.
7. The blasted & treated pipe is heated to the coating application temperature with induction
heater. During this process, temperature is continuously monitored to ensure, it is within the
required process parameters. This temperature range is usually 210 - 220˚C.
8. The preheated pipe is then coated in the coating hook by the 3 coating layers
the 3 layers are:
Layer 1: This is the corrosion protective layer. This layer is of fusion bonded epoxy which
offers very good corrosion protection. The fusion bonded epoxy being polar material, bonds
firmly to the blasted steel surface.
Layer 2: This layer is the copolymer adhesive. The copolymer adhesive is a maelic anhydride
grafted polyethylene compound. This material has good chemical bonding to the fusion
bonded epoxy.
Layer 3: This layer is for physical protection and consists of polyethylene. Since the
copolymer adhesive and polyethylene are similar, they bond well with each other.
Care is taken to ensure that the time gap between two successive layers is maintained as per the
raw material manufacturer’s specifications. Simultaneously an offset traveling lance is used to
line the pipe internally by FBE. The lance moves on rails which are offset and parallel to the
coating conveyors.
9. After the coating is applied & cured the pipe is subjected to water quenching, which brings the
temperature of the pipe down to below 60˚C.
10. The cooled pipe is then put on cutback machines which remove 150 mm of the coating from
either ends for field girth welding.
11. The relevant testing is carried out on the pipe & it is marked and kept ready for dispatch or
rejected as per the QC results. The cutback portion is coated using a temporary corrosion
protection measure for protecting the pipe prior to installation.

* COATING APPLICATION FACILITY DETAILS:

1) Description of equipment for coating:

a) Blasting unit (External) :-

i) Capacity : 350 m²/hr for SA 2.5
ii) Type : Dual turbine airless blasting unit with dust
collection.
iii) Range : 300 mm dia to 2500mm dia 6 – 12 m length.
iv) Dust collection unit : Dual cyclone type.
v) Grit recovery : Floor mounted belt conveyor & bucket
elevator.
vi) Sound level : Max 80 db

b) Blasting unit (Internal):-

i) Capacity : 350 m²/hr for SA 2.5
ii) Type : Dual turbine airless blasting units mounted
on lance.
iii) Range : 300 mm dia to 2500mm dia 6 – 12 m length.

c) Chemical pretreatment:-
i) Operating pressure
ii) Type
iii) Chemical Type
iv) Spreading/reaction rate
: 8 bar
: Airless Spray type with preheating arrangement.
: Iron Phosphate
: Adjustable as per chemical manufacturer
specifications

d) Preheating Unit :-
i) Type : 1000 kW induction coil 600 – 1000 Hz.
ii) Heating Capacity : up to 25 tonnes/hour
iii) Power factor : more than 0.94
iv) Duty Cycle : 100%
v) Input : 575 V +/- 6%, 3 phase

e) FBE coating unit:-

i) Type : 16 gun, 100 kV, electrostatic powder coating
machine.
ii) Output : 40 kg/hr per gun
iii) Spray pattern : Flat jet
iv) Recovery Unit : Cyclone type

f) Adhesive and polyethylene coating unit:-

i) Type : Multi gun non electrostatic sintering machine.
 ii) Output : Variable (upto 500 kg/h)
iii) Spray Pattern : Hollow conical type
iv) Recovery Unit : Gravity type with suction hood & sieve
arrangement.
g) Water quenching unit:-
i) Type : Gravity flow with cooling tower

h) Coating cutback unit:-

i) Type : Motor mounted brass brushes

2) Process control and inspection equipment:-

The following equipments & tools are maintained.

a) Hand weld contact less, digital laser thermometer - 10 - 500˚C
b) High voltage holiday detector up to 45 kV
c) Peel Adhesion tester
d) Pull off adhesion tester
e) ISO surface profile gauge
f) ISO comparator for surface
g) Humidity tester
h) Chloride test strips
i) Cross hatch cutter
j) MFI testing equipment
k) Gel time apparatus
l) Impact testing equipment
m) Cathodic disbondment apparatus
n) Differential scanning calorimeter
o) Elecometer coating thickness instrument.

3) Facility for handling of coated pipe in yard:

The coated pipes are handled in the yard with the help of hydraulic articulated crane. The
pipes are lifted using padded polypropylene slings. Stacking of the pipes is done by placing
wooden inserts/ rubber tyre inserts between the pipes. Sufficient slope is provided to ensure
proper drainage of water.

* APPLICATORS QA PROCEDURE:

1) Incoming raw material inspection :

a) FBE : - Incoming Fusion bonded Epoxy is inspected for get time moisture content.
The results are checked against the TC provided by manufacturer. FBE is stores in air
conditioned room. Different batches of FBE are kept separately to ensure the earlier
batch is consumed before the next one is started.
b) Adhesive : The adhesive material received is checked for MFI &
particle size & distribution. The same is checked against TC provided by
manufacturer.
 c) Polyethylene : The Polyethylene material is checked for MFI & particle size &
distribution. The same is checked against TC provided by manufacturer. The PE powder
is heated to 100˚C prior to being in coating, to drive away any moisture present in the
coating.

2) Incoming pipe inspection:

Incoming pipe, prior to being blasted is checked for transportation damages, traces of grease
or oil etc. The manufacturing details & markings on the pipe are noted down for traceability
of the pipe after coating.

3) Surface preparation:
Grit blasting is carried out in controlled factory environment. It is ensured that the relative
humidity is not exceeded by 85%. Any weld splitters or defects are removed by grinding
and/or chiseling. Pipe, after blasting & chemical pretreatment are given a code which
identifies the time of surface preparation. This ensures that the pipe is coated within 4 hours
of blasting. If the time lapsed is more than 4 hours since blasting, the pipe is reblasted.

4) Heating:
Heating is done by induction. The pipe travel speed through the induction coil is maintained
as a constant level. Contact less laser thermometers recorded the temperature of the pipe
continuously before application of the coating. A recording of the temperature reading is
made after definite interval of time. Thus the temperature data for every pipe is maintained.

5) Coating application:
The Coating output is controlled by the coating machine. A definite output is programmed in
the machine recording to the diameter of the pipe thickness of coating required & the time
travel speed of the pipe. The weight of the powder (coating material) consumed per unit time
is measured and recorded at definite intervals of time. This enables to calculate material
consumption per pipe.

* COATING REPAIR PROCEDURE:

• Pipes showing porosities or very small damage not picked up during holiday test and having
a surface less than 0.5 cm2 or linear damage (cut) of less than 3 cm shall be repaired by stick
welding using material of same quality.
• Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked up
during holiday test, having a total reduced thickness on damaged portion not less than 2.0mm
and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without
exposing to bare metal.
• Defects or size exceeding above mentioned area or holidays of width less than 300 mm shall
be repaired with heat shrinks repair patch by exposing the bare metal surface.
• Defects exceeding the above and in number not exceeding 2 per pipe and linear length not
exceeding 500mm shall be repaired using heat shrinkable sleeves of HTLP80 or equivalent.
* TEST FREQUENCY PLAN:

Below is the test frequency plan for 3LPE coating;

Properties Method of Test Frequency

Thickness testing DIN 30670 One pipe every 25 coated Pipes
Cut back Visual Every pipe
Holiday inspection DIN 30670 100% of all pipes
Impact resistance DIN 30670 Once per order
Indentation Test DIN 30670 Once per order
Adhesion test DIN 30670 One pipe every 25 coated Pipes
Electric resistance DIN 30670 Once per order
Elongation Test ISO 527 Once per order
Stability against U.V DIN 30670 Once per order
Thermal stability DIN 30670 Once per order
Cathodic disbondment ASTM G 8-90 As per agreement
radius

* MARKING OF COATED PIPES:

The pipes will be marked with the following unless otherwise specified by the purchaser:
a) Pipe number
b) Diameter & wall thickness
c) Coated pipe number
d) Lining type
e) Pipe manufacturer name
f) Inspection mark/ punch

* HANDLING AND STORAGE OF COATED PIPES:

Coated pipes are handled by means of slings and belts of proper width (minimum 60mm) made
of non-abrasive/ non-metallic materials. In case, pipes to be stacked are separated row by row
to avoid damages by rubbing the coated surface in the process of taking off the slings. Coated
pipes are stacked completely clear from the ground so that the bottom row of pipes remains
free from any surface water. The pipes are stacked at a slope so that driving rain does not
collect inside the pipe.

* FIELD GIRTH JOINTS:

External field girth weld joints are coated with heat shrink sleeves usually HTLP-60 or
above. They may also be coated by any other joint coating specification as per the clients
specification.
Internal girth weld joints are coated with the help of coating pigs. The material used is a
compatible grade of liquid epoxy.