Professional Documents
Culture Documents
AND REHABILITATION
By :
Mr. K.B.Singh
B.Sc Electrical Engineering (Hons)
Consultant-Coatings & Cathodic Protection
NACE INDIA CHAPTER CHAIRMAN FY 2021-2023
ASME PSD VICE CHAIRMAN FY 2019-2023
CORROSION CONTROL - INTEGRITY MANAGEMENT
CATHODIC
COATING
PROTECTION
S
INTEGRITY
ASSESSMENT OF BURIED PIPELINE
THRU PIPE COATING SURVEYS / CIPL
SURVEY/
INTELLIGENT PIGGING
3
EXTERNAL PIPELINE COATINGS
6
FUNDAMENTALS OF COATING
Active corrosion on buried pipelines can occur where the coating is defective and
the corrosion process may be driven by one the following conditions:
• Ineffective CP
• CP Shielding
• External Drivers
• Stress Corrosion Cracking
7
FUNDAMENTALS OF COATING
1. INEFFECTIVE CP : 3. EXTERNAL DRIVERS:
The commonest causes of ineffective CP are Electrical interference, stray current and galvanic
poor quality monitoring that fails to identify effects can nullify the effect of the applied CP and
under-protection and extensive coating create a corrosion problem where the pipe coating
breakdown that creates a total current is defective. AC induced corrosion is most
demand far in excess of the original CP commonly associated with small coating defects.
design criteria. 4. STRESS CORROSION CRACKING:
2. CP SHIELDING : Stress corrosion cracking on buried pipelines is
CP current is prevented from flowing onto most commonly found beneath a coating that has
the pipe steel by a high resistance barrier, become porous or has lost adhesion. Moisture
such as pipe coating that has lost adhesion must be present at the pipe surface but the critical
to the pipe. This creates the conditions in potential for SCC initiation and growth is less
which pitting and general corrosion occur negative than the commonly accepted protection
and in anaerobic soil conditions the rate of potential of – 850 mV so CP shielding is a factor in
corrosion attack may be accelerated by SCC. Some degree of pressure cycling is required for
bacterial or microbial activity. axial crack growth.
8
MAIN PIPELINE FACTORY APPLIED COATINGS
FUSION BOND FBE coatings generally have a useful life of 25 to 30 years. Beyond this period, the
EPOXY coating starts to blister and disbond especially in high water tables.
(FBE/DFBE)
THREE LAYER
POLYPROPYLEN 3LPP coatings have a useful life of 30 years.
E (3LPP) High temperature coating – tends to crack.
3LPE coatings have a useful life of 50 years. Very stable coating. Tends to disbond
THREE LAYER from steel surface causing surface corrosion. Problem comes if there continuous
POLYETHYLEN access to moisture. Can lead to pitting corrosion. CP does not help. New
E (3LPE) technologies – EMAT are being developed to dectect coating disbondment.
DEGRADATION MECHANISIM
FACTORY PICTORIAL MAXIMUM DEGRADATIO USEFUL LIFE
APPLIED VIEW TEMPERATUR N
COATING E RATING
MECHANISIM
Coal Tar Enamel 60°C Brittleness, 25 years
Cracking & (<5000 0hm m2)
Disbondment CD >800µA2
3 Layer 140°C Cracking of PP layer 25 years
Polypropylene
11
DEGRADATION MECHANISIM COAL TAR ENAMEL
12
DEGRADATION MECHANISIM THREE LAYER POLYPROPYLENE
13
DEGRADATION MECHANISIM DUAL LAYER FBE
14
DEGRADATION MECHANISIM DUAL LAYER FBE
15
DEGRADATION MECHANISIM THREE LAYER POLYETHYLENE
16
DEGRADATION MECHANISIM THREE LAYER POLYETHYLENE
17
DEGRADATION MECHANISIM COMPARISION
STAGE 1
Inspection/Detection PROJECT
MANAGEMENT
STAGE 2
Response to Detection
Repair and Rehabilitation is
STAGE 3
Assessment of Defects
NOT about inspection, and is
NOT about ‘defect
STAGE 4
Repair/Rehabilitate
assessment’…
COST MODEL
it is a engineering exercise that
needs a wide ranging
engineering skills.
23
REHAHBILTATION WORKS
Cathodic
New In-situ Protection
Coating Revamp & Up-
gradation
REHABILITATION WORKS
OPERATIN
G
PIPELINE
COATING IN THE
PIPE TRENCH
SPEED OF
CONDITIONS OF
APPLICATIO
TRENCH SURFACE N
PREPERATIO
N
WHY DO COATINGS FAIL
?
WHY DO COATINGS FAIL
LAYING DAMAGES
COATING AGEING
CP SYSTEMS DO NOT PROTECT HIGH CURRENT ATTENUATION
WHEN COATINGS START TO FAIL WHAT
STEPS ARE TO BE TAKEN
WHEN COATINGS START TO FAIL …
LINE 6 10 70 FBE 9 4
High water table with normal soil. Visco-elastic tape Power/ Hand wire Soft soil padding of at least 20 cm
Abrasive blasting not possible brushing to remove around the periphery. Soft soil may
rust (St2 / St3) be screened from the excavated soil
Very High water table with normal soil Petrolatum tape Power/ Hand wire Soft soil padding of at least 20 cm
Pipe surface wet brushing to remove around the periphery. Soft soil may
rust (St2 / St3) be screened from the excavated soil
38
TYPE OF REHABILITATION COATINGS
Sl
Characteristic Unit Type of Rehabilitation Coatings
No
Petrolatum Bituminous
3 ply/2 ply Visco-elastic
tape tape
Surface Preparation
1 Sa 2½ St 2 / St 3 St 2 / St 3 Sa 2½
2 Thickness (Nominal ±10%) mm ≥ 2.5 ±10% ≥ 2.5 ±10% ≥ 2.5 ±10% ≥ 2.5 ±10%
Holiday detection
3 — 15 kV 15 kV 15 kV at 15 kV
4 J/mm ≥ 10 J ≥ 10 J ≥ 2 J* ≥5J
Impact resistance
40
TYPE OF REHABILITATION COATINGS - 3ply / 2ply
41
TYPE OF REHABILITATION COATINGS - VISCO ELASTIC
Visco Elastic
No Primer • FIELD APPLIED
• ANY LENGTH OF PIPE
WFT 75 microns • MAX OPERATING TEMP: 1000C
• APPLIED THICKNESS 2.5 mm or more
• HIGH IMPACT STRENGTH
Visco Elastic Wrap (Inner corrosion layer) • HIGH INDENTATION STRENGTH
Overlap 10mm Visco Elastic wrap • CATHODIC DISBONDMENT RESISTANT
• ISO 21809 Part 3
Thickness 1.5mm
42
TYPE OF REHABILITATION COATINGS - PETROLATUM
43
TYPE OF REHABILITATION COATINGS - 3PLY / 2 PLY
44
TYPE OF REHABILITATION COATINGS - VISCO ELASTIC
45
TYPE OF REHABILITATION COATINGS - PETROLATUM
46
TAPE COATINGS
49
REHABILTATION OF COATING- 14” DIA PIPELINE
CLEARANCE FROM
TRENCH BOTTOM
500mm
51
REHABILTATION OF COATING- 14” DIA PIPELINE
DUST CONTAMINATION
RATING <2
REHABILTATION OF COATING- 14” DIA PIPELINE
SALT CONTAMINATION
<2micro grams/cm2
REHABILTATION OF COATING- 14” DIA PIPELINE
PRIMER APPLICATION
CHECKING OVERLAP
REHABILTATION OF COATING- 14” DIA PIPELINE
COMPLETED COATING
REHABILTATION OF COATING- 14” DIA PIPELINE
THICKNESS CHECKING
REHABILTATION OF COATING- 14” DIA PIPELINE
HOLIDAY CHECKING @ 15KV
REHABILTATION OF COATING- 14” DIA PIPELINE
66
REHABILTATION OF COATING- PETROLATUM TAPE
67
REHABILTATION OF COATING- CONDENSING GAS PIPELINE
MOISTURE ON PIPE
CONDENSING
68
REHABILTATION OF COATING- CONDENSING GAS PIPELINE
Two-component films provide higher hardness with enhanced resistance to moisture permeation,
soluble salts, and chemicals.
In chemistry, a hardener (Part B) is defined as a separate ingredient that reacts with the first component
(Part A) of a two-component paint.
LIQUID COATINGS
PART 11
COATINGS FOR IN FIELD APPLICATION , COATING
REPAIRS AND REHABILITATION
76
CONCLUSION