COM900 Pipeline Coatings

900 Pipeline Coatings
Abstract
This section contains general information about external and internal pipeline coat-
ings. External pipeline coatings are described in figures which highlight the defini-
tion, recommended services, and other key elements of a coating. Quality control is
viewed from the standpoint of specifications, planning (based on a coating's service
conditions, durability and resistance, construction factors, and application factors),
and inspection. The selection section covers new construction and rehabilitation
coatings.
Pipe is coated or lined internally to prevent corrosion or to increase flow rates by
reducing friction losses. In some cases by installing linings through existing piping,
a corroded line which would otherwise have to be replaced can be salvaged. In this
section, the term, coatings, means the relatively thin paint, while linings are much
thicker cement or plastic. Field-applied means applying a lining or coating to an
existing pipeline.
Internally coated pipe is the main issue, with linings introduced only in terms of
alternatives to internally coated pipe. Both linings and coatings can be shop- or
field-applied.
For general information about:
• Surface preparation, see Section 100.
• Environment, health, and safety as they relate to coatings, see Section 200.
• The economics and colors of Company coatings, see Section 300.
For more detailed information about cement- and plastic-lined pipe, refer to the
Company's Pipeline and Piping Manuals.
Contents Page
910 Pipeline Coatings in General 900-3

920 External Pipeline Coatings 900-3
921 Selection
922 Quality Control
930 Internal Pipeline Coatings 900-54
931 Shop-applied Internal Pipeline Coatings
Chevron Corporation 900-1 September 1996

900 Pipeline Coatings Coatings Manual
932 Field-applied Internal Pipeline Coatings

933 Weld-joint Application & Inspection
940 References 900-59
September 1996 900-2 Chevron Corporation

Coatings Manual 900 Pipeline Coatings
910 Pipeline Coatings in General

The information in this section about pipeline coatings is general in nature. For
assistance with specific projects, contact the Company's coating specialists listed in
the Quick Reference Guide.
920 External Pipeline Coatings

The figures at the end of this section describe external coatings, both pipeline and
girth-weld protection. These figures highlight the definition, recommended
services, status, maximum service temperature, surface preparation, application,
thickness, small repairs, handling/storage, protection, discussion, brands, and refer-
ences of these coatings.
Quality control is viewed from the standpoint of specifications, planning (based on
a coating's service conditions, durability and resistance, construction factors, and
application factors), and inspection.
921 Selection
There are numerous factors to consider when selecting a pipeline coating. Figure
900-1 is a selection flowchart for choosing an appropriate mill-applied coating.
Figure 900-2 lists recommended external pipeline coatings for new construction
projects. The coatings in Figure 900-2 are listed in order of preference.
Figure 900-3 compares advantages and disadvantages of several types of external
pipeline coatings. For detailed information on various types of coatings, consult
Figures 900-4 through 900-21.
Splash-zone Coating for Offshore Platform Risers. See Figure 900-22 for oper-
ating temperatures of splash-zone coatings for offshore platform risers.
Valves, Fittings, Tie-ins. Their unique shape makes valves, fittings, tie-ins, and
other buried objects of irregular geometry hard to coat. As FBE is a shop-applied
coating, choose a spray or hand-applied coating from the list in Figure 900-23 Pipe-
line Fitting & Valve Coating Systems.
Protection.
• Girth Weld
See Figure 900-24 for a list of generic coatings for girth-weld protection.
Figures 900-4 through 900-21 contain more detailed information on girth weld
protection for specific coatings.
• Rock
Choose any acceptable rockshield material (Tuff-N-nuff, Ametek, Rock Shield,
Armor Rock) to protect coatings from mechanical damage from rocks or back-
fill in a ditch. The rock protection is:
– Wrapped around the pipe and bound with plastic straps

– Installed just before the pipe is put into the ditch

– Perforated to prevent cathodic shielding
See also comments about rock protection in the Protection portion of Figures
900-4 through 900-21.
• Construction Boring
Topcoat FBE with Protegal UT 23-10 or Powercrete to give the coating added
protection from damage during slick-bore construction, particularly where rocks in
the soil may abrade the FBE. Both Protegal and Powercrete have greater abrasion
resistance than FBE coatings.
Fig. 900-1 Mill-Applied Coating Selection Flowchart

Fig. 900-2 Recommended External Pipeline Coatings for New Construction—Ranked in Order of Preference (1 of 2)
Rank Buried Onshore Line Subsea Line Elevated Temperature In-plant Short Buried Lines(1)
1. Extruded Plastic with FBE Extruded Plastic with Extruded Plastic with Liquid Epoxy
• Service temp. to 200°F FBE Primer FBE Primer(2) • Some have same chemical
• All soils except hydrocarbon • Higher service • Higher service and temperature resistance
contaminated temperature to 230°F temperature to 230°F as FBE
• Coating thickness per pipe- • Moisture resistant • Moisture resistant • Also can be field applied; so,
line's operating temperature • Field experience • Field experience suitable for high and ambient
currently limited currently limited temperature lines, especially
for in-plant lines
• Hydrocarbon • Hydrocarbon
damages outer damages outer • Cure can be up to 24 hours
plastic jacket plastic jacket before service, per tempera-
ture during application
2. FBE FBE FBE(3) Plastic-backed Tape Wraps

• Service temp. between -76°F • Higher service • Service temperature • Mixed success with butyl
and 200°F temperature to 200°F up to 200°F(4) adhesives as most are:
• All soils • Coating thickness • Coating thickness • Not resistant to hydrocarbons
• Coating thickness per use per temperature per temperature • Poor resistance to soil stress
and pipe movement
• Not applied generally under
ideal conditions
• Least cost, easy to apply
3. Extruded Plastic with Butyl Rubber Coal-tar Enamel Extruded Plastic with
or Asphalt Adhesive • Service temp. 140°F Butyl Rubber Adhesive
• Very economical • Good if selected and • Very economical
• Service temp. to at least 100°F, applied correctly • Service temp. to
some to 180°F • Hard to handle: maximum of 180°F
• Suitable for low-soil stress brittle when cold, • Suitable for low-soil
areas soft when hot stress areas
• Not resistant to hydrocarbons
4. Coal-tar Enamel Tape Wrap(5), (6)

• Service temp. 140°F • Low soil-stress areas
• Good if applied correctly • Select only specialty,
• Hard to handle: brittle when high-temperature
cold, soft when hot tape wraps for
service over 140°F(7)
• Not resistant to
hydrocarbons

Fig. 900-2 Recommended External Pipeline Coatings for New Construction—Ranked in Order of Preference (2 of 2)
5. Tape Wrap(7)
• For low-soil-stress areas
• Not resistant to hydrocarbons
Concrete (Weight) Coating—Normally, we apply a concrete (weight) topcoat to FBE and other offshore coatings for negative buoyancy and
coating protection. For small-diameter lines, FBE does not need protection; therefore, extra steel can provide negative buoyancy. A weighted
topcoat not only protects coal tar from UV rays before we lay the pipeline but also prevents handling damage. See the CRTC Pipeline Manual
for additional information about concrete (weight) coatings.
Extruded Plastic—Continuous plastic coating (either polyethylene or polypropylene) is extruded on a pipe at elevated temperatures. There are
two distinct subcategories of coatings: plastic coatings with a soft-extruded-butyl rubber of flood-coated-asphalt rubber-mastic adhesive, and
plastic coatings with a cured-hard-epoxy adhesive. Sometimes, a copolymer adhesive bonds the plastic outer layer to the epoxy inner layer. There
are also two methods of extruding the plastic coating portion of the coating system: a side or T-shaped die, or a crosshead or circular die [3].
(1) The cost of materials is proportionally higher than for a large project. Weigh the cost against the importance of the pipeline, its access,
its location (populated area vs. wilderness), and soil conditions. Lower costs of future repairs or refurbishing may offset the initial
expense of high-quality coatings.
(2) For abrasion protection against thermal expanding and contracting of elevated temperature lines, increase the thickness of the poly-
ethylene or polypropylene coating.
(3) FBEs permeability to water increases with temperature; but this problem has been solved to date by increasing the thickness of the FBE
according to service temperature. Consider the cost of the increase in thickness.
(4) Currently, FBE is the only economical line coating for temperatures over 180°F. Aramco has successfully pushed FBE to 225°F (22 mils)
in sandy soil; but, the coating softens notably above 210°F. There is a cohesion failure if a knife can remove the coating. Company
recommends only three brands for service over 150°F: Nap-Gard (7-2501 and 7-2504), Valspar D1003, and Scotchkote 206N based on
field experience and test data.
(5) Company recommends only shop-applied Rayclad 120 for protecting new pipelines.
(6) The high cost of good-quality, high-temperature, tape wraps restricts them to large-radius bends.
(7) Check the service history of non-specialty tapes for service temperatures above 100°F. Manufacturers often overstate the upper limits.

Fig. 900-3 Advantages and Disadvantages of External Pipeline Coatings (1 of 2)

Coating Advantages Disadvantages
Fusion Bonded Epoxy • 25+ years experience • Near white metal surface preparation required
• Low current required for cathodic protection • High application temperatures
• Good resistance to cathodic disbondment • Thinnest coating
• -40°F to 200°F temperature range • Difficult to apply holiday free
• Available in all pipe sizes • Difficult to apply consistently
• Excellent hydrocarbon resistance
• Not susceptible to cathodic shielding
• Excellent adhesion to steel
• Continuous coating
Liquid Epoxies (Thermosets) • Temperature resistance up to 200°F • Long cure time (minutes to 24 hours)
• Spray or hand apply in field • May need near white blast surface
• Good chemical resistance • Expensive
• Use for odd shapes
• Can be applied while pipe is in service
Extruded Plastic with Butyl • Low current required for cathodic protection • High initial costs for small diameter pipe
Rubber Adhesive • Minimum holidays on application • Susceptible to cathodic shielding
(Pritec)
• -40°F to 180°F temperature range • Do not use on spiral-welded pipe
• Self-healing adhesive • Hard to handle when warm
• Wide range of sizes • Susceptible to damage from thermal expansion
• Excellent adhesion to steel and contraction
• Continuous coating • Cannot be used on bends

• Limited hydrocarbon resistance
Extruded Plastic (Mapec, Elf • 15+ years experience • Limited hydrocarbon resistance
Atochem, and Himont FBE/PE • Minimum holidays on applications • Limited experience with high temperature
or PP brands) service
• Low current required for cathodic protection
• -40°F to 180°F temperature range
• Wide range of pipe sizes
• Low water absorption
Extruded Plastic • 200°F + temperature resistance • Limited experience (less than 5 years)
(Du Val FBE/PE or PP) • Low water absorption • High cost
• Coating for girth welds and shop bends is the • Girth welds difficult to coat
same as for lines • Coating damage hard to patch but progress is
• Minimum holidays on application being made
• Low current required for cathodic protection
• Excellent adhesion FBE to PE or PP

Fig. 900-3 Advantages and Disadvantages of External Pipeline Coatings (2 of 2)

Coating Advantages Disadvantages
Extruded Plastic, Asphalt • 29+ years experience • Minimum adhesion to steel

Adhesive (Plexco, Bredero • Minimum holidays on application • Do not use above ground
Price, and Shaw)
• Low current required for cathodic protection • Limited storage life
• -40°F to 160°F temperature range • Tears in jacket can go length of pipe
• Adhesive flows at low temperatures
• Poor hydrocarbon resistance
• Susceptible to cathodic shielding
• Hard to handle when hot
Tape Wraps • 30+ years experience • Susceptible to cathodic shielding

(services < 140°F) • Easy to apply • Poor coating-to-coating bond at overlap
• Can be used for bends • Must be applied at proper tension
• Can be used to coat all sizes of pipe • Susceptible to soil stresses
• Can be applied to pipe while in service • Temperature limited
• Non-continuous coating
• Poor service history
Coal/Tar Enamel • 65+ years experience • Carcinogenic fumes when applied

• Minimum holidays on application • Poor UV resistance
• Low current required for cathodic protection • Cracking problem below 32°F
• Good resistance to cathodic disbondment • Soft when hot (100°F)
• Good subsea experience with weight coating • Poor hydrocarbon resistance
• Available for all sizes of pipe
Fig. 900-4 Description of External Pipeline Coating—Asphalt Wrap Coatings

Definition Asphalt wrap coatings consist of filled, air-blown, asphalt enamel that is reinforced with asphalt-embedded
glass cloth or felt and covered with felt
Holiday Detection
coating
1250 thickness
( mils )
Note: Lower holiday detection voltages may be required to prevent coating damage.
Recommended Service ☞Caution The Company no longer recommends this coating because of its poor service history.
Status In the recent past, no-one has applied asphalt-wrap coatings; therefore, pipeline grades of asphalt are no longer
available in the United States. Asphaltic wraps have a poor service history and are susceptible to hydrocarbon
attack and general deterioration in the ground.
The Company has deleted the standard drawing for these wraps from the Piping Manual because these coatings
are now obsolete.
Small Repairs Choose an asphalt-based mastic to patch an asphalt (P-2) wrap.

☞Caution Coal-tar mastics usually are not compatible with asphalt coatings.
The American Asphalt Institute had a classification system for coding asphaltic pipeline coatings that they have discontinued. P-2 identified
the number of wraps and type of asphalt. this system of classification was similar to the NAPCA (National Association of Pipe Coating Applica-
tors) system in which TGF-3 is an example for coat-tar-enamel pipe coating.

Fig. 900-5 Description of External Pipeline Coating—Asphalt Mastic (1 of 2)

Definition Somastic—an asphalt mastic—is a tar-like mixture of
• Inert mineral fillers - 13 per cent
• Sand aggregate - 64 per cent
• Fiberglass fibers - 0.1 per cent
• Asphalt binder
Recommended Service Offshore and onshore ambient-temperature lines where hydrocarbon-soaked soils are not present.
Status Limited availability and marketing have affected Somastic's popularity.
Max. Service Temp Field experience has found manufacturers’ temperature limits to be very optimistic.
☞Caution The Company does not recommend Somastic for temperatures above 140 °F.
Surface Prep Abrasive Blast

Other
Holiday Detection
coating
1250 thickness
( mils )
Application • Heat and mix Somastic ingredients

• Continuously extrude the mixture over primed pipe to form a thick, seamless coating
• Whitewash the black mastic to prevent its softening and aging in sunlight
Girth-weld Coating
• Melt Somastic chips and pour the fluid into a mold that compresses the hot mixture around the
girth weld.
• Taper the Somastic joint coating at the ends to accept heat-shrink wraps for coating the girth welds.
Thickness > 250 mils
Small Repairs Heat-shrink sleeves UT.

☞Caution Select mastics that are compatible with asphalt for repairing coating damage. Coal-tar
mastics are usually incompatible with asphalt coatings such as Somastic.
Handling/Storage Aboveground Storage Limit: One year
Protection/Resistance UV Resistance: Poor

See also Advantages and Disadvantages under Discussion below.

Fig. 900-5 Description of External Pipeline Coating—Asphalt Mastic (2 of 2)

Discussion Three grades of Somastic are currently available, differing in chemical makeup of the asphalt and
temperature ratings.
• Somastic I - 120°F
• Somastic II - 150°F
• Somastic III - 190°F
Choosing a higher grade (higher temperature limit) decreases flexibility at low temperatures.
Service History
Originally developed in 1922 by Standard Oil Company of California, Somastic has been selected for
offshore and high-temperature onshore service. Its thickness and toughness make it especially resistant
to mechanical damage; however, Somastic will fail in hydrocarbon-contaminated soils. FBE has
replaced asphalt enamels because of poor performance. FBE and Pritec have replaced it as an onshore
hot-oil pipeline coating because Somastic has performed poorly in this service.
Most of Somastic's failures occur at elevated temperatures. One of these failures occurred at the
Company's Hawaii Refinery on a 180°F line; however, the Company and other operators have had many
successful Somastic applications at long-term ambient temperatures. Several failures have also
occurred on hot-oil pipelines in California.
Poor quality control inspection during pipeline construction or incompatible mastics may have caused
some failures of Somastic-coated girth welds.
Advantages
• A good coating with a long service history
• Adheres well
• Flexible
• Good resistance to impact, penetration, and cathodic disbonding
Disadvantages
• Not always available
• Susceptible to hydrocarbon attack
• Brittle when cold (< 40°F)
• Soft when hot
• Heavy (expensive to ship)
• Not performed well as a hot-oil pipeline coating
As asphalt-wrap coatings absorb water, there have been questions about applying Somastic offshore.
Water absorption could increase the current requirements for cathodic protection and cause a coating
failure. Shell Oil recently reported that one of their Somastic-coated offshore pipelines was only
5 percent bare after 20 years of service. At present, there is no evidence that Somastic coatings are
unsuitable for offshore service.
Girth-weld Coating Heat-shrink sleeves

(Taper Somastic coating transition area to 45 degree angle.)
Brands Somastic I and III.

Currently available only from Bredero Price International (formerly Energy Coating) in Harvey, Louisiana.
See Also NACE International Standard RP-0276 (Discontinued)

Fig. 900-6 Description of External Pipeline Coating—Coal Tar Enamel (1 of 2)

Definition Coal-tar enamel is a hot, shop-applied, black tar-like coating of iron-mill-coke byproducts. It is layered
with inner or outer wraps (or both) of glass fiber or asbestos felts.
Recommended Service On subsea lines with concrete (weight) coatings.
Status For onshore lines, operators are replacing coal-tar enamels with FBE and extruded plastic; offshore,
coal-tar is very popular.
Max. Service Temp 140°F
Surface Prep Abrasive Blast: SSPC SP6

Other
Holiday Detection 12,000 to 18,000 volts
Application Although we can field- or shop-apply coal-tar enamels, field application is rare because of problems
with inadequate pipe surface preparation, inspection [8], and air quality when melting the coating.
The coating mill sprays or pours heated coal-tar enamel (400°F) on a pipe primed with coal-tar primer.
Simultaneously, they layer two or three glass-fiber, felt-reinforcement wraps that improve the coating's
strength, uniformity, and resistance to soil stresses and mechanical damage.
☞Caution Solvent emissions during application can be an environmental problem.
Thickness 156 mils

The total thickness of the coating including the outer wrap is about 100 mils. Typically ranges from 62 to
188 mils.
Small Repairs The following repair methods are acceptable in the United States, except melted enamel which is prohib-
ited in some states with strict air quality regulations. The melted enamel repair is expensive and is only
warranted if there are many repairs.
• Coal-tar mastic
• Cold- or hot-applied tape made for coal tar (must first remove the damaged coal-tar enamel
completely)
• Melted coal-tar enamel is granny ragged (the process followed to handwrap hot coal-tar enamel on
the bottom half of the pipe’s surface) or poured into a mold formed around the pipe
☞Caution Make all mastic repairs with a coal-tar mastic because asphalt mastics are incompatible
with coal-tar coatings.
Many gas-transmission pipeline operators do not approve of any mastics as this substance has failed in
service, allowing corrosion to develop.
Handling/Storage Aboveground Storage Limit: Six months +
Protection/Resistance Protection
For an outer coating, we recommend fiberglass filler mat and a felt or kraft paper (or both) outer wrap.
The outer wrap protects the coal tar from mechanical damage when it is soft.
Coating applicators usually give the pipe a reflective outer coating of kraft paper, whitewash, or white
emulsion to protect it unless it is concrete (weight) coated. Any of these outer coatings will reduce the
temperature of the coal tar to a minimum in the sun and protect it from UV rays.
Hydrocarbon Resistance: Poor

Fig. 900-6 Description of External Pipeline Coating—Coal Tar Enamel (2 of 2)

Discussion Choosing mineral rather than asbestos felts affects both the cost and the quality of the coating. Mineral
felts are generally comparable with asbestos and cost more as they come from eastern Canada. Regard-
less, select mineral felts because repairs to coal-tar-enamel lines with asbestos felts would be more
costly due to asbestos-handling procedures.
Service History
Coal-tar enamels have been popular for over 70 years. For offshore service, coal-tar enamel is common
as 33 percent of the companies responding to an Oil and Gas Journal survey [9] report using it. For more
than 20 years, Aramco has applied coal tar enamel successfully offshore [10]. While this coating has
also been applied successfully onshore, it is hard to handle, becoming brittle at about 40°F and soft
above about 90°F. The concrete-weight coating applied over the coal tar for subsea applications
protects the coal tar and eliminates the handling problem.
Girth-weld Coatings Shrink wraps or cold applied tape wraps.

Note: The materials of heat-shrink wraps are generally more expensive than cold-applied tape, but heat-
shrink wraps are quicker to apply and less sensitive to an inexperienced worker. Heat-shrink wraps also
reduce the possibility of water ingress as it eliminates the overlap inherent with cold-applied tape wraps.
Brands The coating material is available from Reilly Tar and Chemical Corp., but the number of coal-tar coating
applicators is decreasing because of strict air quality regulations. Per NAPCA specifications, CUSA
production typically orders this coating system as TGF-3.
See Also • Company’s Pipeline Manual for information on weight coatings

• NAPCA Bulletin 1-65-94 “Recommended Specification Designations for Coat Tar Enamel Coatings”(1)
• NAPCA Bulletin 2-66-94 “Standard Applied Pipe Coating Weights for NAPCA Coating Specifications” (1)
• NAPCA Bulletin 3-67-94 “External Application Procedures for Hot Applied Coal Tar Coatings to Steel
Pipe”(2)
• NAPCA Bulletin 6-69-94-1, “Suggested Procedures for Hand Wrapping Field Joints Using Hot
Enamel.”(3)
• AWWA Standard C-203
• COM-MS-5006, Coal-tar Enamel Corrosion Coating of Submarine Pipelines, in this manual for applica-
tion specifications
• Application specifications for coal-tar enamel and concrete (weight) coatings in Figure 900-21:
Coating Specifications for Buried Pipelines.
(1) Chevron USA follows these specifications when ordering coal-tar-enamel coatings
(2) Chevron USA Production typically follows this specification when ordering coal-tar-enamel-coated pipe.
(3) Although this NAPCA specification is for coating girth welds, we follow the same technique for making repairs with hot coal-tar enamel.

Fig. 900-7 Description of External Pipeline Coating—Coal Tar Epoxies

Definition A two-part liquid epoxy compound containing coal-tar pitch
Recommended Service Refurbishing old pipelines, girth weld coatings, tie-ins, valves, and fittings.
☞Caution Unsuitable for hot-oil pipelines.
Status More commonly used as a tank lining, coal-tar epoxy has seen limited use as a buried pipeline coating
system; however, most coal-tar epoxies are incompatible with cathodic protection current.

SSPC SP-10
☞Caution Any less than SSPC SP-10 for buried pipeline may result in cathodic disbondment.
Other
Holiday Detection
coating
1250 thickness
( mils )
Application Spray, brush, or roll

Cure time: Very slow
Thickness 16-20 mils
Small Repairs Patch with same material per manufacturer’s guidelines
Handling/Storage —
Protection/Resistance Cathodic Disbonding

A zinc primer may improve resistance to cathodic disbonding of the coal-tar epoxy's outer layer.
Applying high-built coal-tar epoxies in two coats increases resistance to cathodic disbondment.
Soil Stress & Hydrocarbon Resistance: Excellent
Discussion Applied correctly, coal-tar epoxies are excellent coating systems for buried pipelines; but they are
unsuitable for hot-oil pipelines.
Girth-weld Coatings —
Brands International Tarset Maxi-Build 7080 and Corroguard EP are the only coal-tar epoxies currently recom-
mended, but there are many other coal-tar epoxies on the market that make excellent buried pipeline
coatings.
See Also NAPCA Bulletin 14-83-94, External Application Procedures for Coal Tar Epoxy Protective Coatings to
Steel Pipe

Fig. 900-8 Description of External Pipeline Coating—Cold-Applied Tapes (1 of 2)

Definition There are two types of tape wraps: hot- and cold-applied. Hot-applied wraps generally have a higher
bond strength. Cold-applied tapes can be field- or shop-applied by machine or by hand. Cold-applied
tape wraps are:
• Continuous strips of a plastic-backing material, either polyethylene (PE) or polyvinylchloride (PVC)
• Coated with a butyl-rubber adhesive (Polyken or Tapecoat) or modified bituminous compound (Poly-
guard RD-6)
• Spirally wound on primer-coated pipe
Recommended Service Tapes are still viable because otherwise we cannot accomplish the following tasks economically:
• Repairing damaged coatings (FBE, extruded plastic, and coal-tar epoxy)
• Coating bends that cannot be FBE coated in the field
• Refurbishing old lines that must stay in service
• Refurbishing short new lines in dry, low-soil-stress areas more economically than with extruded
plastic or FBE
☞ Caution Because PVC embrittles badly and shrinks at temperatures of 104 °F or higher, we
recommend PE for all tape applications [6, 7].
☞Caution Our experience does not substantiate manufacturers' claims that cold-applied tapes are
suitable for hot-oil pipelines.
Status Introduced about 40 years ago [5] as an over-the-ditch system, tapes replaced coal-tar enamels and
asphalts that required heating. The tape on thousands of miles of pipe has given mixed results and is
now being replaced with extruded plastic or FBE as the main mill-applied coating for pipelines.
Max. Service Temp Elevated-Temperature Service

Most high-temperature tape systems are hot-applied tape systems. The temperature limits of cold-
applied tapes, depending on the manufacturer, include:
• 140°F for most polyethylene-backed tapes with butyl adhesives
• 150°F for polypropylene-backed tape with bituminous compound (Polyguard RD-6)
• Above 140°F for specialty tapes
A cold-applied tape may suffer thermoshock when raised to the service temperatures of hot-oil pipelines.
Surface Prep Abrasive Blast: SSPC SP-2

Other
While an abrasive blasted surface is ideal, coatings applicators most often field-apply tapes, making
surface preparation difficult. Over-the-ditch cleaning machines have rotating wire brushes to clean the
pipe ahead of primer application. Power tools are essential if cleaning by hand. There are coatings with
minimum sensitivity to surface preparation.
Holiday Detection 3000 to 8000 volts per manufacturer’s guidelines
Application Whether mill- or field-applied:

• Prepare the pipe surface
• Apply a primer
• Spirally apply one layer of tape
• Spirally apply one or more offset layers of tape over the first.
When wrapping the tape around a pipe, there are three critical elements for success: pipe surface prep-
aration, tape tension, and amount of tape overlap. (Check with the tape manufacturer for recommenda-
tion). In a two-layer system, it is also important to stagger the overlaps of each tape layer so that water
has no direct path to the pipe surface.
Before applying the first tape layer, the coating applicators tape any weld seams (girth and longitudinal)
that are not flush with the surface of the pipe. This base layer of tape prevents the spirally applied tape
wrap from leaving a void at the weld seam that may become filled with moisture and create a shielded
corrosion cell.
The primer causes a chemical reaction in the adhesive, which helps bond the adhesive or compound on
the inner layer of tape to the pipe's surface, thus increasing its bonding strength. In a two-layer system,
the first layer of tape provides corrosion protection; the second, and any subsequent layers, provide
mechanical protection for the first layer.

Fig. 900-8 Description of External Pipeline Coating—Cold-Applied Tapes (2 of 2)

Application (continued) The outer wrap (or rock shield) over the tape system must be bonded or not bonded to the tape
depending upon the recommendation of the tape manufacturer. Non-bonded outerwraps create a slip
plane between the inner and outer wraps that helps protect the inner wrap from soil stresses. A non-
bonded outerwrap may cause a cathodic protection shielding problem if it is a solid plastic coating.
Shop-applied tapes outperform field-applied tapes because quality control and inspection are easier in
the coating mill.
To improve field application of cold-applied tapes, relatively small and lightweight wrapping machines
are now commercially available that are power or hand operated. They can also be equipped with a
constant tension brake system to provide uniform tension across width of rolls and through its entire
length.
Thickness Varies with coating system.

The average thickness (not including a rock shield or outer wrap) of a two-layer tape wrap is about
70 mils; of a single-layer tape system, 50 mils.
Small Repairs Generally, coating applicators repair tapes by taping over the damaged tape or by using a mastic. In the
Northwestern Business Unit, Chevron Pipe Line has been successful with Tapecoat's 10/40W system
using a one-inch overlap.
Protection/Resistance UV and Hydrocarbon Resistance: Poor
Discussion Service History

Many early tapes
• Were applied with poor surface preparation, no primer, no tension, and no protective overwrap
• Failed in service
• Have given tapes the reputation of being poor pipeline-coating systems
Advantages
Cold-applied tapes are easy and inexpensive to apply in the field. If applied properly and used in the
proper environment, cold applied tapes are an acceptable pipeline coating.
Tapes are still viable because of the tasks listed under Recommended Service, above.
Disadvantages
Tapes may encounter problems in long-term service, because of improper application, service condi-
tions, pipe diameter, or product design. As they are not a continuous coating, the tape's overlaps greatly
increase the chance of water penetration. Also, the overlaps may bond poorly, catch on the soil (stress),
and pull open. The Company has not verified the suggestion that some new tapes have resolved these
problems.
Some tapes are pressure sensitive (Tek-Rap, Royston) and depend primarily upon mechanical means,
memory, to keep the overlaps closed. If outside forces such as soil stress disturb this memory, the tape
may loosen. Too much or too little tension during application can cause a coating failure from loss of
memory. For protecting buried pipelines, pressure-sensitive tapes are not as desirable as tapes with an
adhesive that bonds at overlaps to the pipe's metal surface and the coating.
Most failures of tapes occur on large-diameter pipe (greater than 12 inches in diameter). Soil stress
becomes a greater problem as the pipe's diameter increases because the soil has more coating surface
area to grab.
Girth-weld Coatings For coating-mill-applied tape wraps (through 12 inches in diameter), shrink sleeves or hand-wrapped
tape
Brands Tapecoat’s 10/40W, Polyken, Polyguard RD-6
See Also • NAPCA Bulletin 16-94, “External Application Procedures for Plant Applied Tape Coating to Steel
Pipe”
• NAPCA Bulletin 6-69-94-9, “Suggested Procedures for Coating Field Joints, Fittings, Connections,
and Pre-fabricated Sections Using Tape Coatings”

Fig. 900-9 Description of External Pipeline Coating—Extruded Plastic with FBE or Liquid Epoxy Primer (1 of 2)
Definition Continuous plastic coating (either polyethylene or polypropylene) with an epoxy primer.
Recommended Service Buried onshore and offshore pipelines up to 200°F.
Status Although this coating system is quite new to the United States, it has been available in Europe for a long
time. Himont, DuVal, and Elf Atochem are the suppliers; Bredero Price (formerly Encoat) has two coating
mills that apply this coating in the United States.
• Himont, an Italian company, is forming an alliance with 3M and Shell Chemical to enter the U.S. pipe-
coating market.
• DuVal is an alliance between Du Pont Canada and Valspar.
• Du Pont Canada and Shaw manufacture polyethylene three-layer systems in Canada. Shaw's has a
liquid-epoxy primer.
Max. Service Temp 200°F Polypropolene; 180°F Polyethylene
☞Caution We do not recommend polypropylene for service temperatures above 200°F without
additional laboratory or field testing.
Surface Prep Abrasive Blast: SSPC SP10
Other: Blast clean the pipe and then transfer it to the extrusion line.
Holiday Detection
coating
1250 thickness
( mils )
Application To produce a bonded, overlapped coating to a specified thickness:

• Apply an epoxy primer with or without a co-polymer adhesive (Mapec, Himont, Du Pont Canada,
DuVal, Elf Atochem).
• Immediately extrude overlapping layers of melted plastic on the pipe, followed by water quenching.
Apply Shaw YJII by the crosshead-extrusion process over a liquid-epoxy adhesive layer; apply other
coatings with the side-extrusion process over an FBE primer.
Quality control standards are more rigid for multi-layer coating systems such as DuVal, Himont, Du Pont
Canada, and Elf Atochem as the adhesive (FBE) must still be tacky when we apply the plastic topcoat.
☞Caution Applying the topcoat:
• Too quickly results in improper curing of the FBE and poor bonding to the pipe's surface.
• Too slowly may produce an improper bond between the plastic and FBE layers.
Thickness The thickness of the plastic topcoat may be 1.5 to 3 mm or more depending upon the pipe's diameter and
the service requirements.
DuVal has a standard 14-mil thickness of FBE as compared to the 75 to 125 microns in the three-layer systems.
Elf Atochem: 59 to 118 mils; DuVal: 20 to 45 mils.
Small Repairs Heat-shrink sleeves
Handling/Storage Aramco has had good experience with Mapec, which is reportedly easier to ship and handle than FBE.
Protection/Resistance UV Resistance: Excellent
See also Discussion below
Discussion Considered the best pipeline coating system available. Company has limited experience with it.
Resistance and Strength
Extruded plastic coatings generally have good impact strength, resist water penetration well, and do not
shrink at elevated temperatures. Physical properties of polyethylene vary with density, high-density poly-
ethylene having superior resistance to impact and moisture.
The shear strength of butyl or asphalt adhesives is poor and decreases substantially with increases in
temperature [4]. This situation allows the pipe to move inside the coating during thermal expansions and
contractions and subjects the outside of the coating to soil stresses. The resulting problems are loss of
adhesion, wrinkling, and, eventually, exposed steel. The adhesives in Elf Atochem, Himont, Du Pont
Canada, DuVal, and Shaw YJII coating systems have greater shear strengths and temperature resis-
tance than butyl or asphalt adhesives.
Mapec gave excellent results in the early 1980's testing, but did not equal thick FBE in hot (250°F) subsea
testing in the late 1980's [15].

Fig. 900-9 Description of External Pipeline Coating—Extruded Plastic with FBE or Liquid Epoxy Primer (2 of 2)
Discussion (continued) Operating Temperatures
• Service Temperatures < 150°F
Acceptable—30214 Mapec's low-density polyethylene plastic.
• Service Temperature of 180°F
– Uninspected but in service (Shaw YJII and a thermo-insulation outer jacket. /DuVal polypropylene
with no thermo-insulated outer jacket
– Chevron Canada Resources has a hot-oil pipeline operating at 180°F, which is coated with
Shaw YJII and a thermo-insulation outer jacket. The girth welds were coated with liquid epoxy
and Raychem high-temperature heat-shrink sleeves. To date, this pipeline has not been inspected
and has been in service for four years.
– The Chevron Pipe Line Western Business Unit has DuVal polypropylene on a hot-oil pipeline oper-
ating at 180°F. This pipeline has no thermo-insulated outer jacket, has not yet been inspected, and
has been in service for about two years. They experienced quality control problems during the
coating's mill- production run and when CCSI field coated the girth welds. While Mobil Pipeline
reports that most of these problems have been corrected, a British Petroleum project also had
quality control problems in South America during 1993-94.
Elf Atochem's coating system has three plastic (polyolefin) top coats that they rate for the following
service temperatures:
• Low-density polyethylene (-40 to 149°F)
• Medium-/high-density polyethylene (-40 to 167°F)
• Polypropylene (-4° to > 212°F)
☞ Caution We do not recommend DuVal Polypropylene for service temperatures above 200 °F
without additional laboratory or field testing.
Du Pont Canada and Valspar rate their DuVal Polyethylene at a maximum operating temperature of 180°F
and their DuVal Polypropylene at a maximum operating temperature of 230°F.
Layers
Because of higher costs of materials, two-layer coatings (e.g., DuVal) are more expensive than three-
layer systems (e.g., Mapec, Elf Atochem, Du Pont Canada, and Himont). Valspar is considering changes
for DuVal to bring its maleic anhydride content nearer the levels of three-layer coating systems.
DuVal must have the proper concentration of maleic anhydride to bond the two layers to each other.
Bredero Price (formerly Encoat) performs a test on DuVal’s raw, modified, plastic material to verify that
there is a proper concentration of maleic anhydride. The middle adhesive layer of the Elf Atochem multi-
layer system bonds the top plastic and FBE layers with maleic anhydride and other chemicals such as
terpolymer of ethylene and acrylic ester. DuVal and Elf Atochem coatings are not as easy to apply as
other pipeline coatings such as FBE and Pritec. Although it is possible to field-apply a two-layer system
over girth welds, field conditions can make it difficult to achieve a quality coating.
Girth-weld Coatings • Induction-heat-applied FBE and plastic is recommended.
• Shrink sleeves
Brands ☞Caution Many pipeline operators are using Himont, DuVal, and Elf Atochem polypropylene coating
system at operating temperatures up to 230°F on both offshore and onshore pipelines. The Company has
limited experience with this coating system at temperatures above 200°F. We do not recommend Elf
Atochem Polypropylene or DuVal polypropylene for service temperatures above 200°F without additional
laboratory or field testing.
The following systems offer superior performance often equal to or better than FBE alone at a premium price.
• Mapec’s low-density polyethylene plastic is acceptable for maximum service temperatures of 150°F.
• The Mapec, Du Pont Canada, Himont, DuVal, and Elf Atochem systems have an FBE primer, and
either a polypropylene or polyethylene jacket.
• Shaw YJII has a liquid-epoxy primer with a polyethylene outer jacket.
• The Mapec, Du Point Canada, Himont, Shaw YJII, and Elf Atochem systems bond the epoxy and
outer plastic with a copolymer adhesive
• The DuVal system has an adhesive copolymer incorporated in the plastic top coat formula.
See Also • CAN/CSA-Z245.21-M92 L’Association Francaise De Normalization NF A49-710
• Mobil Pipeline Specification CM-251-880

Fig. 900-10 Description of External Pipeline Coating—Extruded Plastic—Crosshead-Extruded Plastic with

Asphalt Adhesive (1 of 2)
Definition Continuous plastic coating (either polyethylene or polypropylene) extruded on a pipe at elevated
temperatures.
Recommended Service Onshore pipelines operating below 160°F where FBE is uneconomical or unavailable.
Prices and the performance of the systems (particularly at higher temperatures) vary substantially. See
Discussion below
Status Extruded polyethylene and polypropylene coatings of various costs and qualities are very popular and
readily available in the United States and Canada.
Max. Service Temp Varies with manufacturer.

Onshore, < 160°F. (100°F for some brands)

Other
Holiday Detection
coating
1250 thickness
( mils )
Application[3] The crosshead extrusion method involves:

• Flooding the pipe with a hot asphalt-rubber adhesive
• Passing the pipe through a wiper ring to maintain a nominal ten-mil adhesive thickness
• Passing the pipe through the center of the crosshead die where the plastic is uniformly extruded in a
cone shape around the pipe
• Water quenching that causes the plastic to shrink tightly to the adhesive and pipe
☞Caution Unlike side-extrusion, crosshead extrusion limits size of pipe diameter.
☞Caution Never apply soft adhesives to spiral-welded pipe.
Thickness 35-70 mil
Small Repairs • Heat-shrink sleeves

• Tapes, if soil stress not a problem
Handling/Storage Above-ground Storage Limit: One year
Protection/Resistance Disbonding
Tests of the early 1980's show differences in adhesive strengths and resistance to cathodic disbonding.
Plexco and Encoat (now Bredero Price International) were not as good as Pritec (extruded plastic with
butyl rubber mastic) and Mapec (extruded plastic coating with FBE primer). [2, 4, 13, 14]. Recently
Bredero Price (Encoat) improved the mastic in its Entec coating. Plexco will supply a superior mastic if
requested.
UV Resistance: Fair.
The orange (polypropylene) and yellow (polyethylene) coatings do not resist UV damage well. They
became brittle and cracked when stored for a year in the Californian sun. (This is not a problem with
Yellow Jacket).
Impact, Moisture, Shrink, and Temperature Resistance
Extruded-plastic coatings generally have good impact strengths, resist water penetration well, and do
not shrink at elevated temperatures. Physical properties of polyethylene vary with density, high-density
polyethylene having superior resistance to impact and moisture. Polypropylene offers superior tempera-
ture resistance in hot-oil pipeline service, but the mastic has the lowest temperature limit.

Fig. 900-10 Description of External Pipeline Coating—Extruded Plastic—Crosshead-Extruded Plastic with

Asphalt Adhesive (2 of 2)
Discussion Costs
Wide range in costs. The former X-Tru-Coat coatings (Plexco Plexguard, Bredero Price (Encoat), Entec,
Shaw Yellow Jacket, and Shaw Black Jacket) are inexpensive and work well at ambient temperatures [12].
Temperature
A Company product, the Plexco coating is very economical. Chevron Canada Resources reports that the
high-temperature grade of Yellow Jacket (maximum 185°F limit) works well at 140-160°F. Although
current Plexco and Bredero Price (Encoat) literature places maximum temperature limits of 140°F (poly-
ethylene) to 170°F (polypropylene), be cautious with these products in temperatures above 100°F without
additional testing or documented high-temperature field experience. Yellow Jacket should work up to
160°F, based on the Canadian experience. Black Jacket is a new coating with a mastic superior to Yellow
Jacket, but the Company has no experience with Black Jacket.
Strengths
The shear strength of hot-melt-asphalt adhesives is poor and decreases substantially with increasing
temperature [4]. This situation allows the pipe to move inside the coating during thermal expansions and
contractions and subjects the outside of the coating to soil stresses. The resulting problems are loss of
adhesion, wrinkling, and, eventually, exposed steel.
Girth-weld Coating Heat-shrink sleeves
Brands The crosshead extrusion method was formerly licensed under X-Tru-Coat but current brands are
Bredero Price (Encoat) Entec, Shaw Yellow Jacket and Black Jacket, and Plexco (Plexguard). Shaw,
Bredero Price (Encoat), and Plexco apply this coating system.
• The former X-Tru-Coat coatings (Plexco Plexguard, Bredero Price (Encoat)
• Entec, Shaw Yellow Jacket, and Shaw Black Jacket) are inexpensive and work well at ambient
temperatures [12].
• The Plexco coating is very economical.
• Chevron Canada Resources reports that Yellow Jacket works well at 140-160°F.
See Also • NAPCA Bulletin 15-83-94, “External Application Procedures for Polyolefin Pipe Coating Applied by
the Cross Head Extrusion Method of the Side Extrusion Method to Steel Pipe”
• ANSI/AWWA C215

Fig. 900-11 Description of External Pipeline Costing—Extruded Plastic—Side-Extruded Polyethylene with

Butyl-Rubber Adhesive (1 of 2)
Definition Continuous plastic coating (polyethylene) with butyl rubber adhesive.
Recommended Service Onshore pipeline operating below 180°F rather than FBE for cost or supply reasons
Status Bredero Price (Encoat) applies Pritec at several coating mills in the United States.

Other: Blast clean the pipe and then transfer it to the extrusion line.
Holiday Detection
coating
1250 thickness
( mils )
Application The side-extrusion method produces a bonded, overlapped coating to a specified thickness and involves:
• Running a rotating pipe past the extrusion die at the side of the pipe
• Applying a butyl-rubber-adhesive mastic
• Immediately extruding overlapping layers of melted plastic on the pipe, followed by water quenching
☞Caution Never apply soft adhesives to spiral-welded pipe.
Thickness Typically, plastic top layer is 40 mils, but it can be up to 240 mils. Offshore, Pritec has been applied at a
nominal thickness of 15 mils for the butyl rubber layer and 60 mils for the polyethylene layer. See Protec-
tion, Rocks, below.
Small Repairs Patches work well and are cheaper than shrink wraps but be sure that the edges of a patch adhere
tightly to the surface.
Coating Removal
With a knife, scribe the area to be removed, freeze the coating with CO2 or liquid nitrogen, and jerk the
coating off quickly. (In cold weather, it may be possible to remove the coating without artificial cooling.)
Handling/Storage Aboveground Storage Limit: One year

Ship all plastic coated pipe with rubber spacers between (or 5/8-inch rope rings around) the pipes to
prevent rubbing when the pipe is not nested.
When nesting the pipe, use padded skids and handle the coated pipe with padded equipment and slings.
Cinch-lifting methods apply a torque force to the coating and can damage it.
Protection/Resistance Disbonding
Pritec's polyethylene coating system has significantly superior adhesion and resistance to cathodic
disbonding because of the butyl-rubber adhesive [2,4]. Pritec is specified by its mastic and polyethylene
thickness; e.g., Pritec 10/40 is 10 mils of adhesive and 40 mils of PE.
While Bredero Price, Inc., recommends Pritec 10/40 up to 180°F, CRTC's M&EE Unit has run cathodic
disbonding tests that show thicker coatings being more resistant to disbondment [2].
Pipe Supports
As polyethylene expands and contracts with temperature changes much more than steel, the supports
for the pipe and welded line can damage the coating. On the Rangely CO2 line, gunny sacks full of pine
needles or sawdust provided the best support, while rubber strips or tires and sand bags did not work
well.[4]

Fig. 900-11 Description of External Pipeline Costing—Extruded Plastic—Side-Extruded Polyethylene with

Butyl-Rubber Adhesive (2 of 2)
Protection/Resistance Rocks
(continued) Backfill with soil or sand as Pritec 10/40 does not resist the impact of rock. Be careful of rocks
protruding from the side of the ditch that would damage the coating as the pipe is being lowered into the
ditch. Increase the thickness of the polyethylene layer from its normal 40 mils to 50, 60, 70, 80, 90, or 100
mils when expecting rocky backfill to prevent damage to this coating.
From experience, the Company and others have learned that Pritec 10/40, a common choice, may not be
thick enough in a rocky or high-soil-stress environment.
UV Resistance: Excellent
Hydrocarbon Resistance of butyl rubber mastic & heat-shrink sleeves: Lacking
Impact, Moisture, Shrinkage
Extruded-plastic coatings generally have good impact strengths, resist water penetration well and do
not shrink at elevated temperatures. Physical properties of polyethylene vary with density, high-density
polyethylene having superior resistance to impact and moisture.
Discussion Shear Strength

The shear strength of butyl-rubber adhesives is poor and decreases substantially with increasing
temperatures [4]. This situation allows the pipe to move inside the coating during thermal expansions
and contractions and subjects the outside of the coating to soil stresses. The resulting problems are loss
of adhesion, wrinkling, and, eventually, exposed steel.
Girth-Weld Coating Shrink sleeves
Brands Entec Pritec 10/40
See Also • Girth-weld Protection Coatings, Figures 900-19 to 900-21

• NAPCA Bulletin 14-83-94, “External Application Procedures for Polyolefin Pipe Coating Applied by
the Cross Head Extrusion Method of the Side Extrusion Method to Steel Pipe”
• NACE International RP0185
• COM-MS-5005, “Side Extruded Plastic/Butyl Rubber Adhesive Line Pipe Corrosion Coating,” in this
manual

Fig. 900-12 Description of External Pipeline Coating—Fusion-Bonded Epoxy (1 of 3)

Definition A thermosetting powder sprayed on a hot pipe. The heat melts the powder and causes chemical reac-
tions, converting the epoxy into a hard, continuous coating.
Recommended Service • Onshore and subsea pipelines

• Drilled crossings (Pipe pushed through drilled hole under river or road.)
• Field joints and fittings up to 200°F
Choose FBE over all other coatings for buried onshore lines.
Status Currently, FBE is one of the most widely-used pipeline coatings. Many applicators are available world-
wide. Its cost is significantly lower now because of its popularity and the reduced level of pipeline
construction.
Max. Service Temp 150°F to 200°F depending on coating.

Currently, FBE is the only economical coating to withstand pipeline temperatures up to 200°F.
Surface Prep Abrasive Blast: SSPC SP-10 Near-white Finish

Other:
• Pretreat with phosphoric acid or a chromate surface to enhance FBE/pipe bond, if necessary. Both
pretreatments are recommended especially for pipeline operating temperatures > 150°F.
• Heat surface 425°F to 475°F
☞Caution Keep the preheat below 500 °F to prevent possible changes in properties of the pipe.
Holiday Detection 125 volts/mil
Application When the surface reaches the specified temperature, apply the FBE powder by one of these methods:
• Electrostatic spraying (pipe, elbows, or tees)
• Dipping the part (elbows or tees) in a bed of (fluid) powder
The heat already in the steel is normally sufficient to cure the coating; if not, heat it again, depending on
coating thickness, pipe-wall thickness, and type of epoxy powder.
Thickness Depends on the pipeline's service.

Rules of thumb
• Subsea or dry lines: (150°F, 14 mils (min.) > 150°F, 30 mils (min.)
• River /drilled crossings; highly irrigated / continuous wet-and-dry areas; or areas with agricultural
chemicals: (150°F, 20 mils (min.) > 150°F, 30 mils (min.)
Small Repairs Melt-on Patch Stick

Thermoplastic materials that soften with increasing temperature, the patch stick is a quick, effective
repair method; but, if applied improperly, the patch falls off. To check the bond, pick at the repair with a
knife.
☞Caution Do not use patch sticks on pipelines operating at > 100 °F.
Two-part Epoxy Patching Compound
Thermoset that does not soften when heated, the two-part epoxy chemically decomposes when heated
above a certain temperature but can match the temperature limits of the FBE. A much-higher-quality
coating that has properties closer to FBE than the patch stick, two-part epoxy has a relatively long cure
time (from 30 minutes up to 24 hours, depending on the pipe's temperature); and so contractors do not
like it.
Note: For large repairs, use heat-shrink sleeves if soil conditions permit.


Handling/Storage Aboveground Storage Limit: Two years
Handling
Move FBE-coated pipe carefully with padded equipment or wide slings. Separate coated pipe that is to
be stacked with:
• Nylon rope rings for small-diameter thin-wall pipe
• Rubber spacers for heavy pipe
☞Caution Do not use rubber spacers with lightweight pipe Lightweight pipe cannot compress rubber
spacers, and the stack of pipe will become unstable.
Storage
Stored FBE pipe has
• Relatively good UV resistance, losing about one mil per year from UV chalking.
• A tendency to blister if stored in humid sea air for over a year without protection from the
atmosphere
Protection/Resistance UV Protection
Excellent; protect pipe if it is to be stored in hot, humid, sea-air areas (e.g., climate similar to Gulf Coast)
for more than six months.
Concrete (Weight) Coating
Apply concrete (weight) coating by one of two methods: compression coating or impingement.
• Compression coating involves rotating the pipe above a conveyor belt while the belt compresses
concrete on the pipe. The rotating pipe moves perpendicularly to the conveyor during the
application.
Note: This process is preferred because it does not damage the coating.
• Impingement involves spraying the concrete on the pipe after applying an intermediate coating to
protect the corrosion coating from the sprayed concrete.
Note: Typically we should apply a barrier coating or increase the FBE thickness to 30 mils or more to
avoid creating holidays in coating during the impingement process.
Cathodic Disbonding
At thicknesses greater than 15 or 16 mils, Aramco has found significant improvement in FBE's resistance
to ambient-temperature cathodic disbondment. Aramco specifies 17-22 mils thickness because they
have regions where power supplies do not exist and they often try to throw cathodic protection down
the line to these spots.
Moisture-resistant Pipeline Coatings
While all pipeline coatings absorb moisture during service, plastic coatings do so less than FBE coat-
ings. Multi-layer coatings are designed with an epoxy as a primer and a plastic topcoat.
Increasing the thickness of FBE for hot-oil pipelines does decrease the moisture absorption rate but
creates other problems such as higher cost and reduced flexibility. Suitable for a pipeline operating
temperature of up to 200°F, thicker coatings of FBE do not appear practical for higher operating
temperatures.
Lower-moisture-absorbing FBE coatings do exist, but many are inflexible and unacceptable for pipe that
may be field bent.
British Gas Pipeline in the United Kingdom uses 3M's Scotchkote 226N. The claim is that this coating has
a greater resistance to moisture absorption than Scotchkote 206N. As this coating system became
commercially available only recently in the United States, there is limited information about it.


Discussion Bends
Bends are not easy to coat with FBE. There are two possibilities:
• Heat bends with induction coils and hand spray them in a shop.
• Coat bends that are small enough in a bed of (fluid) powder.
In order of preference, options for coating bends in the field are two-part liquid epoxies or tape wraps.
High-temperature Pipeline Coatings
High-temperature pipeline coatings for hot-oil service need a pipeline coating for a wet-soil environment
at operating temperatures over 200°F. Existing FBE coatings cannot meet this need. Although both DuVal
and Elf Atochem’s polypropylene coatings claim to have operating temperatures up to 230°F, there is
limited field experience with these coatings. It seems unlikely that any polypropylene coating can
survive at continuous operating temperatures over 210°F.
Caution! Presently, the Company does not recommend any polypropylene pipeline coating for operating
temperatures more than 200 °F without additional laboratory testing or field experience.
Nap-Gard's new FBE coating may be suitable for hot-oil service temperatures over 180°F. This coating is
the first dual or polymer-powder-modified FBE coating system [24]. The FBE primer is Nap-Gard 7-2501.
The water-penetration-resistant FBE topcoat, Nap-Gard 7-2504 (also called Nap-Gard Gold) will bond
directly to steel pipe. Any FBE-pipe-coating mill can apply this system which is easier to apply than any
existing multi-layer coating system.
☞Caution The Company does not recommend the Nap-Gard 7-2501/7-2504 coating system for oper-
ating temperatures over 180 °F without additional laboratory testing or field experience.
In California, Shell Pipe Line applied FBE with Pritec as an outer jacket for hot-oil service. This may be
the first multi-layer coating system of this type in the USA. The Pritec protects the FBE from moisture, but
the Pritec mastic is the weak link in this multi-layer coating system.
☞Caution The Company does not recommend using FBE with Pritec for operating temperatures over
180 °F.
Girth-weld Coating • Induction, heat-applied FBE is the best.
• Liquid epoxies may be used.
• Heat-shrink sleeves acceptable in low-soil-stress areas.
☞Caution In hydrocarbon-contaminated soil, use FBE or liquid epoxies.
Brands By Temperature
• > 150°F: 3M Scotchkote 206N, 3M Scotchkote 226N, Valspar D1003LD, Josun D1003LD,
Nap-Gard 7-2501, and Nap-Gard 7-25014
• > 180°F: Nap-Guard’s new FBE coating (7-2504) may be suitable for hot-oil service.
Multi-layer Brands
DuVal, Elf Atochem, Himont, Mapec, Du Pont Canada, and Shaw YJII
See Also • COM-MS-4042 for specifications about purchasing and installing FBE-coated pipe.
• Extruded plastic film for information about multi-layer coating systems with epoxy primers
• Company’s Pipeline Manual for additional information about concrete (weight) coatings.
• AWWA C213
• NAPCA 12-78-94
• CAN/CSA Z245.20-M92

Fig. 900-13 Description of External Pipeline Coating—Hot-Applied Tapes

Definition Depending on its type, a hot-applied tape is coated on a pipe that is either
• Heated in a furnace
• Heated with a torch or the tape itself may be heated with a torch
Recommended Service The Company has very limited experience with hot-applied tape systems; therefore, we cannot report
any field experience or provide much detail about them.
Status —
Raychem states that Rayclad 120 accepts a temperature of 248°F (120°C).
☞Caution The Company has no experience with Rayclad 120 and gives it a temperature rating of
200 °F until there is additional data from laboratory testing or field experience.
Other
Holiday Detection 10,000 to 18,000 volts
Application Coating applicators can use torches for field-installing hot-applied tapes such as Raychem Flexclad and
Canusa Wrapid tape.
Thickness > 27 mils
Small Repairs Heat-shrink sleeves or tape
Protection/Resistance UV Resistance: Poor
Soil-Stress/Hydrocarbon Resistance
Raychem Flexclad and Canusa Wrapid tapes have better soil stress resistance than cold-applied tapes,
but they have poor hydrocarbon resistance
Disbonding
Initially, Polyken Synergy had problems with thermoshock that caused the coating system to disbond in
service. Coating applicators using Synergy report a solution: preheat the tape before applying it to the
pipe's surface.
Discussion Advantage
Tend to resist soil stresses better than cold-applied tapes.
Disadvantage
More expensive than cold-applied tapes.
In General
Polyken Synergy is less expensive than FBE, about the same cost as Pritec, and more expensive than
Plexguard and Entec. It has no marketable characteristics that make it superior to existing mill-applied
coating systems.
Synergy has to be mill applied, and it cannot be applied by a portable coating plant due to its ther-
moshock problems.
☞Caution The Company does not recommend Polyken Synergy because we carried out all of our
laboratory testing on thermoshocked samples that failed. CRTC's M&EE specialists will reconsider
Synergy if it passes testing by an acceptable independent coating laboratory or if pipeline operators
report favorable field experience after five years of service.
A high-temperature, hot-, mill-applied tape that other pipeline operators report to be successful is
Raychem's Rayclad 120. A portable coating mill helps coating applicators to apply this tape properly in the
field. Raychem Rayclad 120 have radiation-crosslinked hot-melt adhesives and polyethylene-based back-
ings. The fact that the polyethylene plastic is radiation-crosslinked gives it greater temperature resistance
and lower moisture-absorption rates than other non-radiated plastic tapes. The radiation-crosslinked hot-
melt adhesives have lower moisture absorption, higher temperature resistance, and higher bond physical
properties than the non-radiated mastics of other hot- and cold-applied tape systems.
Brands Examples of heat-applied tapes are Canusa Wrapid Tape, Raychem Flexclad, Polyken Synergy, and
Raychem Rayclad 120.
See Also —

Fig. 900-14 Description of External Pipeline Coating—Petrolatum and Petroleum-Wax Tapes

Definition Petrolatum tape, a synthetic fiber, is coated with petrolatum compound containing inert fillers and
thermal extenders. Petroleum wax tapes are petrolatum-based corrosion-preventative waxes, impreg-
nating a synthetic fabric backing, and applied over a petroleum-wax primer.
Recommended Service • Coating pipes in the splash zone underneath wharves

• Field coating irregularly shaped, buried, pipe fittings (i.e., valves, ties, bends, etc.)
• Protecting transition zones where buried piping comes above ground
• Coating buried pipe in areas where soil stress is not a problem
• Filling shorted pipeline road casings (petroleum wax)
Note: Excellent for fittings and irregular shapes as long as soil stress is not a problem.
Status This specialty pipe coating has proven very successful for specific applications for over 50 years.

Other
Holiday Detection Use wet spronge jeep
Application Hand apply

• Brush or wipe the surface clean of dirt and all other foreign matter
• Apply a thin film of primer
• Apply the wax tape
☞Caution If the pipe's surface is wet, rub and press the primer to displace the moisture and ensure
that the primer is adhering to the pipe's surface.
Thickness 45 mils
Small Repairs Patch with same material per manufacturer’s guidelines
Protection/Resistance UV Resistance: Good

Hydrocarbon Resistance: Poor
Add a rock shield material to protect the coating from penetration by rocks or soil-stress activity.
Without a rock shield, add special backfill (sand) to a minimum thickness of six inches (150 mm).
Discussion Advantages
• Conforms to irregular shapes
• No drying or curing time required before backfilling
• Easy application with minimum surface preparation
• Easily removed
• Can be applied over wet surfaces
• Excellent resistance to moisture absorption
Disadvantages
Low soil-stress resistance; not recommended for soil-stress areas.
Brands Major manufacturers include Trenton, and Denso North America, Inc. Recently, Tapecoat introduced
some petrolatum products.
See Also —

Fig. 900-15 Description of External Pipeline Coating—Phenolic Epoxies

Definition A solvent-free, ultra-high-build, high-solids content, amine-cured, phenolic epoxy
A solvent-free epoxy requires no evaporation in the curing process and has advantages for elevated
temperature service because it is not as susceptible to solvent retention, which can cause the coating
to break down on high-temperature lines [22].
Recommended Service Field- or mill-applied coating system for high-temperature pipeline service
☞Caution The Company has no experience with this coating system; it is included here as an
introduction only.
Status In Australia, Vessey Chemical manufactures Vepox CC703, reportedly an excellent high-temperature
pipeline coating. Coating mills apply other phenolic-epoxy systems as a powder similar to FBE.
Service Temp This coating system is rehabilitating Australian high-temperature gas pipelines with operating service
temperatures as high as 248°F (120°C).
Surface Prep Abrasive Blast: SSPC SP-10 with surface profile of 70-100 microns
Other
Holiday Detection Vendor’s recommendation.
Application May field apply this coating system with conventional spray equipment using premixed material or with
airless spray equipment [22].
Thickness —
Small Repairs —
Protection/Resistance —
Discussion Bends
Phenolic epoxies are superior to FBE in temperature resistance, but typically we cannot field bend them.
Coatings applicators can field coat field bends with a liquid-phenolic epoxy.
Brands —
See Also —

Fig. 900-16 Description of External Pipeline Coating—Polyester Epoxies

Definition Flake-reinforced polyester epoxies are two-part liquid-epoxy coatings.
Recommended Service Refurbishing old pipelines, tie-ins, valves, and fittings.

☞Caution Where hydrocarbon contamination or soil stress present, use cold-applied tapes.
☞Caution Polyester epoxies are not recommended for hot oil pipeline service.[22. 23]
Status Although this coating has had limited pipeline use because of the high cost of raw materials, it is an
excellent coating system for pipeline valves both atmospheric and buried.

Other
Holiday Detection 4,000 volts
Application • Spray, brush, or roll

• Very slow cure time
Note: Spray recommended; brush acceptable for patching small areas.
Small Repairs Patch with liquid epoxy per manufacturer’s guidelines.
Discussion Polyester epoxies have excellent resistance to UV, hydrocarbon, and soil stress.
Brands Master Builder's Ceilcoat Flakeline 251 is one recommended brand, but other excellent polyester
epoxies are available.
See Also —

Fig. 900-17 Description of External Pipeline Coating—Polyurethane (1 of 2)

Definition The reaction of isocyanates with hydroxyl-containing compounds makes the resins in polyurethane coat-
ings. Two types of urethanes are available for buried pipelines: elastomeric and highly crossed linked.
• Elastomeric Polyurethane—Generally has tensile and elongative properties, producing elongation in
excess of 20 percent.
• Highly Cross-linked Polyurethane—Molecular cross linking takes place in a thermoset material
during cure. High cross-linked materials generally have better resistance to chemicals; lower cross-
linked materials have lower resistance to chemicals but often have very high elongation.
Other forms include
• Moisture-cure Polyurethane—Single component, generally TFT, systems applied in thin-film deposi-
tions; rely on a level of moisture for curing.
• Single-component Polyurethane—Base and activator exist as mix; remain fluid until applied.
• Dual- or Plural-component Polyurethane—Separate base resin and an activator are mixed just
before applying.
Recommended Service • All services up to temperature limits of the coating system

• Refurbishing old pipelines where hydrocarbon contamination or soil stress prevent use of cold tapes
• Field recoating pipelines
• Mill-coated protection for FBE-coated pipe from construction damage during boring or as a rock
shield
☞Caution Do not select elastomeric polyurethane as a primary pipeline coating
☞Caution Not recommended for hot-oil pipeline service
Status Under the tradename, Protegal, TIB Chemie makes most polyurethane coatings applied during pipeline
rehabilitation projects. Others are Madison Chemical's Corropipe and Valspar's Valpipe 100.
Max. Service Temp ☞Caution Not recommended currently for service temperatures above 180 °F [22].
Other
Holiday Detection 125 volts per mil of coating thickness
Application Type of Polyurethane

• Moisture-cure single-component polyurethanes: brush or roll on the pipe's surface.
☞Caution TDI, an isocynate, makes it dangerous to spray moisture-cure polyurethanes.
• Dual-component polyurethanes: spray for major projects; brush or roller for spot touchup and small
repairs to coatings; also, trowel.
Method
• Spray: Typically, coating applicators spray dual-component polyurethanes on a pipe's surface with
special plural-component equipment that helps combat difficulties with temperature and ensures
better adhesion.
• Brush, trowel, roller: Cure time of dual-component polyurethanes is typically longer when it is
applied this way. Tack-free condition is normally 30 minutes to 4 hours depending on ambient temper-
atures; hot air accelerates the cure cycle.
Small Repairs Use manufacturer’s recommended polyurethane patching material
Protection/Resistance See Discussion below.
Resistance UV & Hydrocarbon: Excellent

See also Discussion below.

Fig. 900-17 Description of External Pipeline Coating—Polyurethane (2 of 2)

Discussion Most moisture-cure polyurethanes are
• Slow in curing
☞Caution The curing process combines with oxygen in the atmosphere; do not use in
production runs.
• Sensitive to high-low humidity
• Lower in mechanical/abrasive resistance than dual-component polyurethanes, FBE, and liquid epoxy
coatings
• Not high build and several coats (4-6 mils) needed to reach the desired total thickness
Elastomeric polyurethanes have
• Higher moisture-absorption rates than highly crossed-linked polyurethanes
• Higher mechanical/abrasive resistance that may make them desirable as rock shields for other pipe
coatings.
Advantages
The high solids, high build, and fast cure properties make dual-component polyurethane suitable for
pipeline-rehabilitation projects. Highly crossed-linked polyurethanes have low rates of moisture absorp-
tion. The exothermic nature of the iso/polyol reaction allows us to spray aromatic polyurethanes at
temperatures as low as -20°F (-29°C) and as high as 140°F (60°C).
While cure time is temperature dependent, urethanes are less temperature dependent than other
systems such as liquid epoxies. To accelerate cure time, normal practice is to pre-heat the pipe to 180°F
in the mill; to 150°F by induction coil in the field.
Disadvantages
Existing pipe-coating mills are not equipped to apply this coating system economically. Dual-component
polyurethanes require special, plural-component, heated, spray equipment that has a pot life of less than
30 seconds.
Service History
In Texas, some major, large-diameter, gas-transmission pipelines were recoated with TIB Chemie's
Protegal. Soil stresses had damaged the original asphalt or coal-tar enamel. There has been no report of
any coating failures to date.
Girth-weld Coating As we typically field-apply polyurethane, the coating applicators coat the girth-weld and joint surfaces
at the same time. They may coat girth welds at coating transitions with cold-applied tapes or heat-shrink
sleeves.
Brands TIB Chemie Protegal UT32-10, Madison Chemical Corropipe, Valspar Valpipe 100
See Also —

Fig. 900-18 Description of External Pipeline Coating—Thermoset Epoxies

Definition A two-part, liquid, thermosetting compound that cures without heat.
Recommended Service Liquid epoxies are good for repairing FBE coatings and for refurbishing old pipelines, girth-weld coat-
ings, tie-ins, valves, and fittings.
Status Two-part liquid epoxies have worked well in accelerated laboratory tests and in limited field use.
Both Hempel Epoxy 8553 and Hempel Nap-Wrap Epoxy 8553 passed CRTC's hot-subsea-coating test.
Previously, only 20+ mil-thick FBE coatings passed it consistently. The hot-subsea-coating test subjects
a coated pipe to 250°F internal temperature and -0.90 volts of cathodic protection while the pipe is
suspended in 65°F sea water for 90 days.
Aramco is replacing tape wraps with Hempel Epoxy 8553 as their primary refurbishing and tie-in coating.
They apply the coating to a 20-25 mil thickness in two coats.

Note: Aramco has had success applying Hempel Nap-Wrap Epoxy 8553 to 200°F lines in operation.
Other
Application • Spray, brush, or roll

• Can be field applied
• Cure time very slow
Small Repairs Patch with Hempel Nap-Wrap Epoxy 8553 per manufacturer’s guidelines.
Protection/Resistance The tape wrap or membrane in Hempel Nap-Wrap Epoxy 8553 gives the coating added strength and
resistance to abrasion.
High-temp (225°F) Hydrocarbon & UV Resistance: Excellent
Chemical Resistance: Good
Because it is a thermoset, this epoxy does not soften with temperature; but, it has chemical, tempera-
ture, and mechanical properties similar to FBE.
Tape
We can apply Hempel Epoxy 8553 either alone or with a tape wrap (Hempel Nap-Wrap Epoxy 8553).
Brands Hempel Epoxy 8553 and Hempel Nap-Wrap Epoxy 8553
See Also —

Fig. 900-19 Description of External Pipeline Coating—Girth-Weld Protection—Heat-shrink Sleeves (1 of 2)

Definition Shrink sleeves are tubes or wraparound strips of a heat-shrinkable backing of cross-linked poly-
ethylene. The backing has either a butyl-rubber adhesive or a semi-crystalline adhesive.
Recommended Service Field joints, tie-ins, small pipeline recoating jobs, and mechanically damaged mill-applied coatings
Status Heat shrink sleeves are readily available from manufacturers in pre-sized or bulk (cut-to-fit) packages.
Max. Service Temp —
Surface Prep Abrasive Blast: SSPC SP-3 for most sleeves. Refer to manufacturer’s guidelines.
Other
Holiday Detection
coating
1250 thickness
( mils )
or Vendor’s recommendation
Application Basic
• Prepare the surface (minimum: clean with hand power tools).
• Bevel the edge of the pipeline coating (only for thick coatings such as coal-tar enamel and asphalt
mastic).
• Position the shrink sleeve.
• Apply heat by torch or induction, depending on the adhesive.
Tubes
• Place tubes loosely on the pipe near the girth-weld area before fit-up and welding.
• Apply tubes over the girth-weld area as soon as possible after welding is completed because adhe-
sive is exposed to the atmosphere.
Strips (Wraparound sleeves)
• Apply the strips any time after welding is completed and before the pipe is buried.
• Wrap the strips around the field joint until the ends overlap.
• Seal the overlapping seam with a strip of the coating.
• Apply heat to shrink the coating into place.
Aramco uses induction coils to apply heat shrink wraps at a rate of 120 per day.
☞Caution Consult the manufacturer for instructions on application procedures.
Thickness 70 to 80 mils
Small Repairs —
Protection/Resistance Shrink sleeves are thick, therefore, abrasion resistant. When heated, the adhesive melts and the polyeth-
ylene backing shrinks. This forces the adhesive to flow into the irregularities of the area to be coated.
The shrunken wrap is an abrasion-and- penetration-resistant coating.
CRTC's Materials and Equipment Engineering group conducted dragging tests to simulate an offshore-
tow installation. The leading edge peeled and eroded, and tape wraps failed at overlaps because every
protruding surface eroded.
Because of these tests, the Company bonded a sacrificial half-sleeve in front of the actual shrink
sleeves of a Pritec-coated offshore line. The Company installed this pipeline successfully, despite drag-
ging it across an ocean floor.
See also Disadvantages and Selection in Discussion, below.

Fig. 900-19 Description of External Pipeline Coating—Girth-Weld Protection—Heat-shrink Sleeves (2 of 2)

• Quick and easy to apply, requiring a minimal surface preparation and skill
• Service temperature ratings between -30°F and 230°F
• Compatible with FBE, extruded plastic, tape wraps, coal-tar enamels, asphalt mastics, liquid epoxies,
and polyurethane coatings.
Disadvantages
• The polyethylene backings expand when exposed to hydrocarbons.
• A torch, required for the applying the wraps, can damage the primary coating.
• Some heat shrink sleeves have low resistance to damage from soil stress.
Selection
Choice of Adhesive: The adhesive establishes two categories of temperature limits for sleeves, each
having specific characteristics:
• 150°F or lower: typically a butyl-rubber adhesive which
– Can flow when heated by torch which causes no damage to the PE backing or line coating.
– Generally changes color at the proper temperature, allowing less-experienced workers to apply
the sleeves properly.
• 150°F or higher: typically a semi-crystalline adhesive which
– Needs greater heat to melt the adhesive than butyl-rubber adhesives.
– Needs induction coils for a more even, consistent heat and to prevent damage to the pipeline
coating and sleeve from the flame of the torch. Torches are also acceptable for heating the pipe.
The properties of the adhesive may also affect the sleeve's selection:
• Semi-crystalline or hot-melt adhesives have good physical properties and bond strengths but gener-
ally have poorer resistance to cathodic disbonding than butyl-rubber adhesives.
• Butyl-rubber adhesives are generally more susceptible to soil stresses but have a higher resistance
to cathodic disbonding.
Other Selection Factors: The choice of sleeve may also depend on the pipe's size, construction
schedule, and the experience of the people applying it.
• Wraparound
– Less costly
– No time constraints for application (can apply after creating any weld)
– Bulk, cut-to-fit sizes
• Tube
– Must place loosely over pipe before creating weld
– Only for 3/4-inch- to 12-inch-diameter pipe
– Quicker and easier to apply than wraparound sleeves
– Superior to wraparound because there are no seams
Brands In the U.S., the Company usually selects Raychem and Canusa sleeves. Other brands currently available
are UBE Industries, Ltd., Tokyo and Nitto Electric Industrial, Ltd.
For DuVal, Himont, and Elf Atochem polyethylene girth welds, there are heat-shrink sleeves compatible
with the coating and rated for the operating temperature of the pipeline. Canusa has developed a multi-
layer heat-shrink sleeve for coating the girth welds of multi-layer coatings such as Shaw YJII, Mapec,
Himont, Elf Atochem, and DuVal. Raychem is developing heat-shrink sleeves for polypropylene pipe
coated with Elf Atochem, Himont, and DuVal brands.
See Also —

Fig. 900-20 Description of External Pipeline Coating—Girth-Weld Protection Coating—Induction Heat-Applied FBE
Definition Applying FBE to the girth-weld area by induction heat
Recommended Service To protect girth welds of FBE- coated pipelines
Status Common on large projects, critical lines, and high-temperature lines. It was expensive, but the cost now
nearly equals heat-shrink sleeves due to improved application techniques on large projects.
Max. Service Temp —
SSPC SP-10 Near-white Metal Finish
Other
After welding, clean the pipe chemically and then blast it to SSPC SP-10. Brush blast the field joint and two
inches of FBE on either side of the joint to clean and roughen the coating's surface.
☞Caution Proper surface preparation is critical to this type of coating. Also, protect the pipe's
surfaces from high humidity, rain, or surface moisture [9, 11].
Application • Induction heat the weld zone to approximately 500°F (depending on the coating manufacturer's specifi-
cations).
• Immediately apply the FBE powder so that residual heat in the pipe cures the coating. A motorized
unit, called a powder application ring, sprays the powder on the joint as the sprayer rotates around
the pipe.
☞Caution Do not force cool or quench, which means that the pipe must be out of service during the
coating process to prevent cooling too quickly.
Thickness —
Small Repairs —
Induction heat-applied FBE is the best girth-weld area protection coating for FBE-coated pipelines
because it is the same material as on the pipe's joint.
Disadvantages
Application requires abrasive blasting and accurate heat control. It is sensitive to environmental effects
such as humidity.
Brands Commercial Resins Company, Commercial Coating Services Incorporated (CCSI), and Pipeline Induction
Heat Ltd. (PIH) are among the contractors who have equipment and trained personnel for field applying
FBE over pipeline girth welds.
See Also • Figure 900-3 Advantages and Disadvantages of External Pipeline Coatings

Fig. 900-21 Description of External Pipeline Coating—Girth-Weld Protection—Induction Heat-Applied Plastic with
FBE Primer
Definition Induction heat-applied plastic with FBE primer is a field-applied process for coating EPHA girth welds.
Recommended Service For joints coated with extruded plastic with hard adhesive (EPHA)
In EPHA, hard adhesive is liquid epoxy or FBE primer.
Status Common on high-temperature pipelines

Coating the girth welds on pipe joints coated with Elf Atochem, Himont, and DuVal polypropylene is diffi-
cult; however, Raychem is developing a heat-shrink sleeve for coating girth welds on these joints.
Max. Service Temp Vendors claim up to 230°F.
Surface Prep Abrasive Blast: SSPC SP-10 Near-white Metal Finish

Other: Chemical cleaning and blasting to an SSPC SP-10
Holiday Detection —
Application • Heat the weld and adjoining FBE coating from 438°F to 463°F with an induction coil.
• Apply the FBE powder to the heated surface.
• Apply the top, plastic layer(s), at the proper time, over the FBE primer.
Note: Post heating of the plastic layer may be required depending upon the coating thickness
Timing
Requires excellent timing when applying the plastic layer over the FBE layer.
• Too quick: improper curing of the FBE and poor bonding to the pipe's surface
• Too slow: improper bonding between the plastic and FBE
Thickness —
Small Repairs —
Discussion Advantage
The best girth-weld protection for EPHA- coated pipelines because it is the same material as the pipe
joint
Disadvantages
• Requires abrasive blasting
• Requires accurate heat control; otherwise, the joint coating near the girth-weld may become
damaged
• Requires excellent timing during application
• Is sensitive to environment, such as humidity
Brands There are two companies experienced with applying specific brands of these coatings:
• Commercial Coating Services Incorporated (CCSI) with DuVal
• Pipeline Induction Heat Ltd. (PIH) with DuVal, Himont, and Elf Atochem
See Also —

Fig. 900-22 Operating Temperature for Splash-Zone

Coating for Offshore Platform Risers
Temperature Coating
Below 140°F Sprayable (Tidegard 171)
Up to 180°F Vulcanized Neoprene
Up to 250°F Monel Sheathing
Fig. 900-23 Pipeline Fitting and Valve Coating System

Max Coating Hydro- Soil
Generic Coating Svc Holiday Detector Thickness Surface carbon Stress
Type Name Temp °F Voltage (Mils) Prep Resistant Resistant
Coal Tar Epoxy Tarset 14 300 V 16-20 SSPC SP-10 Yes Yes
Maxi-Build
7080
Extruded Du Val 200 20-45 SSPC SP-10 Yes Yes

Plastic with coating
1250 thickness
FBE Primer
( mils )
Fusion Scothkote 200 125 V/Mil 14-30 SSPC SP-10 No Yes

Bonded Epoxy 206N
(FBE)
Heat Shrink- Canusa 135 >27 SSPC SP-3 No No

able Tape Wrapid Tape coating
1250 thickness
( mils )
Heat Shrink- Raychem Flex- 135 >27 SSPC SP-3 No No

able Tape Clad coating
1250 thickness
( mils )
Petroleum Denso HT 120 use wet spronge 45 SSPC SP-2 No No

Tape jeep
Polyester Flakeline 251 160 4000V 35-40 SSPC SP-10 Yes Yes
Polyurethane Protegal UT 180 150 V/Mil 25-30 SSPC SP-5 Yes Yes
32-10RG
32-50RG
32-10
Polyurethane Valpipe 100 160 125 V/Mil 25-30 SSPC SP-5 Yes Yes
Polyurethane Madison 135 125 V/Mil 25-30 SSPC SP-5 Yes Yes
Corropipe 2TX
Thermoset Nap-Wrap 225 125 V/Mil 20-30 SSPC SP-10 Yes Yes
Epoxy Epoxy 8533
Wax Tape Trenton #1 120 use wet 70-90 SSPC SP-2 No No

Wax spronge jeep

Fig. 900-24 Generic Coatings for Girth Weld Protection
Suggested Coating Material for the Girth Weld Preferences
Original Coating Joining Coating 1 2 3 4 5
Asphalt Enamel Asphalt Enamel Heat Shrink Asphalt Enamel

Wrap
FBE Heat Shrink Tape Liquid Epoxy Asphalt

Wrap Enamel
EPSA Heat Shrink Tape

Wrap
Polyester Epoxy Heat Shrink Tape Polyester Epoxy

Wrap
Tape Tape
Coal Tar Enamel Coal Tar Enamel Heat Shrink Coal Tar Epoxy Tape Coal Tar Mastic
Wrap Enamel
FBE Heat Shrink Tape Liquid Epoxy Coal Tar

Wrap Enamel

Wrap
Asphalt Enamel Heat Shrink Tape Coal Tar Asphalt

Wrap Epoxy Enamel
Polyester Epoxy Heat Shrink Polyester Tape

Wrap Epoxy
Tape Tape
EPHA EPHA EPHA Heat Shrink Tape

Wrap
EPSA EPSA Heat Shrink Tape

Wrap
EPHA Heat Shrink Tape

Wrap
Polyester Epoxy Heat Shrink Tape

Wrap
Tape Tape
FBE FBE FBE Heat Shrink Liquid Epoxy Tape

Wrap

Wrap
EPHA FBE EPHA Heat Shrink Liquid Epoxy Tape

Wrap
Polyester Epoxy Heat Shrink Polyester Epoxy Tape

Wrap
Tape Tape
Tape Tape Tape
Note: EPSA = Extruded Plastic with Soft Adhesive

EPHA = Extruded Plastic with Hard Adhesive
Note:

Rehabilitation Coatings
There are two ways to refurbish an old line: replace the pipeline or remove the old
coating and recoat.
Replacing the Pipe (Coating the Transition Girth Welds). Consider cold-applied
tapes or heat-shrink sleeves to coat tie-in girth welds because these coatings are
compatible with almost all coating systems.
Note Tie-in girth welds connect the replacement section of pipe to the existing pipe.
If soil stress is not a problem, apply either heat-shrink sleeves or cold-applied tape
to girth welds on the tie-in (coating transition).
If soil stress is a problem, apply heat-shrink sleeves on the tie-in.
If the soil has hydrocarbon contamination, select FBE-coated pipe over extruded
plastics. Avoid heat-shrink wraps or cold-applied tapes on the girth welds, and
select liquid epoxy for the girth welds of the pipe replacement. If there is both soil
stress and hydrocarbon contamination, select liquid epoxy rather than cold-applied
tapes or heat-shrink sleeves.
Replacing the Coating. Pipeline recoating may be carried out in-the-ditch or over-
the-ditch.
Note In-the-ditch means that the pipeline is neither removed from its site nor from
service and may still be under pressure.
Over-the-ditch means that the pipeline is taken out of service and the pipe removed
from the ground.
☞ Caution While recoating a pipeline that is under pressure, follow all pipeline
safety guidelines. Be aware that machinery for recoating pipe may be unsafe for a
pressured pipeline.
When replacing the coating, grit or sand blast to remove the old one completely if
local air quality regulations permit.
If the old coating system contains asbestos, follow special asbestos-handling proce-
dures such as work wet, use plastic containment, and wear special protective
clothing.
Asbestos-containing coatings include Somastic, most asphaltics such as P2, Modi-
fied P2, P3, and P4 Wraps, and coal-tar enamel.
Note To identify asbestos-containing coatings on Company pipelines, research
construction records and pipeline inventory line sheets for coating information.
CRTC's M&EE Unit has project files that may also contain information about pipe-
line coating projects.
For the latest information about asbestos-removal techniques for pipelines, contact
Chevron Pipe Line Company's Health, Environment, & Loss Prevention personnel.

☞ Caution Government regulations about removing asbestos vary across the United
States and change periodically. Review the current asbestos-removal regulations
before starting a pipeline-rehabilitation project.
Selecting the Coating. Factors involved in choosing a field-applied rehabilitation
coating system include consideration of the following:
• Soil
• Temperatures
– Operating temperature of the pipe
– Temperature of the pipe during recoating
– Dew point temperature during coating
See Figure 900-25 for a brief description of field-applied, pipeline coating systems
for rehabilitating pipelines. The coating systems are listed in order of preference.
922 Quality Control

Among the elements of quality control for external pipeline coatings are specifica-
tions and standards, planning, service conditions, durability and resistance,
construction factors, application factors, and inspection.
Specifications and Standards

The following figures list specifications to help ensure the success of an external
coatings project.
• Coating Specifications for Buried Pipelines (Figure 900-26)
• Industry Standards for Pipeline Coatings (Figure 900-27)
Planning
There are many factors involved in planning an external coatings project for pipe-
lines. The main ones are as follows:
• Service Conditions
– Maximum continuous service temperature
– Soil conditions
– Accessibility of the line for field application and repair
• Durability and Resistance of Coatings
– Durability
– Chemical Resistance
– Ultraviolet (UV) Resistance
– Resistance to Mechanical Damage
– Resistance to Temperature
– Cathodic Shielding and Disbonding

Fig. 900-25 Field-Applied Rehabilitation Coating Systems in Order of Preference

Rank System
1. Liquid Epoxies
• Excellent resistance to chemicals and temperatures
• Poor (long) cure times
• Dust and insects can contaminate this coating while it is curing, causing holidays
• Poor choice during winter, more practical during ideal dry summer weather
• Brush, roll, or spray with standard spray equipment
There are basically four types of liquid epoxies: coal-tar, thermoset, phenolic, and polyester epoxies.
• For all services: thermoset and phenolic
• Not for hot-oil pipelines: polyester and coal-tar epoxies
• For temperatures up to 220°F: phenolic and some thermoset epoxies
2. Polyurethane
• Excellent resistance to chemicals and temperature
• Preferred over liquid epoxies for faster cure time
• Summer: Fast-cure urethane coatings may be buried within 15 minutes
• Winter: Fast cure urethane coatings can take from one to five hours to cure enough for burial, depending on the method
of application
• Spray with required, heated, plural-component, spray equipment
• For temperatures up to 180°F
3. Hot-Applied Wraps and Tapes(1)

• Recoating for short sections of pipe
• Needs a rock shield in high-soil-stress environment
• Too labor intensive for rehabilitating major pipelines
• Low resistance to hydrocarbon – not for hydrocarbon-contaminated soils
• Available as high-temperature heat shrinkable wraps and tapes
• May not be applied to pipelines in service if flowing product prevents pipe surface from being heated properly
4. Cold-Applied Tapes(1)
• Very economical
• Needs proper tension during application
• Needs an outer wrap of rock shield in high-soil-stress areas
• Low resistance to hydrocarbon and temperature
(1) If this coating fails, it may cause a shielded corrosion cell, creating a corrosion leak on a cathodic protected pipeline

Fig. 900-26 Coating Specifications for Buried Pipelines

Coating Spec Number(1) Spec Title Project Date Written
Fusion Bonded Epoxy COM-MS-4042 Fusion Bonded Epoxy for Company's Standard Spec 3/31/88
(FBE) External Coating
09-AMSS-089 Shop-Applied External FBE Aramco Spec 8/10/85

Coatings
PA 131 Fusion Bonded Epoxy External Mesquite Pipe Line Project 6/30/87
Line Pipe Corrosion Coating
P-I-002 Fusion Bonded Epoxy Corrosion Western Producing Spec 8/21/84

of Submarine Pipelines (Platform Gail)
Extruded Plastic PA 129 Extruded Polyethylene Point Arguello Pipeline and 7/6/84
Corrosion Coating with Butyl Natural Gas Companies
Adhesive
09-AMSS-090 Shop-Applied Extruded PE Aramco Mapec and Pritec 3/27/85

External Coating System Spec
COM-MS-5005 Side Extruded Plastic/ Butyl Company's Standard Spec 1996

Rubber Adhesive Line Pipe
Corrosion Coating
Coal Tar Enamel PA 171 Coal Tar Enamel Wrap Point Arguello Pipeline and 1/3/85
Natural Gas Companies
NR-2510 Spec for TGF-3 Pipeline Coating Northern Producing Spec 9/17/87
PA 155 Water Line Coal Tar Enamel Point Arguello Pipeline 12/20/85
Corrosion Coating Company
COM-MS-5006 Coal-Tar Enamel Corrosion Company's Standard Spec 1996

Coating of Submarine Pipelines
Concrete Weight PA 136 Pipe Weight Coating Point Arguello Pipeline and 2/20/85
Coating Natural Gas Companies
PA 176 Pipe Weight Coating Quality Point Arguello Pipeline and 4/15/85
Assurance Natural Gas Companies
— Pipeline Continuous Concrete Sudan Petroleum Develop- 2/24/84

Coating ment Project
PA 132 Polymer Cement Barrier Point Arguello Pipeline and 7/6/84

Coating (over FBE Powder Pipe Natural Gas Companies
Coatings)
E-4512 Concrete Weight Coating for Richmond Deep Water 9/23/86

Submarine Pipelines Outfall Project
Field-Applied Tape — Spec for Over-the-Ditch Rangely 2/26/85

Wrap Application for Mainline Pipe
and Facility Piping
PA 150 Polyethylene Tape Wrap with Point Arguello Pipeline and 7/6/84
Butyl Adhesive Natural Gas Companies
09-AMSS-095 Hand-Applied Pressure Aramco Spec 9/22/85

Sensitive Tape Wrap for
Temperatures up to 55°C (130°F)
Shrink Sleeves 09-AMSS-096 High-Temperature Heat Shrink Aramco Spec 9/22/85

Sleeves
(1) See CRTC's Materials Engineering File 6.55.70 Specifications

PA Specifications were written by Chevron Pipe Line Company

Fig. 900-27 Industry Standards for Pipeline Coatings (1 of 2)

Spec. No. Description
American Petroleum Institute (API) Standards
RP 10E Application of Cement Lining to Steel Tubular Goods, Handling, Installation, and Joining
RP 5L1 Recommended Practice for Railroad Transportation of Line Pipe
FP 5L5 Recommended Practice for Marine Transportation of Line Pipe
American Water Works Associated (AWWA)
ANSI/AWWA C203 CT Protective Coating & Lining for Stl. Water Lines
ANSI/AWWA C205 Cement Mortar Lining for Steel Pipe 4" & Larger
ANSI/AWWA C209 Cold-Applied Tape Coatings for Special Sections
ANSI/AWWA C210 CTE for the Interior & Exterior of Steep Pipe
ANSI/AWWA C213 FBE for the Interior & Exterior of Steep Pipe
ANSI/AWWA C214 Tape Coating for the Exterior of Steel H20 Pipes
ANSI/AWWA C215 Extruded Polyolefin for Exterior of Steel H20 Pipes
AWWA C602 Cement Lining Water Lines 4" & Larger—in Place
British Standard
BS 4164 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines, Enamel, and Tape Hot-Applied
British Gas Standards
PS/PA3 Painting at Site of New Components for Long Term Protection
PS/CW1 External Wrap of Line Pipe using Coal Tar
BGC/PS/CW2 Cold-Applied Wrapping Tapes & Tape Systems
PS/CW3 External Wrap Operations using Hot-Applied Bitumen
PS/CW5 Code of Practice for the Selection and Application of Field-Applied External Coating (Other than Resin)
MR0274 Material Requirements for Polyolefin Cold-Applied Tapes for Underground Submerged Pipeline Coatings
PUB. 6H189 A State-of-the-Art Report of Protective Coatings for Carbon Steel and Austenitic Stainless Steel Surfaces
Under Insulation and Cementitious Fireproofing
Canadian Standards
CAN/CSA-Z245.20-M90 External FBE Coating for Pipe
CAN/CSA-Z245.21-M92 External Polyethylene Coating for Pipe
German Standards (DIN)
DIN 30670 Polyethylene Coating of Steel Pipes and Components
DIN 53516 Determination of Abrasion Resistance
L'Association Française De Normalisation (AFNOR) Standard
NFA 49-710 Steel Tubes External Triple-Layer Polyethylene-Based Coating Application by Extrusion
NACE International Standards
RP0169 Control of External Corrosion on Underground or Submerged Metallic Piping Systems
RP0285 Control of External Corrosion on Metallic Buried or Submerged Liquid Storage Systems
RP0181 Liquid Applied Internal Protection Linings and Coatings for Oil Field Production Equipment
RP0185 Extruded Polyolefin Resin Coating Systems for Underground or Submerged Pipe
RP0188 Discontinuity (Holiday) Testing of Protective Coatings

Fig. 900-27 Industry Standards for Pipeline Coatings (2 of 2)

Spec. No. Description
NACE International Standards (continued)
RP0190 External Protective Coatings for Joints, Fittings, and Valves on Metallic Underground or Submerged
Pipelines and Piping Systems
RP0274 High Voltage Electrical Inspection of Pipeline Coatings Prior to Installation
RP0490 Holiday Detection of Fusion Bonded Epoxy External Pipeline Coatings of 10 to 30 Mils (0.25 to 0.76 MM)
RP0675 Control of External Corrosion on Offshore Steel Pipelines
TM0170 Visual Standard for Surfaces of New Steel Airblast Cleaned with Sand Abrasive
TM0174 Laboratory Methods for the Evaluation of Protective Coatings used as Lining Materials in Immersion
Services
TM0175 Control of Internal Corrosion in Steel Pipelines and Piping Systems
TM0183 Evaluation of Internal Plastic Coatings for Corrosion Control of Tubular Goods in an Aqueous Flowing
Environment
TM0185 Evaluation of Internal Plastic Coatings for Corrosion Control of Tubular Goods by Autoclave Testing
TM0186 Holiday Detection of Internal Tubular Coatings of 10 to 20 mils (0.25 to 0.76 MM) Dry Film Thickness
TM0375 Abrasion Resistance Testing of Thin Film Baked Coatings and Linings using the Falling Sand Method
TM0384 Holiday Detection of Internal Tubular Coatings of less than 10 mils (0.25 MM) Dry Film Thickness
National Association of Pipe Coating Applicators (NAPCA) Standards
Bulletin 1-65-94 Designation for Coal Tar Enamel Coatings
Bulletin 2-66-94 NAPCA Coating Specifications for Standard Applied Pipe Coating Weights
Bulletin 3-67-94 External Application Procedures of Hot Applied Coal Tar Coatings to Steel Pipe
Bulletin 5-69-94 NPACA Specifications for Pipeline Wrappers
Bulletin 12-78-94 External Application Procedures for Plant-Applied Fusion Bonded Epoxy (FBE) Coatings to Steel Pipe
Bulletin 13-79-94 External Application Procedures for Coal Tar Epoxy Protective Coatings to Steel Pipe
Bulletin 14-83-94 External Application Procedures for Polyolefin Pipe Coating Applied by the Cross Head Extrusion Method
for the Side Extrusion Method to Steel Pipe
Bulletin 15-83-94 External Application Procedures for Plant-Applied Tape Coating to Steel Pipe
Bulletin 6-69-94-1 Suggested Procedures to Hand Wrap Field Joints using Hot Enamel
Bulletin 6-69-94-2 Suggested Procedures for Coating of Girth Welds with Fusion Bonded Epoxy
Bulletin 6-69-94-3 Suggested Procedures for Coating Field Joints, Fittings, Connections, and Pre-Fabricated Sections using
Tape Coatings
Bulletin 6-69-94-4 Suggested Procedures for Field Joint Application using Mastic Mix and Field Mold
Bulletin 6-69-94-5 Suggested Procedures for Coating Field Joints using Heat Shrinkable Materials

• Construction Factors
– Impact Resistance
– Flexibility in Cold Weather
– Field Repair
– Limitations of Temporary Storage
– Climate During Construction Project
– Construction Methods During Project
• Application Factors
– Cost
– Site
Service Conditions
Note FBE has the widest range of operating temperatures, greatest resistance to
chemicals and soil stress of all pipe-coating systems.
• Maximum Continuous Service Temperature
Figures 900-23, 900-28, and 900-29 list information about service conditions
of various field- or mill-applied coatings and coatings for fittings and valves.
• Soil Conditions (sand vs. clay, wet or dry, hydrocarbon or other chemical
contamination, pipe-soil stresses, soil resistivity data)
– Hydrocarbon or Chemical Contamination
To combat hydrocarbon or chemical contamination, it is necessary to
apply a pipe coating that is resistant to the chemicals in the soil.
– Soil Stresses
Soil stresses occur mainly in clay soils; not usually in sandy soils. Soil
stresses resulting from wet/dry or freeze/thaw seasonal cycles can,
however, damage pipe coatings.
– Soil Corrosivity
Typically, soil corrosivity increases with decreasing soil resistivity. In
highly corrosive soils, you may need to apply a high-performance coating
system to the pipe.
– Microbiologically Influenced Corrosion (MIC) Activity
Some pipe coatings, such as cold-applied tapes, have low resistance to
bacteria-generated, chemical byproducts that are also corrosive to the
steel pipe.
• Accessibility of the Line for Field Application and Repair
Pipe laid under river crossings, offshore, or in other hard-to-access locations
may need low-maintenance pipe coatings.

Fig. 900-28 Mill-Applied Pipeline Coating Systems (1 of 2)

Surface
Prep Resistance
Max Svc Holiday Hydro- Soil

Generic Type Trade Name Temp. °F Detector Voltage Color SSPC SP- carbon Stress
Asphalt Mastic Somastic Type I 140 Black 6 No Yes

coating
1250 thickness
( mils )
Asphalt Mastic Somastic Type III 140 Yellow 6 No Yes

coating
1250 thickness
( mils )
Coal Tar Enamel Reilly #230A Enamel 140 Black 6 No No

coating
1250 thickness
( mils )
Crosshead-Extruded Shaw Black Jacket 150 Black 6 No Yes

Plastic with Asphalt (Polyethylene) coating
1250 thickness
Adhesive
( mils )
Crosshead-Extruded Shaw Yellow Jacket 160 Yellow 6 No Yes

1250 thickness
Adhesive
( mils )
Crosshead-Extruded Encoat Entec 100 Yellow 6 No Yes

1250 thickness
Adhesive
( mils )
Crosshead-Extruded Encoat Entec 100 Orange 6 No Yes

Plastic with Asphalt (Polypropylene) coating
1250 thickness
Adhesive
( mils )
Crosshead-Extruded Plexco Plexguard 100 10,000 V Yellow 6 No Yes

Plastic with Asphalt (Polyethylene)
Adhesive
Crosshead-Extruded Plexco Plexguard 100 10,000 V Orange 6 No Yes

Plastic with Asphalt (Polypropylene)
Adhesive
Dual FBE O'Brien Nap-Gard 200 125 V/Mil. Gold 10 Yes Yes
“Gold” 7-2501 &
7-2504
Extruded Plastic with Elf Atochem 180 Black 10 No Yes

FBE Primer (Polyethylene) coating
1250 thickness
( mils )
Extruded Plastic with Elf Atochem 200 Gray 10 No Yes

FBE Primer (Polypropylene) coating
1250 thickness
( mils )
Extruded Plastic with Du Val 180 Blue 10 No Yes

FBE Primer (Polyethylene) coating
1250 thickness
( mils )

Fig. 900-28 Mill-Applied Pipeline Coating Systems (2 of 2)

Surface
Prep Resistance
Max Svc Holiday Hydro- Soil

Generic Type Trade Name Temp. °F Detector Voltage Color SSPC SP- carbon Stress
Extruded Plastic with FBE Du Val 200 Blue 10 No Yes

Primer (Polypropylene) coating
1250 thickness
( mils )
FBE 3M ScotchKote 206N 200 125 V/Mil. Green 10 Yes Yes
FBE O'Brien Nap-Gard 200 125 V/Mil. Red 10 Yes Yes

7-2501
FBE Valspar D1003LD 200 125 V/Mil. Beige 10 Yes Yes
FBE Lilly Pipeclad 1500 150 125 V/Mil. Green 10 Yes Yes
Heat-Applied Tape Raychem Rayclad 120 20 Black 3 No Yes

coating
1250 thickness
( mils )
Heat-Applied Tape Ygill 140 White 6 No No

coating
1250 thickness
( mils )
Side-Extruded Pritec 10/40 180 14,000 V Black 10 No Yes

Polyethylene with Butyl
Rubber Adhesive
Durability & Resistance

Durability. Proper surface preparation is essential to prevent premature failure of
coatings.
Minimum specifications for the surface preparation of pipeline are listed in Figures
900-23, 900-28, and 900-29 for mill- and field-applied pipeline coating systems
and for pipeline fittings and valve coating systems. See also the list of standards for
surface preparation in Figure 900-30.
In the Company's pipe-coating specifications, there are details about the quality
control inspections necessary during the coating mill's production run.
Chemical Resistance. Chemical resistance is important in a coating if:
• There was a spill where the pipe will be laid
• The location has a high potential for a spill
Figures 900-23, 900-28, and 900-29 give the rates of hydrocarbon resistance for
various pipeline coatings.
The rating for extruded plastic and tape wraps is based on the following:
Polyvinylchloride (PVC) is more resistant than polypropylene which, in turn, is more
resistant than polyethylene.

Fig. 900-29 Field-Applied Pipeline Coating System

Surface
Prep Resistance
Holiday
Max Svc Detector SSPC Hydro- Soil
Manufacturer Trade Name Generic Type Temp °F Voltage Color SP- carbon Stress
Hempel Nap-Wrap Thermostat 225 125 V/Mil Gray 10 Yes Yes

Epoxy 8553 Epoxy
Celcoat Flakeline 251 Polyester Epoxy 160 4000V White 10 Yes Yes
Porter Int'l Tarset Max- Coal Tar Epoxy 140 3000V Black 10 Yes Yes
Build 7080
TIB Chemie Protegal Polyurethane 135 150 V/Mil Black 5 Yes Yes
32-10
TIB Chemie Protegal Polyurethane 180 150 V/Mil Black 5 Yes Yes
32-10RG
TIB Chemie Protegal Polyurethane 180 150 V/Mil Red 5 Yes Yes
32-50RG
Valspar Valpipe 100 Polyurethane 160 125 V/Mil Gray 5 Yes Yes
Madison Chem- Corropipe 2TX Polyurethane 140 200 V/Mil Black 5 No No

ical
Reilly Tar & #230 A Enamel Coal Tar Enamel 140 Black 6 No No
Chemical coating
1250 thickness
( mils )
Raychem Flexclad Applied Tape 135 Black 3 No No

coating
1250 thickness
( mils )
Canusa Wrapid-Tape Applied Tape 135 Yellow 3 No No

coating
1250 thickness
( mils )
Tapecoat 10/40W Cold-Applied 120 8,000 V Black 2 No No

Tape
Tapecoat H-50 Cold-Applied 120 6,500-8,500 V Black 2 No No

Tape
Tapecoat CT Cold-Applied 120 7,000 V Black 2 No No

Tape
Polyguard RD-6 Cold-Applied 120 3,000-5,500 V Black 2 No No

Tape
Polyken 900 Series Cold-Applied 120 10,000 V White 2 No No

Tape
Denso HT Petrolatum Tape 120 Wet Spronge Jeep Brown 2 No No
Trenton #1 Wax Tape Petroleum Wax 120 Wet Spronge Jeep Brown 2 No No
Tape

Fig. 900-30 Standards for Surface Preparation

Description Foreign Standards
NACE
SSPC Internt'l Short Long Canadian Swedish British
SP 1 — Solvent Cleaning Removal of oil, grease, dirt, soil, salts, — — —

and contaminants by cleaning with
solvent, vapor, alkali, emulsion, or
steam.
SP 2 — Hand Tool Removal of loose rust, loose mill scale, 31 GP-401 St. 2 —
Cleaning and loose paint to a degree specified, (Approx.)
by hand chipping, scraping, sanding,
and wire brushing.
SP 3 — Power Tool Removal of loose rust, loose mill scale, 31 GP-402 St. 3 —
Cleaning and loose paint to degree specified, by
power tool chipping, descaling,
sanding, wire brushing, and grinding.
SP 5 NACE #1 White Metal Removal of all visible rust, mill scale, 404 Sa. 3 BS 4232
Blast Cleaning paint, and foreign matter by blast Type 1 First Quality
cleaning by wheel or nozzle (dry or
wet) using sand, grit, or shot. (For very
corrosive atmosphere where high cost
of cleaning is warranted.)
SP 10 NACE #2 Near-White Blast cleaning nearly to white metal — Sa. 2-1/2 BS 4232
Blast Cleaning cleanliness, until at least 95% of each Second Quality
element of surface area is free of all
visible residues. (For high humidity,
chemical atmosphere, marine or other
corrosive environment.)
SP 6 NACE #2 Commercial Blast cleaning until at least two-thirds 31 GP-404 Sa. 2 BS4232
Blast Cleaning of each element of surface area is free Type 2 Third Quality
of all visible residues. (For rather
severe conditions of exposure.)
SP 7 NACE #4 Brush-off Blast cleaning of all except tightly 31 GP404 Sa. 1 Light Blast to
Cleaning adhering residues of mill scale, rust, Type 3 Brush Off
and coatings, exposing numerous
evenly distributed flecks of underlying
metal.
SP 8 — Pickling Complete removal of rust and mill — — —

scale by acid pickling, duplex pickling,
or electrolytic pickling. May passify
surface.
• Plastic coatings swell and eventually fail under prolonged exposure to hydro-
carbons.
• Hydrocarbons attack and dissolve the soft adhesive that holds plastic coatings
to the pipe. Typically, soft adhesives have a lower resistance to hydrocarbon
than the plastic jacket.
Ultraviolet (UV) Resistance. While all coatings degrade in sunlight, there are
some practical solutions:
• To prevent degradation of coatings on pipes that are stored outside, whitewash
the coatings if they have poor UV resistance.

Consult the manufacturer of the coating for recommended procedures for UV

protection and for help with determining the condition of coated pipe already
stored outside.
If the degree of degradation is unknown in a stack of pipe, use unexposed pipe;
as only the top and outside joints are exposed to UV rays.
• Plastic coatings, such as extruded and tape wrap, degrade in the sun, hardening
and often splitting. Thermal expansion-and-contraction problems occur
because plastic expands much more than steel.
• FBE coatings chalk in sunlight, but the chalk protects the coatings. Millage
loss is only a problem when rain and wind remove the chalk steadily for a long
time. FBE coatings can also blister if stored too long in hot, humid climates
such as is found in the Gulf Coast.
For information about the outdoor storage life and UV resistance for external pipe-
line coatings, see Figure 900-31.
Resistance to Mechanical Damage. Coated pipe is subject to damage during
handling, shipping, installing, or servicing. As a result, consider taking these
preventive measures:
• Make the coating thicker to improve its resistance to mechanical damage.
• Handle coated pipe with padded equipment, and stack and ship it with rubber
spacers between each pipe. Set the spacers to separate the pipe far enough so
that gravel and cinders thrown up from the road or rail tracks are not caught
between pipes and abrade the coating.
• Consider wrapping the pipe in plastic or installing pillowed supports.
• Store the pipe on sand wind-rows and cover it with tarps.
See Section 921 of this manual, Selection, for information regarding Rock Protection.
Cathodic Shielding. When a coating separates from a cathodically protected pipe,
it can shield the pipe from the protection of the cathodic current. Significant local-
ized corrosion occurs where earth or water (or both) becomes trapped between the
separated coating and the pipe's surface.
The current from cathodic protection does not increase to give a warning. The only
way to determine the amount of corrosion on a cathodically shielded line is with
metal-loss inspection tools which detect changes in the thickness of the pipe's wall.
Note the following about cathodic shielding:
• Tape wraps are most susceptible because water has a greater chance of pene-
trating the overlaps (often poorly bonded and susceptible to soil stresses) and
because they have high electrical resistivity.
• Water can seep under continuous, extruded plastic coatings at field joints or
mechanically damaged areas.

Fig. 900-31 Pipe Storage and Ultraviolet (UV) Resistance

Storage Limit
Generic Type Trade Names Resistance (Years) Remarks
Asphalt Mastic Somastic Poor 1 Protect from sunlight.
Coal Tar Enamel Reilly Tar and Chemical Poor 1 Protect from sunlight.
Coal Tar Epoxy International Tarset Good 1 —

Maxi-Build 7080
Cold-Applied Tapes Tapecoat 10/40W, H-50, and Poor — Normally applied in ditch and
CT Polyguard RD-6, Polyken 900 immediately buried.
series
Crosshead-Extruded Plastic Bredero Price Entec Fair 1 Fair except for Plexco
with Asphalt Mastic Plexco Plexguard Plexguard, which may be
Shaw Yellow Jacket and Black poor.
Jacket
Fusion Bonded Epoxy (FBE) 3M 206N and 226N Excellent 2 Excellent except in hot,
Nap-Gard 7-2501 and humid sea atmospheres
7-2504 (Gold) where blistering of coating
Lilly Pipeclad 1500 occurs.
Valspar-D1003LD
Heat-Applied Tapes Canusa Wrapid Tape Poor — Normally applied in ditch and
Raychem Flexclad immediately buried.
Multi-Layer Extruded Plastic Elf Atochem Excellent 2 —

with FBE Primer Du Val
Himont
Mapec, Du Pont Canada
Petrolatum Tapes Denso MT Good — Use as an atmospheric pipe

coating.
Polyester Epoxies Master Builder's Oilcote Excellent — Use as an atmospheric pipe

Flakeline 251 coating.
Polyurethanes TIB Chemie Protegal Excellent — Use as an atmospheric pipe

UT32-10 coating.
Valspar Valpipe 100
Radiation Cross-Linked Heat- Raychem Rayclad 120 Poor 1 Protect from sunlight.
Applied Tapes
Side-Extruded Polyethylene Bredero Price Pritec Excellent 1 —

with Butyl Rubber Mastic
Thermoset Epoxies Hempel Nap-Wrap Excellent — Use as an atmospheric pipe

Epoxy 8553 coating.
Wax Tape Trenton #1 Wax-Tape Good — Use as an atmospheric pipe

coating.
• The adhesive strength of FBE (also a continuous coating) is greater than its
cohesive strength, resulting in complete rupture of the film rather than
disbonding[1].
Note Adhesive strength means metal to coating; cohesive strength means coating
to coating.
Cathodic Disbonding. Excessive currents can cause free hydrogen to form at holi-
days. Hydrogen bubbles form on and break away from the exposed pipe metal,

exerting high pressure between the coating and the metal. Pressure occurring under
the edges of a damaged coating disbonds the coating from the pipe, exposing more
metal. This phenomenon causes the rapid disbonding of an otherwise good coating.
Note Excessive current are amounts that exceed the hydrogen-over-voltage
potential.
Note Holidays are minor areas of damage—breaks or flaws—in an applied
coating.
Run a laboratory test to determine the relative resistance of a coating to cathodic
disbonding. While it is often difficult to relate laboratory results to field conditions,
this particular test is an excellent tool for judging whether or not some coatings,
such as FBE, have been applied properly.
Example: A 24-hour, 150°F test for cathodic disbonding of FBE provides a good,
quick check for undercure, under thickness, surface contamination, and poor
surface preparation. Problems with the coating process show up as a sudden
increase in the amount of coating that disbonds during the test.
See also Section 6.0 of Specification COM-MS-4042.
Construction Factors
Impact Resistance. Pipe coatings with high impact resistance are less likely to be
damaged during transportation and construction. In general, resistance to impact
decreases in this order:
1. Extruded plastics with hard adhesives
2. FBE
3. Extruded plastics with soft adhesives
4. Asphalt mastics
5. Coal-tar enamel
Flexibility in Cold Weather. Coated pipe is sometimes bent in the field in weather
conditions that make coatings more brittle. The Canadian Standards Association
(CSA) Pipe Bend Test shows that FBE and extruded-plastic coatings with hard
adhesives have the widest temperature range during construction of all pipe-coating
systems. Both FBE and extruded-plastic coatings with hard adhesives pass the CSA
Pipe Bend Test as they can survive bending during typical Canadian winter
weather. Coal-tar enamels can, however, soften in warm weather and fail during the
field-bending process.
Field Repair. Some pipe coatings are harder to repair in the field than others. FBE
is the easiest to patch. While extruded plastics with hard adhesives can be difficult
to repair, manufacturers are making progress with these coatings.
For information about recommended field repair methods, contact CRTC’s coating
specialists (listed in the Quick Reference Guide) or review pipe-coating specifications.

Limitations of Temporary Storage. Most pipe coatings have maximum storage

limits depending on the climate of the storage area. Storage is usually a problem
only if the pipe is coated and stored for longer than one year before construction
starts.
Climate during Construction Project. The climate during the construction project
may affect coatings.
• Some coatings, such as coal-tar enamels and asphalt mastics, become soft and
difficult to handle during hot weather.
• See Flexibility in Cold Weather (above).
• Some field-applied coatings have temperature dependent cure times.
Construction Methods during Project. Coatings for pipe laid in the ditch need
to be less abrasion resistant than coatings for pipes used in trenchless construction
techniques such as slick-bore, drilled, or pushed methods.
Application Factors
The application factors that most often affect coating decisions are cost, site, and
field support from the manufacturer and coatings applicator.
Cost. The following project components affect cost:
• Size of project
• Coating materials
• Surface preparation
• Application
• Transportation
• Girth-weld coating (field joints)
• Field repairs
Balance the costs of the initial installation against the reliability expected.
• Select premium-quality coatings where failures are especially costly (e.g., subsea,
congested areas, hard-to-access lines, and lines where leaks are intolerable).
• Consider that less-expensive coatings are generally poorer in quality and tend
to fail prematurely, resulting in higher maintenance costs and possible early
corrosion failure of the line.
In Figure 900-32, there is a list of approximate costs for the various pipeline coat-
ings. The cost of transporting pipe from the mill to the ditch can become significant
for heavier coatings such as coal-tar enamels and Somastic.
Site. While shop-applied coatings are inherently of higher quality than field-applied
coatings, their handling costs are generally higher, and they are susceptible to ship-
ping damage.
For large coating projects, consider setting up portable coating plants near the job
site to reduce costs, time, and potential shipping damage. You should also ensure

Fig. 900-32 Costs (1988)—External Pipeline Coatings

Material(1)
Coating Cost/Ft2 $ Total Applied Ft(2) Comments
(3) (4)
Fusion Bonded Epoxy (FBE) — 0.38 10 ¾" OD 0.219" wall; 12 mil min. coating thickness
(4)
— — 0.41 10 ¾" OD 0.219" wall; 14 mil min. coating thickness
— — 0.36(4) 12 ¾" OD 0.219" wall; 14 mil min. coating thickness

(4)
— — 0.38 12 ¾" OD 0.219" wall; 14 mil min. coating thickness
— — 0.52-0.56 KLMR line bid range, 16 mil avg., 14 mil min. of poly-
ethylene, 18" OD, 0.250" wall, 80,000 feet of pipe
Extruded Plastic — 0.42-0.48 KLMR line bid range, 10 mil adhesive, 40 mil of poly-
(Pritec brand) ethylene, 18" OD, 0.250" wall, 80,000 feet of pipe
(Plexco P.E) — 0.39 12
(Plexco P.P) — 0.42 12
Coal Tar Enamel — 0.45-1.00 Wide variation is due to application and locale. The
$1.00/ft2 is for the Richmond Effluent Project, 5960 feet of
36" OD pipe
Liquid Epoxies (Thermosets) 0.66 — For 20 mils
Tape Wrap; < 140°F 0.80-0.90 — Does not account for overlap
Raychem Hotclad 1.40 — Does not account for overlap
Field Coating of Weld Joints
Shrink Sleeves 2.00 —
FBE 30./weld — Includes delivery, cleaning, and application
Valves and Fittings
Protegal 3210 6.00 — 25 mils
Denso Tape 0.65 — Does not account for overlap
Porter Tarset 0.24 — 16 mils
Hempel 0.66 — 20 mils

Epoxy 8553
(1) Costs in this column where obtained from applicators without consideration of job size. These numbers do not take into account the
cost of labor, surface preparation and plant location.
(2) See Company's Cost Estimating Manual for additional cost information.
(3) Material costs on small project of 16 mils; add 5 percent of cost for additional mils over 16.
(4) Mesquite project; 168 miles of pipe.
that the pipe receives proper surface preparation and is neither dirty nor corroded
when the coating is applied.
☞ Caution Consider over-the-ditch applications only when refurbishing old lines
that cannot be taken out of service or for new lines at remote locations.
Field Support from Manufacturer and Coatings Applicator. If construction
delays occur due to coatings problems, determine the level of field support received
from the manufacturer or coatings applicator or both.

Inspection
Refer to the coating specification for information about inspecting a given pipeline
coating.
930 Internal Pipeline Coatings

Pipe is coated on the inside to prevent corrosion or to increase the efficiency of
flow by reducing losses from friction. There are other alternatives—cement and
plastic linings—which are critiqued as a comparison to coatings in Figure 900-33
Internal Coating/Lining Alternatives for Pipelines.
Fig. 900-33 Internal Coating/Lining Alternatives for Pipelines

Material Recommended Services Advantages Limitations Approximate Cost(1)
Cement Lining Produced water Thick, usually very Joints are potentially a weak Shop = $1.60/ft
Salt water reliable against water link, not good in many chemicals
Almost always for new corrosion Min. pipe diameter: 2-3 inches
lines Temp. approx. 250°F Pressure
approx. 5,000 psig.
Velocity approx. 10 fps
Plastic Liner Process chemicals Excellent corrosion resis- Typically comes in 20-ft flanged Include pipe and
(shop-applied) tance to a variety of lengths flanges = $80/ft (PPL)
services Flange joints can leak to $300/ft (Teflon)
Pipe diameter 1-16 inches
Temp. approx. 200°F
(PPL) to approx. 500°F (Teflon)
Plastic Liner Produced water Very reliable Pipe diameter 3-16 inches (but $9.20/ft
(field-applied) Salt water Very few joints larger sizes can be done)
(HPDE) New existing lines Can salvage existing lines Temp. ± 200°F
Coatings Produced water Fair to good corrosion Joints are potentially a weak link
(shop-applied) Salt water resistance Relatively thin film (may give
Flow friction reduction shorter, less reliable life)
Coatings Produced water Fair to good corrosion Good chance of field foul-ups
(field-applied) Salt water resistance Spotty history of quality control
Flow friction reduction Relatively thin film (may give
New or existing lines shorter, less reliable life)
(1) Except as noted, costs are for lining an 8-inch pipe at the shop location. Pipe costs extra. Costs are for rough comparative
purposes only.
Note For detailed information about lining pipelines, see also the Company's
Pipeline and Piping Manuals.
Shop- or mill-applied coatings control corrosion of known aggressive systems or
help reduce friction. Field-applied coatings primarily extend the service life of pipe-
lines by preventing additional damage from corrosion. If internal damage from
corrosion results in an unacceptable operating pressure, replace the pipeline or
install a plastic liner to increase the pipeline's maximum operating pressure (MOP).

931 Shop-applied Internal Pipeline Coatings

This section discusses the following issues regarding shop-applied internal pipeline
coatings:
• Quality control
• Coatings selection
• Surface preparation
• Application
• Inspection
Quality Control
Specifications. Although the Company does not have a specification for internal
pipeline coatings, information is available from CRTC specialists in M&EE.
Coating Quality. If holidays occur, you should not repair FBE coatings and liquid
coatings with a primer but you must burn the material off and recoat. You can patch
FBE and liquid-epoxy coatings that do not have primers by following the manufac-
turers' recommendations.
If the specification requires a 100-percent-holiday-free coating, the coatings applica-
tors must make the pipe smooth enough, clean enough, and capable of being coated
to this requirement.
The Company's representative is responsible for specifying proper surface preparation.
Coatings Selection
As liquid coating systems need a furnace bake, there is no known method to apply
them to internal weld joints; therefore, there are two, basic, internal coating
systems: heat-cured powder and baked-on liquid.
Heat-cured Powder. The heat-cured powder is a thermosetting resin, applied by
FBE process, with or without primer. Typically, select unprimed FBE for environ-
ments requiring improved flow efficiency or having mild internal corrosion, and
primed FBE for environments with severe internal corrosion.
Baked-on Liquid. Baked-on liquid may be epoxy, epoxy-phenolic, or possibly a
polyurethane.
For fresh water, saltwater, and production water at temperatures up to about 150°F,
select straight epoxies such as O'Brien NapGard, Scotchkote 134, Scotchkote 206N,
and Scotchkote 150.
For very corrosive environments with higher temperatures (200°F to 400°F), choose
epoxy-phenolic or epoxy-modified phenolics.
Note Phenolics tend to be brittle and will crack when bent.
For internal coating of girth welds in the field, the Company typically chooses
Scotchkote 206N because it cures in less than one minute from the residual heat of
the weld joint.

The range for field-and-mill application of FBE is a 25- to 48-inch diameter and up
to a maximum wall thickness of 0.750 inches.
Surface Preparation
All pipe needs the same surface preparation: cleaning and abrasive blasting,
followed in some cases, by priming.
Cleaning. Chemical treatment is the best cleaning method, but costly disposal is a
factor. Thermal burnoff at 600°F to 800°F is particularly important for a heavy mill
scale/rust.
Abrasive Blasting. Suitable abrasive is necessary to obtain the desired anchor
profile and a white metal (SSPC SP5) finish. Finish is checked visually with a high-
intensity light.
Priming. In water service, internal FBE does not usually require a primer; however,
you should alert the coatings manufacturer if the water is aggressive (contains CO 2
or H2S, is hot, or at high pressure).
Application
See the list of current contractors in the Quick Reference Guide.
Inspection
Virtually all shops inspect and test internally coated pipe, for holidays, adhesion,
and bends.
Holidays. The inspector checks 100 percent of the coating against an agreed-upon
standard (e.g., 100 percent holiday free, or 4 holidays maximum per length of pipe).
Typical voltage is 100 to 125 volts per mil of coating thickness.
Adhesion. Typically, the inspector cuts an x pattern into the coating and prods it with
a knife to check adhesion. The inspector conducts the test every two hours on the
weld cutback area of a section of pipe that is left deliberately unmasked for this test.
Bends. Typically, once per shift, often at a cool temperature, the inspector tests the
flexibility of the coating by bending a strip of coated metal over a specified mandrel
and checks it for holidays and cracks.
932 Field-applied Internal Pipeline Coatings

Liquid epoxy is the only internal coating that the Company field applies (in situ),
generally for one or more of the following reasons:
• To prolong the life of a line
• For product purity
• To reduce friction loss
Brands of field-applied, internal pipeline coatings include Hempel 233U,
Hempel 458U, Sigma In-Situ Pipecoating 15, Sigmaguard HTR.

Factors affecting field-applied coating are its limitations, the coating contractors
and applicators, acceptable brands, surface preparation, application, and inspection.
Limitations
Field application of internal pipeline coatings is less likely to produce pinhole-free
coatings than shop-applied systems. Field application is also unsuccessful with slip-on
flanges because the ID discontinuity at the pipe ends causes excess coating deposits
which rapidly disbond in shingles to plug the line or create a site for corrosion.
Coating Contractors and Applicators

Select coating contractors and applicators carefully because they can have a
profound affect on the success of a project.
Improperly applied coatings may result in inadequately protected lines, delays in
returning the line to service, and complete loss of the line.
Before choosing a coatings applicator, review in detail the work history (resume) of
the foreman and personnel proposed for the job.
See the list of contractors who field-apply pipeline coatings in the Quick Reference
Guide.
Acceptable Brands
Sigma Coatings In-Situ Pipecoating 15 and Hempel 233U have longer pot lives, but
Sigmaguard HTR and Hempel 458U have better high-temperature resistance. All
products have the same chemical resistance.
Note For more detailed background on field-applied coatings, see the references
at the end of this section [16, 17, 18, 19, 20, 21].
Surface Preparation
Prepare an internal steel pipe by cleaning it in one of two ways:
• Inhibited acid
• Abrasive blasting
Existing pipelines may also require initial cleaning by scraper pigs and with
solvents.
Application
See list of current contractors for pipeline coatings in the Quick Reference Guide.
Inspection
Compared to shop-applied internal coatings, inspection of field-applied internal
coatings is relatively crude.
The inspector often visually examines a flanged, removable spool located near the
middle of the line and also tests it for holidays and thickness. Video cameras allow
full-length inspection of the line for pipe sizes as small as 10 to 12 inches in diameter.

933 Weld-joint Application & Inspection

In Figure 900-34, Properties of Internal Pipeline Coatings, a method of weld-joint
protection is recommended for each coating system, where applicable.
Fig. 900-34 Properties of Internal Pipeline Coatings

System Recommended Services Advantages Limitations Weld Joint Protection
Shop-Applied
Heat-Cured Powder:
Epoxy with Primer Sour water Good corrosion Resistant to low Mechanical joints
Wet sour gas (CO2 up to resistance concentrations of H2S
10%) Girth weld cannot be
Inspection and disposal coated
wells
Epoxy without Primer Produced water Can coat girth weld with Low resistance to H2S ≥ 8-inch pipe diameter:
Fresh water crawler crawler < 8-inch pipe
Salt water (CO2 up to Fair corrosion resistance diameter: mechanical
10%) joints
Baked Liquid:
Epoxy Produced water Sizes up to 20 inches: Mechanical joints

Fresh water very low flexibility
Salt water Temp. ± 150°F
Cannot repair holidays
Epoxy-Phenolic Sour water Good corrosion Cannot bend Mechanical joints

Wet sour gas (CO2/H2S) resistance Maximum pipe diameter:
20 inches
Temp. ± 400°F
Cannot repair holidays
Field-Applied In situ:
Liquid Epoxy Sour water Good corrosion High chance of foul-up if Does not apply
Produced water resistance wrong contractor has job
Fresh water High temp. service
Salt water (+200°F)
Flow friction reduction Extends serviceable life
Gas lines of existing line
Application
The crawler is the method for applying internal pipeline coating systems. Mechan-
ical joints are also available as an alternative for 2- to 12-inch-sized pipes.
Crawlers. A self-propelled, in-line tool that performs a task under remote control,
the crawler works in either field or shop. For the latter, that means that the shop can
join pipe lengths to reduce the number of field-welded joints. Currently, the
minimum pipe diameter for a crawler is ten inches.
Some of the crawler's coating tasks are as follows:
• For non-primed FBE internal coatings, crawlers clean and coat the girth welds.
• After welding, an abrasive-blasting crawler travels through the pipe to clean
the cutback area of weld splatter slag and to degloss the powder.

• An induction coil, applied to the pipe's exterior, heats the girth weld area and a
powder-coating crawler then travels through the pipe.
There are basically two circumstances under which shop or field coatings applica-
tors cannot use a crawler:
• The pipe requires a liquid primer or coating
• The pipe diameters are less than ten inches
Mechanical Joints. One alternative to the crawler is mechanical joints. There are at
least a dozen mechanical joint systems that provide a continuous internal seal.
Some, such as Crimp-Kote from Tuboscope Vetco International, are fully mechan-
ical interference-fit joints. Some are elaborate mechanical sleeve systems, which
may include welding. Most require special equipment for field installation.
Mechanical joints are usually available in 2- to 12-inch sizes.
Inspecting Internal Pipeline Coatings

Inspection varies with the coating material and the application method. For informa-
tion about inspecting internal pipeline coatings, contact CRTC's specialists listed in
the Quick Reference Guide.
940 References
1. O'Carroll, B. M., “The Performance of Pipe Coatings in Relation to Cathodic
Protection,” 5th International Conference on the Internal and External Protec-
tion of Pipes, Innsbruck, Austria, October 25-27, 1983.
2. Materials Laboratory Report, 150°F Cathodic Disbondment Tests of Pipeline
Coatings, C.A. Shargay, September 17, 1982, File No. 6.55.5.
3. Article, What's New in Distribution/Transmission Pipeline Coatings, Ron
Sloan.
4. Materials Laboratory Report, Rangley CO2 Pipeline Coating Tests, J. H.
Kmetz, File: 6.55.75, December 21, 1984.
5. Davis, J. A. and Thomas, S. J., “Properties and Application Procedures for
Polyethylene Tape Coating Systems,” Pipeline, April 1985, p. 6.
6. Materials Laboratory Report, Sudan Pipeline Coatings - Tape Wrap Tests,
L. J. Klein, File 6.55.50.
7. Materials Laboratory Report, Aramco Mastic Tape Tests, Final Report,
C. A. Shargay, File 6.55.50, April 27, 1983.
8. Choate, L. C., “New Coating Developments, Problems, and Trends in the
Pipeline Industry,” Materials Performance, April 1975.
9. O'Donnell, John P., “Coal-Tar Enamel Resins: Most-Preferred Pipe Coating,”
Oil and Gas Journal, July 6, 1981.

10. Ward, D. K., Moore, D. E., and Hawkins, P. J., “External and Internal Pipeline
Coatings in the Arabian Gulf Area,” 5th International Conference on the
Internal and External Protection of Pipes, Innsbruck, Austria, October 25-27,
1983, Paper C3.
11. Chevron Pipe Line Company Memo, Field Joint Coatings from P. T. Groff to
R. G. Lueders, July 1, 1987.
12. Memo to CRTC File, Bakersfield Experience with Extruded Plastic Control
Pipe, E. H. Niccolls, File 6.55.15, May 24, 1990.
13. Materials Laboratory Report, KLM Pipeline Reclamation Trial Coatings,
K. K. Kirkham, File 6.55.15, January 4, 1984.
14. Materials Laboratory Report, KLM Pipeline Reclamation Trial Coatings,
B. J. Cocke, File 6.55.15, October 25, 1983.
15. Materials Laboratory Report, Hot Subsea Pipeline Coatings Disbonding Tests,
N. E. Daley, File 6.55.30, December 27, 1988.
16. E.H.Niccolls, InSituInternalPipelineCoatings, Materials Laboratory File
N28.15, July 17, 1981.
17. S. E. Pfeiffer, “Fusion Bond Coated Girth Welds, External/Internal,” Corrosion
83 Paper 117, NACE International.
18. P. J. Bryant, “Internal In-Place Pipe Coating,” Pipeline Gas Journal, Volume
214, Pages 17-18, February 1987.
19. S. V. Daily, “An Alternative Surface Preparation Procedure for the Application
of Internal In-Situ Pipeline Coating,” Corrosion 88 Paper 308, NACE Interna-
tional.
20. S. Selinek, “In Situ Internal Coating of Pipelines—North Sea Experience,”
Corrosion 90 Paper 254, NACE International.
21. R. E. Carlson, Jr., “Internal Lining of Pipeline Weld Joints,” Material Perfor-
mance, Volume 31, Number 9, pages 46-49, September 1992.
22. Dr. J. M. Leeds, “A High-temperature (120°C) Gas Pipeline Coating-
Refurbishment Programme, Using High-solids Epoxy,” Pipeline Risk Assess-
ment, Rehabilitation and Repair Conference, Houston, Texas, May 20-23, 1991.
23. P. Barrien, S. E. McConkey, M. A. Trzecieski, “Coating Evaluation Program
for 116°C Service Temperature,” Corrosion 84 Paper # 358, NACE Interna-
tional, New Orleans, Louisiana, April 1984.
24. John Bethea and Adel Botros, “A New Approach to Fusion Bonded Epoxy
Coatings for Pipeline Protection,” API Pipeline Conference, April 1994.
25. NAPCA Bulletin 1-65-91, “Recommended Specification Designations for Coat
Tar Enamel Coatings.”

26. NAPCA Bulletin 2-66-91, “Standard Applied Pipe Coating Weights for
NAPCA Coating Specifications.”
27. NAPCA Bulletin 3-67-91, “External Application Procedures for Hot Applied
Coal Tar Coatings to Steel Pipe.”
28. NAPCA Bulletin 6-69-90-1, “Suggested Procedures for Hand Wrapping Field
Joints Using Hot Enamel.”
29. AWWA Standard C-203, “Coal-tar Protective Coatings and Linings for Steel
Water Pipelines - Enamel and Tape Hot Applied.”
30. AWWA Standard C-213, “Fusion-bonded Epoxy Coating for the Interior and
Exterior of Steel Water Pipelines.”

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900 Pipeline Coatings

910 Pipeline Coatings in General 900-3

Chevron Corporation 900-1 September 1996

932 Field-applied Internal Pipeline Coatings

September 1996 900-2 Chevron Corporation

910 Pipeline Coatings in General

920 External Pipeline Coatings

Chevron Corporation 900-3 September 1996

– Installed just before the pipe is put into the ditch

Fig. 900-1 Mill-Applied Coating Selection Flowchart

September 1996 900-4 Chevron Corporation

2. FBE FBE FBE(3) Plastic-backed Tape Wraps

4. Coal-tar Enamel Tape Wrap(5), (6)

Chevron Corporation 900-5 September 1996

September 1996 900-6 Chevron Corporation

Fig. 900-3 Advantages and Disadvantages of External Pipeline Coatings (1 of 2)

• Continuous coating • Cannot be used on bends

Chevron Corporation 900-7 September 1996

Fig. 900-3 Advantages and Disadvantages of External Pipeline Coatings (2 of 2)

Extruded Plastic, Asphalt • 29+ years experience • Minimum adhesion to steel

Tape Wraps • 30+ years experience • Susceptible to cathodic shielding

Coal/Tar Enamel • 65+ years experience • Carcinogenic fumes when applied

Fig. 900-4 Description of External Pipeline Coating—Asphalt Wrap Coatings

Small Repairs Choose an asphalt-based mastic to patch an asphalt (P-2) wrap.

September 1996 900-8 Chevron Corporation

Fig. 900-5 Description of External Pipeline Coating—Asphalt Mastic (1 of 2)

Status Limited availability and marketing have affected Somastic's popularity.

Surface Prep Abrasive Blast

Application • Heat and mix Somastic ingredients

Thickness > 250 mils

Small Repairs Heat-shrink sleeves UT.

Handling/Storage Aboveground Storage Limit: One year

Protection/Resistance UV Resistance: Poor

Chevron Corporation 900-9 September 1996

Fig. 900-5 Description of External Pipeline Coating—Asphalt Mastic (2 of 2)

Girth-weld Coating Heat-shrink sleeves

Brands Somastic I and III.

See Also NACE International Standard RP-0276 (Discontinued)

September 1996 900-10 Chevron Corporation

Fig. 900-6 Description of External Pipeline Coating—Coal Tar Enamel (1 of 2)

Recommended Service On subsea lines with concrete (weight) coatings.

Max. Service Temp 140°F

Surface Prep Abrasive Blast: SSPC SP6

Holiday Detection 12,000 to 18,000 volts

Thickness 156 mils

Handling/Storage Aboveground Storage Limit: Six months +

Chevron Corporation 900-11 September 1996

Fig. 900-6 Description of External Pipeline Coating—Coal Tar Enamel (2 of 2)

Girth-weld Coatings Shrink wraps or cold applied tape wraps.

See Also • Company’s Pipeline Manual for information on weight coatings

September 1996 900-12 Chevron Corporation

Fig. 900-7 Description of External Pipeline Coating—Coal Tar Epoxies

Max. Service Temp 140°F

Surface Prep Abrasive Blast

Application Spray, brush, or roll

Thickness 16-20 mils

Small Repairs Patch with same material per manufacturer’s guidelines

Protection/Resistance Cathodic Disbonding

Chevron Corporation 900-13 September 1996

Fig. 900-8 Description of External Pipeline Coating—Cold-Applied Tapes (1 of 2)

Max. Service Temp Elevated-Temperature Service

Surface Prep Abrasive Blast: SSPC SP-2

Holiday Detection 3000 to 8000 volts per manufacturer’s guidelines

Application Whether mill- or field-applied: