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COATING

Coating is the process to use a external


agent on the parent material to protect it
from the external environment and
increase the life of the material.
COATING IN THE PIPELINE SECTOR

 Pipe that carry the oil and gas is generally


buried or exposed in to external environment
may lead to corrosion, metal loss or third
party damage.
 To prevent all these the pipes are coated at the
time of construction and then lower in to the
trench.
IF CP is then WHY?
 CP system is in the pipeline to protect the
corrosion of the pipe. It does not help to
reduce the metal loss ,Erosion etc.
 CP itself is not 100% efficient to control
the corrosion .It needs continuous
observation to be effective. Because soil
resistivity changes time to time.
Property of coating material
 Low permeability to water & salts.
 Low permeability to Oxygen
 Good Adhesion to pipe steel
 Adequate Temp. stability
 Ease of Application.
 Flexibility to strain
 Resistance to Biodegradation
 Resistance to Cathodic disbondment
 Easy to repair.
 Non Toxic, Environment Friendly
TYPE OF COATING
 Three layer polyethylene coating
 Fusion bonded Epoxy powder coating
 Three layer polypropylene coating
 Asphalt Enamel coating
 Neoprene rubber coating
 High Performance Composite Coating
 polyurethane coating
OFFSHORE PIPE COATING

 Concrete coating
 polyurethane foam coating
 Polypropylene Insulation coating
INTERNAL COATING

 Centrifugally Applied Cement Mortar Lining


 Internal FBE Lining
 Thin Film Internal Epoxy Coating
THREE LAYER POLYETHYLENE
COATING
 This consists of a high performance fusion
bonded epoxy (FBE) followed by a copolymer
adhesive and an outer layer of polyethylene
which provides tough, durable protection.
 3LPE Systems provide excellent pipeline
protection for small and large diameter pipelines
with moderate operating temperatures.
Advantage
 The tough outer layer of polyethylene protects
pipelines during transportation and installation
thereby reducing costly repairs
 Also providing added in-ground protection
against shear forces, chemicals and abrasive soil
conditions.
 Increasing the thickness of the polyethylene outer
layer, the 3LPE system can provide a high level
of mechanical protection
TYPICAL PROPERTIES
PROPERTY 3LPE
 Minimum Pipe Diameter 90 mm (3.5”)
 Maximum Pipe Diameter 1220 mm +(48”+)
 Minimum Pipe Length 5.5 m (18’)
 Maximum Pipe Length 24.4 m (80’)
 Min. Recommended Operating Temp. -40°C (-40°F)
 Max. Recommended Operating Temp. 85°C (185°F)
Multi-Layer PE Coating
It is a two layer corrosion protection system
that combines the proven protective qualities
of a polyethylene outer coating with a special
butyl rubber adhesive.
Advantage
 Resistance to mechanical damage.

• Resistance to soil contaminants and cathodic


disbondment.
• Temperature range from -32°C to 80°C.
• Long term corrosion protection on pipelines
up to 145” in diameter.
TYPICAL PROPERTIES
PROPERTY Multi Layer PE
 Minimum Pipe Diameter 100 mm (4”)
 Maximum Pipe Diameter 3680 mm (145")
 Minimum Pipe Length 5.5 m (18’)
 Maximum Pipe Length 24.4 m (80’)
 Min. Recommended Operating Temp. -40°C
 Max. Recommended Operating Temp. 80°C
3LPE COATING FOR HIGHER
TEMPERATURE PIPELINE
It is a multilayer coating consisting of a layer
of fusion bonded epoxy, a copolymer adhesive
and an outer layer of high density polyethylene
which offers a tough, durable pipe coating
solution.
BENEFITS
 Excellent corrosion, moisture and soil
stress resistance
 Outer thickness can be varied to offer
greater mechanical protection
 Excellent bend-ability and impact
resistance
 It is seamless and lamination free
TYPICAL PRODUCT PROPERTIES
PROPERTY 3LPE for high Temp.
 Minimum Pipe Diameter 90 mm (3.5”)
 Maximum Pipe Diameter 300 mm (12”)
 Minimum Pipe Length 5.5 m (18’)
 Maximum Pipe Length 24.4 m (80’)
 Min. Recommended Operating Temp. -40°C
 Max. Recommended Operating Temp. 85°C
FUSION BONDED EPOXY POWDER
COATING
 FBE is a high performance anti-corrosion
coating that provides excellent protection for
small and large diameter pipelines with
moderate operating temperatures.
 FBE’s excellent adhesion to steel
 FBE also provides excellent resistance to
cathodic disbondment which reduces the total
cost of cathodic protection during the
operation of the pipeline.
Advantage
 Provides tough physical properties that
minimize damage during handling,
transportation, installation and operation
 FBE has also been designed for good
chemical resistance under most soil
conditions.
TYPICAL PROPERTIES
 PROPERTY FBE
 Minimum Pipe Diameter 90 mm (3.5”)
 Maximum Pipe Diameter 1220 mm + (48”+)
 Minimum Pipe Length 5.5 m (18’)
 Maximum Pipe Length 24.4 m (80’)
 Min. Recommended Operating Temp. -40°C
 Max. Recommended Operating Temp. 85°C
THREE LAYER
POLYPROPYLENE COATING
3LPP System is a multilayer coating composed of
three functional components. This anti-corrosion
system consists of a high performance fusion bonded
epoxy (FBE) followed by a copolymer adhesive and
an outer layer of polypropylene which provides the
toughest, most durable pipe coating solution
available. 3LPP Systems provide excellent pipeline
protection for small and large diameter pipelines with
moderate operating temperatures.
BENEFITS
 The FBE component of the 3LPP System provides
excellent adhesion to steel .
 providing superior long term corrosion resistance and
protection of pipelines operating at high temperatures.
 superior adhesion properties of the FBE also results in
excellent resistance to cathodic disbondment which
reduces the total cost of cathodic protection during the
operation of the pipeline.
 tough outer layer of polypropylene protects pipelines
during transportation and installation thereby reducing
costly repairs.
TYPICAL PROPERTIES

PROPERTY 3LPP
 Minimum Pipe Diameter 90 mm (3.5”)
 Maximum Pipe Diameter 1220 mm + (48”+)
 Minimum Pipe Length 5.5 m
(18’)
 Maximum Pipe Length 24.4 m
(80’)
 Min. Recommended Operating Temp. -40°C (-40°F)
 Max. Recommended Operating Temp. 110°C (230°F)
ASPHALT ENAMEL COATING

Asphalt Enamel is a durable coating by


modified bitumen (asphalt) that has been
successfully used for corrosion protection of
steel pipes.
Benefits
 Asphalt Enamel's excellent adhesion to steel
provides a track record of long term corrosion
resistance.
 pipelines convey fluid when the continuous
temperature of the fluid being transported does not
exceed 90°C (194°F).
 As opposed to coal tar enamel, which contains
carcinogens, AE is a much safer and more
environmentally friendly system.
TYPICAL PROPERTIES
PROPERTY Asphalt Enamel
 Minimum Pipe Diameter 90 mm (3.5”)
 Maximum Pipe Diameter 1200 mm + (48" +)
 Minimum Pipe Length 5.5 m (18’)
 Maximum Pipe Length 18 m (59’)
 Min. Recommended Operating Temp. -40°C
 Max. Recommended Operating Temp. 90°C
NEOPRENE RUBBER COATING
 system consists of a multi-layer coating consisting on
a primer, bonding agent and an outer layer of
polychloroprene
 Polychloroprene is normally hot-bonded to the steel
using a vulcanization process in a steam autoclave.
This process both cures the rubber and bonds it to the
steel. Polychloroprene provides tough, durable
protection for pipelines and risers with excellent
resistance to water take-up, hydrocarbons and ozone.
Polychloroprene can also be applied as a field joint
coating on site being cured using heated electrical
tapes.
Benefits
 Polychloroprene system provides excellent adhesion to steel
thereby giving long term corrosion resistance.
 Impact protection to risers and pipelines operating at 95°c
(203°f).
 The superior adhesion properties of the polychloroprene also
results in excellent resistance to cathodic disbondment.
 The tough outer layer of polychloroprene protects pipelines and
risers during transportation and installation thereby reducing
costly repairs while providing added protection against shear
forces, impact, chemicals and abrasion. .
TYPICAL PROPERTIES
PROPERTY PCP (Neoprene)
 Minimum Pipe Diameter 90 mm (3.5”)
 Maximum Pipe Diameter 1220 mm + (48”+)
 Minimum Pipe Length 2 m (6.5’)
 Maximum Pipe Length 17 m (56’)
 Min. Recommended Operating Temp. -40°C
 Max. Recommended Operating Temp. 95°C
HIGH PERFORMANCE COMPOSITE
COATING
 High Performance Composite Coating (HPCC) is an
advanced composite system that represents the latest
development in anti-corrosion systems. The product
consists of fusion bonded epoxy, polyolefin adhesive
and tough polyethylene.
 HPCC is designed to protect buried oil and gas
pipelines in environments where superior mechanical
protection, moisture and corrosion resistance and
high operating performance characteristics are
required.
BENEFITS
 The FBE component of HPCC provides
excellent adhesion to steel, thereby providing
superior long term corrosion resistance.
 protection of pipelines operating up to 85°C.
 The superior adhesion properties of the FBE
also provides excellent resistance to cathodic
disbondment which reduces the cost of cathodic
protection during the operation of the pipeline.
 The unique application process of HPCC
provides a fused, monolithic profile that prevents
de-lamination and loss of adhesion.
 During construction, the system demonstrates
excellent field handling and flexibility
characteristics, thus minimizing construction
installation costs.
 HPCC provides excellent uniform coverage of
the weld bead profile, thus preventing “tenting”
and weaknesses in the coating cross-section.
 The polyethylene component protects the
pipeline during transportation, thereby, reducing
costly repairs while also providing added in-
ground protection against shear forces,
chemicals and abrasive soil conditions.
TYPICAL PROPERTIES
 PROPERTY HPCC
 Minimum Pipe Diameter 400 mm
(16”)
 Maximum Pipe Diameter 1220 mm + (48”+)
 Minimum Pipe Length 18.3 m
(60’)
 Maximum Pipe Length 24.4 m
(80’)
 Min. Recommended Operating Temp. -40°C (-40°F)
 Max. Recommended Operating Temp. 85°C (185°F)
Concrete Weight Coating
It is designed to provide negative buoyancy
and mechanical protection for pipelines in sub-
sea and wet environments. It uses an impinged
application method making it ideal for large
diameter pipelines. It is available in various
thicknesses and densities and can be applied
over anti-corrosion and insulation coatings.
BENEFITS
 It can be applied over anti-corrosion and
insulation coating systems.
 It is most appropriate weight coating system
without compromising the long term corrosion
protection or flow assurance requirements of the
pipeline.
 It have wide range of densities and thicknesses
to meet project requirements.
 This feature can improve installation, optimize
negative buoyancy and minimize cost.
TYPICAL PROPERTIES
 PROPERTY Concrete Weight Coating
 Minimum Pipe Diameter 100 mm (4”)
 Maximum Pipe Diameter 1220 mm (48”)
 Minimum Pipe Length 8.5 m (28’)
 Maximum Pipe Length 18 m (60’)
 Minimum Concrete Thickness 25 mm (1”)
 Maximum Concrete Thickness 230 mm (9”)
 Compressive Strength 20.7 - 41.4 MPa
(3000 - 6000 psi)
 Density 2243 - 3364 kg/m3
(140 - 210 lbs/ft3)
COMPARISON OF
PIPELINE COATINGS
ASPHALT / COAL TAR: 1940 TO 1970
ADVANTAGES DISADVANTAGES
EASY TO APPLY SUBJECT TO OXIDATION AND
CRACKING
MINIMAL SURFACE SOIL STRESS HAS BEEN AN ISSUE
PREPARATION REQUIRED
LONG TRACK RECORD IN LIMITATIONSAT LOW APPLICATION
CERTAIN ENVIRONMENTS TEMPERATURES
WITHOUT FAILURE
PERMEABLE TO CATHODIC ENVIRONMENTAL AND EXPOSURE
PROTECTION IN EVENT OF CONCERNS
FAILURE
  ASSOCIATED WITH CORROSION AND
STRESS CRACK CORROSION FAILURES
Table 1 Comparison of coating candidates
COATING ADVANTAGES DISADVANTAGES

FBE 1. Excellent corrosion resistance. 1. Low impact resistance results in considerable field damage.
2. Does not shield cathodic 2. Sensitive to steel surface preparation and condition.
protection system. 3. High moisture absorption and permeation especially at higher
3. High adhesion limits damaged temperatures.
area. 4. Affected by UV during storage.

HPCC 1. Excellent handling 1. Thickness constraints- 1.5 mm


2. Excellent corrosion resistance 2. Sensitive to steel surface preparation and condition
3. Excellent low temperature impact
resistance and flexibility
4. Excellent moisture resistance
5. Excellent raised weld coverage

3LPE 1. Excellent handling 1. Prone to thinning across raised weld seams.


2. Excellent low temperature flexibility 2. Side extrusion prone to de-laminations and voids.
and impact resistance 3. High cost due to minimum thickness constraints
3. Excellent corrosion resistance 4. Sensitive to steel surface preparation and condition
4. Excellent moisture resistance