SPC Australasia

“One Single ,Uniform coating for the entire pipeline using LPE – Liquid Polymer coatings “

Paper presented at the ACA ( Australian Corrosion Association ) Perth 2004

Jeevan Menon

BSc,BE

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Slide 2/20 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 .

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Slide 3/20 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.

2.

3.

4.

5.

6.

Hardness Corrosion protection of the steel Flexibility Abrasion resistance Impact resistance User friendly application – Spraying with Plural Gun , - Spraying with standard Airless - Manual application with brush or roller

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Bitumen (Bit)

Pipeline Coatings

Coal-Tar Enamel (CTE) Cold-Applied Tapes (CAT) 2-Layer Polyethylene (2LPE) Fusion Bonded Epoxy (FBE) 3-Layer Polyethylene (3LPE) 3-Layer Polypropylene (3LPP) Liquid Polymer Epoxies Offshore

Onshore Offshore Onshore Onshore / Offshore Onshore / Offshore Onshore / Offshore Onshore /Offshore Onshore/Offshore

Negative Buoyancy (Concrete Weight Coated) Insulated Pipe (PU foamed pipe with Jacket) Deep Water Solutions (Thermotite)

Offshore Onshore / Offshore Offshore

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Slide 4/20 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

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3LPE Pipe line coating

Outer Layer – PE coating Tie adhesive layer Inner Layer –FBE FBE Steel Pipe PE coating -Mechanical FBE Powder – Corrosion

Three layer Polyethylene Coating 3LPE , Trilaminate

PE Layer Tie Adhesive

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Slide 5/20 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 3862

Australian Std. “External fusion-bonded epoxy coating for steel pipes” (Australia)

NACE RP0394

“Application, Performance, & Quality Control of Plant-applied, Fusion-bonded Epoxy External Pipe Coating” (NACE International based in USA)

CSA Z245.20

“External Fusion Bond Epoxy Coating for Steel Pipe” (Canada)

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Slide 6/20

Hot Water Soak Adhesion

Requirements of FBE Standards :

AS (60 °C / 28 days) - # 1-3 rating - hard to peel with knife

SP2888 Soak at 75 °C - 28 days

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 days @75C

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Bend Flexibility

• Requirements of FBE Stds.: • NACE (at -18°C): Slide 7/20 > 2.5 degrees/pipe diam. •SP2888 LPE Results •at 0°C •at -18°C > 2.5 degrees/pipe diam.

> 2.5 degrees/pipe diam. SP 2888 LPE is much more flexible than FBE Note: AS3862 requirement of 3.75 degrees for Field Pipe bending is not relevant

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Impact Resistance

•

Requirements of FBE Stds. at 23 °C

•AS: •NACE: •CSA: >1.5 J (13 in-lb) >1.5 J >1.5 J •

SP2888 LPE Results

• at 23°C : >3.0 J (26 in-lb) Slide 8/20

SP2888 Impact > 3.0 Joules

• at 0°C : >3.0 J (26 in-lb) SP2888 has twice the impact resistance of FBE

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Cathodic Disbondment

Slide9/20 •

Requirements of FBE Stds. at 65 °C :

• AS: < 8mm / 24 hrs • NACE: • CSA: < 8mm / 24 hrs < 10mm / 48 hrs •

SP2888 LPE Results:

• 65°C / 48hrs: <5.5mm

SP2888 CD at 65 °C - 48 hrs

• 80°C /28days: <10 mm SP2888 LPE has better disbondment characteristics than FBE

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Application Coating Yellow Jacket( 2 layer HDPE) coating FBE Powder coating Yes Yes 3LPE Yes Liquid Polymer Epoxy Yes No *No No Yes No No No Yes No **No No Yes No No No Yes *FBE as a single coating is not suitable for HDD applications ** FBE on the joints is expensive and not user friendly

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•

Summary

Slide 11/20

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 SPC

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Slide 12/20

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

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References: Main Line Coatings

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

1998 - 26Km - 34" 1999- 30Km -42" 2000- 15Km -42" 2.4

Great Lakes pipeline -Canada-USA

1999 - 50 Km - 36" 2.5

Westcoast Energy Canada

- 5 Km -36" 2.6

TransCanada rehab of Trunk line

over 200km 36"-42" between 1998-2000

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Transcanada Pipelines SPC

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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 Myall Creek Project

monitoring upright Pipes 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

as all induction bends and anchor flanges .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

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

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

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Comparison of coating Pipe in Thailand with SP2888 and 3LPE in

i i i i

Batam or Kuantan- Bangkok Ring Mains Soi Noi Project 30” x 18.34 Wt Pipe x 69630 metres

i i i i

3LPE (per lin metre) SP2888 ( Per lin metre) 37840 metres 2.5mm $37.32 18mil $38.23

31280 metres 3.5mm $50.93 25mil $40.23

510 Metres 3.5mm $50.93 25mil $40.23

.

.

.

.

Bare Pipe receiving $1.67

$0 At Batam/Kuantan Coated Pipe Loadout $2.25

Coated Pipe Freight $24.33

i i i i

$0 $0 Total Cost

$167.43

Cost Savings of approx 29.11% 6 3 $118.68

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

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

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

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

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

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

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SP8888 150 C for Chevron’s M12,M13&M14 Projects 6” , 8” and 12” Slide 19/20

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SPC Brushgrade

Brush Grade Application

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Pre-measured kits

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Mix to achieve uniform color

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4 minutes by hand

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or 1 min. with drill stirrer SPC

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SPC Brushgrade

Application by Roller

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SPC Brushgrade

Brush Application

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Slide 20/20

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