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SPC SPC Australasia Jeevan Menon BSc,BE “One Single,Uniform coating for the entire pipeline using LPE – Liquid Polymer coatings “ Paper presented at the.

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Presentation on theme: "SPC SPC Australasia Jeevan Menon BSc,BE “One Single,Uniform coating for the entire pipeline using LPE – Liquid Polymer coatings “ Paper presented at the."— Presentation transcript:

1 SPC SPC Australasia Jeevan Menon BSc,BE “One Single,Uniform coating for the entire pipeline using LPE – Liquid Polymer coatings “ Paper presented at the ACA ( Australian Corrosion Association ) Perth 2004

2 SPC SPC Australasia Typically several different types of coatings are used in a pipeline project (where different coating Parameters are needed). These different sections of a pipeline are: the Mainline coating the Bends and fittings the HDD sections the Field Joint coating and the Coating repairs on site. This creates issues of compatibility, Coating Standardization and increased coating costs. Slide 2/20

3 SPC SPC Australasia Liquid Polymer epoxy (LPE) coatings exhibit characteristics which can be designed to suit the application. Typically for an ideal Pipeline coating to cater for all the pipeline sections,the following Parameters are essential : 1.Hardness 2.Corrosion protection of the steel 3.Flexibility 4.Abrasion resistance 5.Impact resistance 6.User friendly application – Spraying with Plural Gun, - Spraying with standard Airless - Manual application with brush or roller Slide 3/20

4 SPC SPC Australasia Bitumen (Bit)Onshore Coal-Tar Enamel (CTE)Offshore Cold-Applied Tapes (CAT)Onshore 2-Layer Polyethylene (2LPE)Onshore / Offshore Fusion Bonded Epoxy (FBE)Onshore / Offshore 3-Layer Polyethylene (3LPE)Onshore / Offshore 3-Layer Polypropylene (3LPP)Onshore /Offshore Liquid Polymer Epoxies Onshore/Offshore Offshore Negative Buoyancy (Concrete Weight Coated)Offshore Insulated Pipe (PU foamed pipe with Jacket)Onshore / Offshore Deep Water Solutions (Thermotite)Offshore Bitumen (Bit)Onshore Coal-Tar Enamel (CTE)Offshore Cold-Applied Tapes (CAT)Onshore 2-Layer Polyethylene (2LPE)Onshore / Offshore Fusion Bonded Epoxy (FBE)Onshore / Offshore 3-Layer Polyethylene (3LPE)Onshore / Offshore 3-Layer Polypropylene (3LPP)Onshore /Offshore Liquid Polymer Epoxies Onshore/Offshore Offshore Negative Buoyancy (Concrete Weight Coated)Offshore Insulated Pipe (PU foamed pipe with Jacket)Onshore / Offshore Deep Water Solutions (Thermotite)Offshore Pipeline Coatings Increasing Technology - Operating Temperature Special

5 SPC SPC Australasia Review of Pipeline coatings used in Australia : -Yellow Jacket – ( 2 layer HDPE coating ) a soft mastic with a PE Outer jacket -FBE ( Fusion Bonded Epoxy) Powder -Trilaminate or Three layer PE coating consisting of: -1 st Layer – FBE -2 nd Layer – Tie adhesive -3 rd Layer –PE jacket Slide 4/20

6 SPC SPC Australasia PE Layer Tie Adhesive FBE Steel Pipe 3LPE Pipe line coating Outer Layer – PE coating Tie adhesive layer Inner Layer –FBE PE coating -Mechanical FBE Powder – Corrosion Three layer Polyethylene Coating 3LPE, Trilaminate

7 SPC SPC Australasia Using Fusion Bonded Epoxy (FBE) Powder Coating as a bench mark, lets compare the performance of these Liquid Polymer Epoxy( LPE) coatings-using existing pipeline coating Standards FBE Performance Standards: AS Australian Std. “External fusion-bonded epoxy coating for steel pipes” (Australia) NACE RP “Application, Performance, & Quality Control of Plant-applied, Fusion-bonded Epoxy External Pipe Coating” (NACE International based in USA) CSA Z “External Fusion Bond Epoxy Coating for Steel Pipe” (Canada) Slide 5/20

8 SPC SPC Australasia Hot Water Soak Adhesion Requirements of FBE Standards : AS (60°C / 28 days) - # 1-3 rating - hard to peel with knife NACE (24 hrs)- hard to peel with knife CSA (95°C/24hrs)- hard to peel with knife SP2888 liquid Polymer Coating Results: 95°C / 24 hrs: - coating does not soften - coating cannot be removed 75°C / 28 days: - coating cannot be removed SP2888 cannot be removed even after exposure to 28 SP2888 Soak at 75°C - 28 days Slide 6/20

9 SPC SPC Australasia SP2888 LPE Results at 0°C> 2.5 degrees/pipe diam. at -18°C > 2.5 degrees/pipe diam. SP 2888 LPE is much more flexible than FBE Bend Flexibility Requirements of FBE Stds.: NACE (at -18°C): > 2.5 degrees/pipe diam. Slide 7/20 Note: AS3862 requirement of 3.75 degrees for Field Pipe bending is not relevant

10 SPC SPC Australasia Impact Resistance Requirements of FBE Stds. at 23°C AS:>1.5 J (13 in-lb) NACE: >1.5 J CSA:>1.5 J SP2888 Impact > 3.0 Joules SP2888 LPE Results at 23°C : >3.0 J (26 in-lb) at 0°C : >3.0 J (26 in-lb) SP2888 has twice the impact resistance of FBE Slide 8/20

11 SPC SPC Australasia Cathodic Disbondment SP2888 LPE Results: 65°C / 48hrs: <5.5mm 80°C /28days: <10 mm SP2888 LPE has better disbondment characteristics than FBE SP2888 CD at 65°C - 48 hrs Requirements of FBE Stds. at 65°C : AS: < 8mm / 24 hrs NACE: < 8mm / 24 hrs CSA:< 10mm / 48 hrs Slide9/20

12 SPC SPC Australasia Application Coating CorrosionProtection HDDapplication Bends andfittings ? Field Jointcoating? Remoteapplication Yellow Jacket( 2 layer HDPE) coating YesNo FBE Powder coating Yes*NoNo**NoNo 3LPE YesNo Liquid Polymer Epoxy Yes *FBE as a single coating is not suitable for HDD applications ** FBE on the joints is expensive and not user friendly Slide 10/20

13 SPC SPC Australasia Summary Liquid Polymer Epoxy (LPE) Coatings exceeds FBE coating performance requirements. One single coating is used as : a Mainline coating –For Bends and fittings – HDD –Field Joint coating and repairs Can be applied on site with standard Equipment Slide 11/20

14 SPC SPC Australasia Latest developments in LPE technology. Development of an LPE oxidation / priming system that can be applied to high-density polyethylene (Trilaminate ) coatings without the requirement for grit blasting. Laboratory results have produced tensile adhesion results in excess of 2000 PSI (13.79 MPa) and excellent CD results Slide 12/20

15 SPC SPC Australasia 2.1 JP ONE Asset Pipe line Thailand 33km x 14" - Coated in Thailand 2.2 Chevron Thailand M11 - M14 project Various 3.5 Km 2.3 Transcanada Pipelines( TCPL)- Canada Km - 34" Km -42" Km -42" 2.4 Great Lakes pipeline -Canada-USA Km - 36" 2.5 Westcoast Energy Canada - 5 Km -36" 2.6 TransCanada rehab of Trunk line over 200km 36"-42" between References: Main Line Coatings

16 SPC SPC Australasia Transcanada Pipelines

17 SPC SPC Australasia Major SPC liquid Epoxy installation list – Projects in Australasia May 2004 Tweed River McConnell Dowell 900metres x 16"Directional join Century Zinc project Bechtel USA monitoring upright Pipes Myall Creek Project 504 metres x6”(river) Crossings &HDD Wide Bay Project 800 metres x 6"(road and river ) Duke's Eastern Gas pipeline NSW repairs to the Coating damage Duke Energy –Tasmanian Pipeline Craigieburn Bypass –GASNETVictoria 600 mm BendsSpray Grade -Mainline Docklands relocation projectGASNET /ORIGIN Energy Various lengths 30",18", 12" 8"and 4" Moranbah Gas Project Worley QLD & Orrcon.508mm Pipes, induction Bends, HDD Pipes for Road and river crossings and two buried tanks Spring Gully Gas project -Origin Energy 18 metre lengths of pipe x12” as well as all induction bends and anchor flanges Chevron Offshore and Onshore high temperature Risers and pipelines 150C –Thailand 3.5 km xSP8888 rated for 150C tested and approved by Chevron. Used for their M11- M14 Platforms SP8888 spray grade used for all risers, pipelines and induction bends SP8888 brushgrade used for the joints and coating repair

18 SPC SPC Australasia BP – Project BTC Pipeline 1200 km x 42” & 48 “ - 3LPE coated Pipe SP2888 Brushgrade for the joints

19 SPC SPC Australasia Bangkok Ring Mains ( Soi Noi Project ) Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x metres 30"x 18.34WT Pipe x metres Bangkok Ring Mains ( Soi Noi Project ) Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x metres 30"x 18.34WT Pipe x metres Bangkok Ring Mains ( Soi Noi Project ) Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x metres 30"x 18.34WT Pipe x metres Bangkok Ring Mains ( Soi Noi Project ) Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x metres 30"x 18.34WT Pipe x metres Comparison of coating Pipe in Thailand with SP2888 and 3LPE in Batam or Kuantan- Bangkok Ring Mains Soi Noi Project -30” x Wt Pipe x metres Coating Batam /Kuantan Thailand 3LPE (per lin metre) SP2888 ( Per lin metre) metres 2.5mm $ mil $ metres 3.5mm $ mil $ Metres 3.5mm $ mil $40.23 Bare Pipe receiving $1.67 $0 At Batam/Kuantan Coated Pipe Loadout $2.25 $0 Coated Pipe Freight $24.33 $0 Total Cost $ $ Cost Savings of approx 29.11%

20 SPC SPC Australasia Moranbah Gas project –Worley - 508mm coated in Brisbane SP2888 Slide 13/20

21 SPC SPC Australasia Moranbah Gas project –Worley 508mm HDD coated in Brisbane coated with SP2888 Slide 14/20

22 SPC SPC Australasia Coating repairs of Duke ‘s EGP Pipeline (FBE) with SP2888 brushgrade. Slide 15/20

23 SPC SPC Australasia Docklands Project 30” Pipes sprayed in Melbourne Slide 16/20

24 SPC SPC Australasia Tweed River project HDD String 900 metres x 16” SP2888 mainline coating with Brushgrade on the joints- Coated in Brisbane Slide 17/20

25 SPC SPC Australasia SP2888 brushgrade used for buried Stoppel Flanges –GPU Gas Net Melbourne Slide 18/20

26 SPC SPC Australasia SP C for Chevron’s M12,M13&M14 Projects 6”, 8” and 12” Slide 19/20

27 SPC SPC Australasia SPC Brushgrade Brush Grade Application Pre-measured kits Mix to achieve uniform color 4 minutes by hand or 1 min. with drill stirrer

28 SPC SPC Australasia SPC Brushgrade Application by Roller

29 SPC SPC Australasia SPC Brushgrade Brush Application

30 SPC SPC Australasia Slide 20/20


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