Coating Presentation TP Bangkok - 23 Jan 2014

22/01/2014
1
Coating Overview
Audrey BERGERON
Bangkok J anuary 23
rd
2014
1
2
About the instructor
Title Coating specialist
Region / Entity Asia Pacific / TPS
Business segment Subsea Onshore Offshore
Education Meng./ Chemical Engineering
Contact abergeron@technip.com
22/01/2014
2
3
About Technip Singapore
Shallow to deep water
(3000 m)
S-laying
Rigidd pipes (4 to 60 )
Piggy-backed pipeline
installation
Pipe-in-pipe, CRA
OFFSHORE
PIPELINE
INSTALLATION
Lifting up to 1200 tons
Installation of
platform, subsea
structures, skids,
modules, etc.
OFFSHORE
STRUCTURE
INSTALLATION,
HEAVY LIFTING
4
Spools
Risers
Buckle Initiator Structures
PLEM
Manifolds
Skids
Crossing Structures
Installation Aids
FABRICATION
SERVICES
Full-time divers
Saturation to 300m
Pipelines, platform, SCM
de-commissioning /
removal
DIVING, IMR,
DECOMMIS-
SIONING
22/01/2014
3
5
G1201 - 3
rd
Generation DP Pipelay Vessel incl. 1200MT Pedestal Crane
Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification process and requirement
6
22/01/2014
4
7
3LPP/PE:
CS:
CUI:
CWC:
FBE:
FJC:
GSPU:
HP/HT:
HSS:
MLPP/PE:
PE:
PFP:
PP:
PU:
SPU:
SS:
TSA:
Three Layer PolyPropylene / PolyEthylene
Carbon Steel
Corrosion Under Insulation
Concrete Weight Coating
Fusion-Bonded Epoxy
Field J oint Coating
Glass Syntactic PolyUrethane
High Pressure/ High Temperature
Heat Shrinkable Sleeves
Multi-Layer PolyPropylene / PolyEthylene
PolyEthylene
Passive Fire Protection
PolyPropylene
PolyUrethane
Syntactic PolyUrethane
Stainless Steel
Thermal Spray Aluminum
Abbreviations
8
Summary
1. HSE moment
8
22/01/2014
5
1. HSE moment
Find the difference:
9
1. HSE moment
10
22/01/2014
6
11
Summary
1. HSE moment
11
Why do we need coating? What kind of coating?
Corrosion protection
Anti corrosion paint
Passive Fire Protection (PFP)
Intumescent Epoxy
Cementitious coating
Fouling release
Anti fouling paint
12
22/01/2014
7
Mechanical protection
Polyolefin coatings
Negative buoyancy
Concrete weight coating
Prevent CUI
(corrosion under insulation)
Metallizing
(Thermal spray aluminum)
13
Anti slip
Paint + natural aggregate
Insulation
PU foam
Aesthetic aspect
Polyurethane, Acrylic
14
22/01/2014
8
15
Summary
1. HSE moment
15
16
3. Introduction to corrosion
According to NACE: Corrosion is a deterioration of a material because
of reaction with its environment.
Liquid water is in contact with metal
AND
corrosive agent is present in the water
CORROSION =
22/01/2014
9
17
Corrosion impact:
o Safety: unsafe corroded structures / equipment
o Cost: For the US, the annual cost of corrosion worldwide is
around 3% of GDP (US$ 250 Billion)
18
Different types of corrosion
Uniform corrosion
o Uniform loss of mass for external surfaces. Concerns
mainly carbon steel and cast iron.
o Solution: corrosion allowance (3 to 6 mm), painting,
cathodic protection.
Galvanic corrosion
o Creation of an electric current between 2 materials with
different potential.
o Common cases: aluminum/stainless steel, carbon
steel/stainless steel.
o Solution: isolation joints, cathodic protection, coating
Erosion corrosion
o Erosion (abrasion): removal of metal by mechanical
action of liquids (or solids). Erosion-corrosion :removal of
corrosion products by mechanical action of liquids ( or
solids).
o Solution: improve flow by design of the piece, change for
better material, corrosion allowance
22/01/2014
10
19
Different types of corrosion
Pitting corrosion
o High chloride concentration leads to passivation layer
breakdown.
o Affects stainless steel, aluminum, titanium
o Solution: increase molybdenum content in SS (CRA),
coating
Chloride stress corrosion cracking
o Combined action of seawater and mechanical stress
o 316 Austenitic stainless steels subject to CSCC if
chloride concentration >50 ppm and temperature >
50
o Solution: coating, change material grade (316 SS to
22Cr or 25Cr)
20
Corrosion
prevention
Corrosion
prevention
Design
Coating
Chemical
treatment
Cathodic
protection
Material
selection
22/01/2014
11
21
How to prevent corrosion?
Design: avoid water retention, moisture / salts entrapment
Inhibitors: chemical added into a fluid to decrease corrosion rate
Material selection. Examples:
o SS 304L very sensitive to CSCC in offshore environment. SS 316L, 22Cr
duplex or Inconel 625 are preferred.
o Carbon Steel can be selected for offshore structures, provided it is protected
by coating and cathodic protection.
Cathodic protection: protection of the surface by another sacrificial
metal (Zn, Al, Mg, ) who has a more electronegative potential.
Protective coating
22
Summary
1. HSE moment
22
22/01/2014
12
Clean the surface from contaminant
Create roughness for coating adhesion.
objectives
Surface preparation: The key step to the coating success
dust grease
mill scale
oil
Soluble
salts
Former
coating
contaminants
Long term stability
to the coating
Did you know?
75% of premature coating failures are caused by
inadequate or improper surface preparation
23
Substrate: carbon steel, stainless steel, Aluminum, galvanized
steel
Degree of cleanliness required (paint system type and thickness)
Geometry of the piece (area difficult to access with machines)
Place where surface is prepared (on site, applicators plant)
Selection of the method depends on:
24
22/01/2014
13
1. Prior to commencement
check for fabrication or welding defaults: rough
edges, cuts and welds shall be rounded to a
2mm radius to improve coating coverage and
adhesion on the surface.
remove weld spatters.
2. Solvent cleaning.
Degrease and remove oil, grease, soluble contaminants with solvent
cleaning (fresh water, emulsion cleaners, detergents, organic solvents,
petroleum based solvents, alkaline cleaners). Does not remove
Chlorides, mill scale or other inorganic materials.
3. Abrasive blasting or other method
Remove chlorides and sulfates, create desired surface profile for
primer adhesion, create a uniformaspect.
25
steel shot or grit (carbon steel
surfaces),
aluminum oxide or garnet
sand (stainless steel or carbon
steel surfaces).
Projection of abrasive
particles to remove rust
and other contaminant and
create a rough surface
Abrasive blast cleaning
26
22/01/2014
14
Abrasive blasting
equipment
27
Surface preparation: other methods
Power tool cleaning (hand or
mechanical). Example: rotary wire brush.
Water jetting. Only to remove previous
coating, does not create roughness.
Pickling. Dipping of steel in an
acid bath
28
22/01/2014
15
Substrate Type of system Cleanliness (ISO 8501-1 or
SSPC)
Profile
surface
(ISO 8503)
Carbon steel external
surfaces
Typical paint system
with DFT >200m
Sa 2
eq. to SSPC SP10 50-75 m

Carbon steel internal
surfaces
Internal coating
(lining)
Sa 3 eq. to SSPC SP5 or Sa 2
eq. to SSPC SP10

50-75 m
Stainless steel,
Galvanized steel
Typical paint system Sweep blasting eq. to SSPC SP7 20-40 m
- Carbon steel
- Stainless steel
TSA - Sa 3 eq. to SSPC SP5
- Sweep blasting eq. to SSPC SP7
70-120 m
29
30
Summary
1. HSE moment
30
22/01/2014
16
5.1 Corrosion protection
coatings
31
Definition
Application
Selection
Protection mode
Specification
32
5.1. Corrosion protection coatings - Definition
PAINT
=A+B
Binder
(polymer)
Pigments
+fillers
Solvent
Additives
Reactive
+solvent
Component A
Component B
22/01/2014
17
33
5.1. Corrosion protection coatings - Definition
2 component- thermoset coatings
Excellent adhesion, chemical and water resistance
Shall be top-coated by UV-resistant topcoat
EPOXY
2 component
Resistant to UV, good gloss and color retention
POLYURETHANE
2 component min. zinc content 85%
Very high substrate adhesion good chemical resistance
Max thickness 80 m, subject to mud-cracking -careful with
repairs
INORGANIC ZINC
Cure at ambient temp. or with help of heat
For heat resistance up to 600 , or foul release
SILICONES
2 component coatings
Very good for immersion service
Suitable up to 230
PHENOLIC
EPOXIES
2 component used as linings very resistant to chemicals and
temp.
High thickness (2 x 1000 m)
VINYL ESTER
2 component short pot life (45 min at 20 ) - Glass flake reinforced
Excellent resistance to abrasion, water and moisture good for salt
and fresh water environment and walkways
POLYESTER
Major paint used for corrosion protection purpose
Spray application : Air spray vs Airless spray
- Spray pattern
easily adjusted
- High quality of
finishes
(automotive)
- Overspray
causes high loss of
coating
- Add solvent to
improve
atomization but
leads to low
thickness
Air spray
Airless spray
- Less overspray
- Heavier film built
- Better production
rates
-Little control of
coating quantity
- Speed makes it
difficult for small
pieces
5.1. Corrosion protection coatings Application
34
22/01/2014
18
Brush application
Brush is only for
o Small areas not easily
accessible by spray
o Repairs and touch-up
o Stripe coats, corner, edges,
welds, bolting, flanges
o When environmental conditions
prohibit the use of spray
Roller application
Do not use roller unless specific client approval
- Helps coating to have
a good adhesion on
substrate (for primers
and underwater
coatings)
- Good penetration into
surfaces that cannot be
properly cleaned
- Slow application (can
be an advantage in
some cases)
- Low DFT achieved
5.1. Corrosion protection coatings Application
35
36 Steel
Finish coat (polyurethane)
Intermediate coat (Epoxy based)
Zinc rich primer (inorganic zinc, zinc
rich epoxy)
Primer with inibitors (zinc phosphate)
1 Barrier
2 Galvanic
3 Inhibition
Impermeability to water vapor, oxygen and salts
(Chloride), thick film, electric resistance
pigmented epoxies (high solid content, mica
flakes)
1. Barrier
effect
Primer contains a metallic pigment with a more
electronegative potential inorganic zinc
silicates and zinc rich organic primers (epoxies)
2. Galvanic
effect
Isolation of the substrate surface by addition of a
metallic compound chemically bonded to the
surface zinc phosphate pigment
3. Inhibition
5.1. Corrosion protection coatings Protection
mode
22/01/2014
19
Selection of coating depends on:
Atmospheric corrosivityof environment (marine C5M,
industrial C5I, high C4, )
Substrate (carbon steel, stainless steel, galvanized
steel, aluminum, CRA, )
Equipment operating temperature
Durability of the coating / installation
1
2
3
4
5.1. Corrosion protection coatings - Selection
37
5.1. Corrosion protection coatings Specification
Frequently encountered coating systems Onshore offshore systems
Substrate System DFT (m)
CS operating below 120
(Uninsulated)
Zinc rich primer (epoxy or inorganic zinc)
Epoxy high build
Polyurethane topcoat
50-75
150-200
50
CS operating between 120and 450
(Uninsulated)
Inorganic zinc primer
Al pigmented silicone
50-75
25
25
SS operating below 120
(Uninsulated)
Epoxy primer, zinc free
Epoxy high build
Polyurethane topcoat
50
150-200
50
SS operating between 120and 600
(Uninsulated)
25
25
Insulated CS and SS operating below 200
Epoxy phenolic
Epoxy phenolic
100
100
Insulated CS and SS operating between
200 and 600
TSA
Sealer (silicone)
250
40
Bulk items (any substrate, any
temperature, valves, piping, )
Universal coating, inorganic copolymer
(compatible with PU topcoat for color
marking)
As per
manufacturer
38
22/01/2014
20
Frequently encountered coating systems Onshore offshore systems
Internal coatings (Carbon steel surfaces)
Application System DFT (m)
Potable water below 60 Solvent free epoxy
Solvent free epoxy
300
300
Crude oil, diesel, condensate, below 60 :
bottom up to 1m +roof and upper 1m of wall
Abrasion resistant epoxy
Abrasion resistant epoxy
150-180
150-180
methanol, MEG below 80 Inorganic zinc primer 60
Process vessel below 120 Solvent free epoxy Novolac 300-600
Galvanized surfaces
Galvanized steel operating below 120 Epoxy primer, zinc free
High build epoxy
Polyurethane
50
100
50
39
Frequently encountered coating systems Subsea systems
CS and SS in splash zone
operating below 100
Abrasion resistant epoxy (glass flakes)
Abrasion resistant epoxy (glass flakes)
300
300
CS and SS immersed
operating below 100
Abrasion resistant epoxy or high build epoxy
Abrasion resistant epoxy or high build epoxy
175
175
Antiskid surfaces
Carbon steel Epoxy primer
Ultra high build epoxy +non-skid aggregates
Polyurethane
50
600-3000
60
Note: 1. Surface friction coefficient may need to be indicated.
2. Use of Aluminum oxide (and other non-ferrous irregular surfaces) is preferred
40
22/01/2014
21
41
Checks and Quality Controls
Before painting application
o Operator and inspector Qualification certificates
o Instrumentation device calibration certificates
Surface preparation
o Environmental conditions (Dew Point, surface TC and Ambient TC measurement),
o Abrasive contamination,
o Grade of cleanliness +surface roughness,
o Chloride content +dust level
Painting application
o Wet and dry film thickness,
o Visual inspection
After painting application
o Curing of inorganic zinc,
o Adhesion test
o Pinhole detection (only for immersed, underground and internal coatings)
5.2 Specific coatings
42
Metallizing
Passive Fire Protection
Fouling-release coatings
22/01/2014
22
Thermal SprayAluminum
Spraying of moltenAluminumwire byflame sprayor arc spray
Goodfor immersionandCUI prevention.
AppliedonCarbonsteel or Stainless steel operatingup to 600
- Excellent corrosion
protection properties
- Excellent resistance to
mechanical damages
- Very high durability (up
to 50 years)
- Zero VOC.
- Porous: need to apply a
sealer on top (epoxy or
silicone).
- Cost effective process
- HSE rules must be strictly
followed.
- Critical surface
preparation: high degree
of cleanliness required
5.2 Specific coatings: Metallizing (TSA)
43
TSA coating systems
CS and SS operating below
120
TSA
Epoxy sealer compatible with TSA
250
40
CS and SS operating above
120
TSA
Silicone sealer compatible with TSA
250
40
Application examples
Bulk valves (all temperatures, CS and SS)
Offshore or immersed structures
Flare top
TSA applicators
Norimax
WASCO
MTM Metalization
44
22/01/2014
23
Splitter column Turret component
45
5.2 Specific coatings: Metallizing
Other Thermal Spray Coatings:
Zinc
Al-Zn
Stainless steel
Inconel
Copper Nickel
Monel
Hastelloy
Harder material Higher operating temperature gun
46
22/01/2014
24
Steel begins to lose strength as its temperature rises in a fire structural collapse.
PFP is designed to protect structures supporting high risk and valuable equipment.
Objective: prevent the substrate to rise in temperature during a fire to avoid steel to collapse:
o J et fire
o Hydrocarbon fire
o Cellulosic fire
0
200
400
600
800
1000
1200
1400
0 30 60 90 120 150 180
T
e
m
p
e
r
a
t
u
r
e

C
Time (minutes)
Fire Curves
Cellulosic
Hydrocarbon
Jet Fire
Jet fire: Release of hydrocarbon fuel
under pressure through a relatively
small opening such as a crack or hole
high levels of turbulence, erosion
of the PFP coating.
Pool fire: Hydrocarbon fuel burning
under atmospheric pressure.
5.2 Specific coatings: PFP
47
48
- Provides corrosion
protection
- Low DFT for 2h
protection (2-10
mm)
- Low density
- Requires the use
of skilled applicators
- Cost effective
Organic coatings: Intumescent epoxy
They are inert at ambient temperature but react when exposed to
temperatures above about 200C. The reacted coating forms a thick carbon
based char. Appliedwith reinforcement mesh
22/01/2014
25
49
Spray application equipment
Source: PPG
Typical Plural Component
Pump
Typical plural component
mixing block and spray gun
Thickness of PFP is determined by:
o Size, shape of steel section to protect (beams, hollow section)
o Critical failure temperature
o Duration of protection needed
Calculation of DFT with Hp/A value.

Low A
High Hp
Fast Heati ng
Low Hp
Hi gh A
Slow Heati ng
Source: PPG
Hp =heated perimeter
exposed to fire
A =cross-section area of steel
element
The higher Hp/A value, the higher PFP thickness will be required.
50
22/01/2014
26
51
52
- Cheap, easy to install
and repair
- Hard and durable
- Heavy
- Thickness around 25 mm
for a 2h fire protection
- Poor flexibility
- Risk of hidden corrosion in
reinforcement by water
ingress
Inorganic coatings: Cementitious
Lightweight with nominal density around 500 kg/m
3
.
Must be topcoated with a high water vapor permeability
coating. Must also be applied with mesh reinforcement.
22/01/2014
27
53
PFP systems
Fireproofed carbon steel
surfaces
Zinc rich epoxy or inorganic zinc silicate
Intumescent PFP epoxy
Polyurethane
50
As calculated
50
Fireproofed stainless steel
surfaces
Zinc free epoxy primer
Intumescent PFP epoxy
Polyurethane
50
As calculated
50
Fireproofed carbon steel
surfaces
Zinc rich epoxy or inorganic zinc silicate
High build epoxy
Cementitious PFP
50
150
As calculated
Fireproofed stainless steel
surfaces
Zinc free epoxy primer
High build epoxy
Cementitious PFP
50
150
As calculated
Objective: prevent formation of biofoulingon vessels and
structures (mussels, barnacles, algae, etc.).
2 mechanisms: fouling release coatings and antifouling
coatings (biocide release).
Fouling release coatings:
- Silicones
- Fluoro-polymer
Prevent attachment of micro-organisms on the structure
by creating a smooth finish with low surface tension.
5.2 Specific coatings: Fouling release coatings
Source: PPG
TBT-based coatings are prohibited
54
22/01/2014
28
55
5.2 Specific coatings: Fouling release coatings
Fouling release system
Any (riser, structure, hull, etc.) Epoxy primer
Foul release coat (1 or 2 coats)
Finish coat
50-100
200-600
100-150
Note: Fouling release systems depend on each coating manufacturer; all products of the system should
be compatible with each other. The proposed system is for example only.
56
5.2 Specific coatings: Shop primers
Thin film inorganic zinc primer applied on applicators plant
for more accurate control of application process.
Typical application: steel plates for tank storage.
Purpose: Protect against corrosion and environment during
transport and before erection.
Primer is applied automatically or not at 15-30 m.
Source: TOTAL GTS presentation
22/01/2014
29
57
58
22/01/2014
30
59
Summary
1. HSE moment
59
6.1 Pipe coating
60
Selection
Properties
Standards
Systems
Subcontractors
Futures challlenges
22/01/2014
31
6.1. Pipe coating - Selection
Pipeline protection =Combination of
Adequate protective coating,
Supplementary cathodic protection
Selection of the coating system depends on:
o Pipe material characteristics
o Service / design temperature
o Pipeline design thermal profile
o Maximum water depth
o Specific properties requirement (cathodic disbondment, elongation, strength, )
o Laying method
61
Properties for Corrosion protection coating
Main properties
o Strong adhesion to the pipe
o Corrosion properties
o Strong resistance to cathodic
disbondment
o Durability for design life of the
pipe
o Good mechanical strength
6.1. Pipe coating - Properties
62
22/01/2014
32
Properties for Thermal insulation coating
Pipes are insulated to prevent hydrate formation, waxing and to satisfy separator
arrival temperature.
Main properties
o Thermal conductivity
o Density
o Adhesion to base material
Properties for Weight coating
Main properties
o Density
o Compressive strength
63
Types of pipe coatings
o Fusion Bonded Epoxy (FBE), Liquid epoxy
o 3-layer Polyethylene (3LPE) / Polypropylene (3LPP)
o MLPP Foam / syntactic
o GSPU, SPU
o Concrete Weight Coating (CWC)
Corrosion
protection
Flow
assurance
Negative
buoyancy
64
22/01/2014
33
65
International standards in pipe coating: ISO 21809
3LPE/PP: ISO 21809 - 1
FBE: ISO 21809 - 2
CWC: ISO 21809 - 5
ISO 21809 replaces DIN (German), NF (French), CSA (Canadian)
Other standards or specifications
AWWA (American Water Works Association): AWWA C213-07 (FBE)
DNV-RP-F106 (FBE, 3LPP, 3LPE)
NACE RP0394-2002 (FBE)
DNV-OS-F101 (CWC)
NO STANDARD FOR INSULATION COATING
6.1. Pipe coating - Standards
Liquid coating
- Mainly used for buried pipe operating at elevated temperature, where 3LPE and 3LPP cannot be
considered.
- Generally a high built coating applied by airless spray with DFT up to 3000 m.
- Maximum service temperature can go up to 200, depending on the type of resin (epoxy, epoxy
novolac, phenolic epoxy, vinyl ester).
- Can be reinforced with glass flakes to improve moisture and mechanical resistance.
- Can be applied as an internal lining to protect against corrosive fluid. In this case, thickness up to
300 m.
6.1. Pipe coating - Systems
66
22/01/2014
34
67
Fusion Bonded Epoxy (FBE)
Coating system description Single layer fusion bonded epoxy
Type of protection Corrosion protection
Typical coating thickness 350-500 m
Design temperature 90
Water depth limit Unlimited
Major characteristics - Excellent long term corrosion resistance to steel,
- Cathodic disbondment resistance (reduce cost of
cathodic protection)
- Good chemical resistance.
68
FBE coating process
Source: Bredero Shaw
22/01/2014
35
69
Three Layer Polypropylene (3LPP)
Coating system description FBE +PP Adhesive +Solid PP
Typical coating thickness 2- 4.5 mm
Design temperature 110 (up to 130 with high temperature FBE)
Major characteristics - High film thickness
- Good PP flexibility mechanical protection to the
pipe.
- Good impact strength
70
3LPP coating process
22/01/2014
36
71
Three Layer Polyethylene (3LPE)
Coating system
description
FBE +PE Adhesive +Solid PE
Typical coating
thickness
2- 4.5 mm
Major characteristics - Cheaper than 3LPP, but does not have as good mechanical
characteristics as 3LPP.
3LPE process is the same as 3LPP
72
Multilayer PP (MLPP) Foam MLPP
Coating system
description
FBE +PP Adhesive +(Solid PP) +PP Foam +Solid PP
Type of protection Corrosion protection +Mechanical protection +Thermal
insulation
Typical coating
thickness
Depends on thermal requirements
Water depth limit 600 m
Major characteristics K-value around 0.17 W/m.K, density 600-800 kg/m
3
1. FBE
2. 2. PP adhesive
3. Solid PP
4. PP foam
5. Outer PP shield
22/01/2014
37
73
Multilayer (MLPP) Glass syntactic MLPP
Coating system
description
FBE +PP Adhesive +(Solid PP) +GSPP +Solid PP
Type of protection Corrosion protection +Mechanical protection +Thermal
insulation
Typical coating
thickness
Major characteristics K-value around 0.16 W/m.K, density 650-700 kg/m
3
Hydrostatic pressure resistance is reinforced by glass
microspheres added into the PP matrix.
74
Syntactic PU - polymer syntactic (sPU)
Coating system
description
FBE +sPU
Type of protection Corrosion protection +Thermal insulation
Typical coating
thickness
Major characteristics - K-value around 0.12 W/m.K, density 600-700 kg/m
3
- Thin wall +low polymer mechanical properties decrease
compression resistance of the foam.
22/01/2014
38
75
Syntactic PU - Glass syntactic (GSPU)
Coating system
description
FBE +GSPU
Type of protection Corrosion protection +Thermal insulation
Typical coating
thickness
Major characteristics - K-value around 0.16 W/m.K, density 800 kg/m
3
- Hydrostatic pressure resistance reinforced by glass
microspheres added into the PU matrix.
- Grade of glass influences the collapse pressure and
theoretical maximum water depth.
76
Injection moulding PU process
22/01/2014
39
Concrete Weight Coating (CWC)
Purpose: provide negative buoyancy
and mechanical protection to the pipe.
Mixture of cement, iron ore and wire wrap
Main properties:
o Density (1900-3700 kg/m
3
): varies iron ore
quantity.
o Compressive strength: depends on cement
and water content.
o Thickness: depends on pipe diameter.
o Water absorption: ISO standard recommend
a maximum of 5% vol.
Reinforcement
o Rigid preformed cages
o Wire mesh fabric
77
78
Concrete Weight coating
Type of protection Negative buoyancy +Mechanical protection
Typical coating thickness Depends on pipe diameter
Design temperature N/A
Major characteristics Density (1900-3700 kg/m3): varies with iron ore quantity.
22/01/2014
40
79
Impingement method
80
Wrap-on method
22/01/2014
41
81
Elastomer coatings (Neoprene, EPDM, butyl rubber, etc.)
Mainly used for splash
zone protection
Be careful of chamfering
can cause failure of
the bond
Source: Yadana riser F. Duesso
82
APAC
Bredero Shaw
WASCO Energy
Americas
Bredero Shaw
CRC Evans
EMEA
Bredero Shaw
Eupec
Socotherm
Tenaris
6.1. Pipe coating - Subcontractors
22/01/2014
42
83
Operators - Gap analysis with ISO 21809-1: Microsoft Excel
Worksheet
6.1. Pipe coating - Operators
84
Microsoft Excel
Worksheet
Operators - Gap analysis with ISO 21809-1:
ENI =based on ISO
TOTAL SHELL and PETRONAS: more stringent on different tests
6.1. Pipe coating - Operators
22/01/2014
43
85
HT/HP
- R&D programm in different pipe coating applicators and manufacturers
to test different materials like glass syntactic silicones
Arctic
- Bredero Shaw involved in J IP for new material in arctic conditions
Flexible weight coating
Ultra deep waters thermal insulation
6.1. Pipe coating Future challenges
6.2 Field joint coating
86
Definition
Selection
Standards
Systems
S-Lay installation
Subcontractors
22/01/2014
44
Field joint definition: Part of pipe left barefor welding prior to installation
Purpose of FJ C: anticorrosion or thermal insulation.
Field joint is the weak point in a pipe coating system.
Welded joints are highly sensitive to corrosion.
pipe
3LPP
coating
Cut back length shall be predetermined and mainly
depends on type of FJ C.
Properties shall be the same as the parent coating
(pipe coating).
FJ C are mostly applied in field application shall
be easy, fast and reliable.
FJ C =FBE, HSS, Polyolefin tapes, IMPP, IMPU, PE, PP, liquid resins
FJC
6.2. Field joint coatings - Definition
87
density, thermal conductivity (if thermal
insulation), coating breakdown factor
Line pipe working conditions
mechanical protection expected
(impact strength, abrasion,
compressive strength, flexibility, water
absorption, curing time)
Pipe laying environment
Parent coating
Parent coating FJC possibilities
FBE FBE
Heat Shrinkable Sleeves
Liquid coating
Polyethylene HSS
Liquid coating
PE flame spray
Polypropylene PP flame spray / tapes
IMPU
IMPP
Liquid coating
Concrete coating HSS +HDPUF
6.2. Field joint coatings - Selection
88
22/01/2014
45
6.2. Field joint coatings - Standards
International standards in field joint coating: ISO 21809
ISO 21809 - 3
Other standards or specifications
DNV-RP-F102
NACE RP0303 - HSS
EN 12068 tapes and HSS
NO STANDARD FOR INSULATION COATING
89
FBE
Coating system
description
FBE
Typical coating
thickness
350-500 m
Design temperature 90, modified epoxies can withstand higher temperatures
Major characteristics - The most widely used coating
- Good chemical resistance
- Very good corrosion protection
- Very common and easy to find subcontractors
- Low impact resistance
Overlap on parent
coating
50 mm
6.2. Field joint coatings - Systems
90
22/01/2014
46
Heat Shrink Sleeves: 2-layers (mastic HSS)
Coating system
description
Mastic adhesive +Polyolefin backing on St3 steel
Typical coating
thickness
2 mm
Design temperature Up to 100 (depending on product: PE or PP)
Major characteristics Manual application with gas torch
Example of HSS system PE:
- KLNN Canusa
- WPC 100M (Berry Plastic)
PP:
- GTS PP 100
Overlap on parent
coating
100 mm
91
Heat Shrink Sleeves: 3-layers (hot-melt HSS)
Coating system
description
Liquid epoxy +hot-melt adhesive +Polyolefin backing on Sa
2
1/2
steel
Typical coating thickness 2 mm
Design temperature >100 (depending on product: PE or PP)
Major characteristics Manual application with gas torch
Example of HSS system PE:
- GTS 80 (Canusa)
- HTLP80 (Berry Plastic)
PP:
- GTS PP (Canusa)
Overlap on parent
coating
100 mm
92
22/01/2014
47
PP tape wrap
Coating system
description
FBE +Adhesive PP +PP tape
Typical coating
thickness
3 mm
Major characteristics - Applied in spiral or wrapped by hand or by wrapster
with the determined overlap (50% recommended).
- Only compatible with 3LPP pipeline coating
Example of tape wrap
system
FBE: Scotchkote 226N (3M)
Adhesive: HifaxEP 510/60m (Basell)
PP tape: HifaxEP 510/60 (Basell)
Overlap on parent
coating
70 mm
93
Flame spray PP
Coating system
description
FBE +Adhesive PP +PP powder
Typical coating
thickness
3 mm
Major characteristics Similar to tape wrap
Overlap on parent
coating
70 mm
94
22/01/2014
48
Injection moulded polyurethane (IMPU)
Coating system
description
FBE +Solid PU or PU primer +Solid PU
Type of protection Corrosion protection +thermal insulation
Typical coating
thickness
+4 mm
Design temperature Up to 130
Example of system FBE: Scotchkote 226N (3M)
Solid PU: Hyperlast FJ 302 (DOW)
Overlap on parent
coating
70 mm
95
Injection moulded polypropylene (IMPP)
Coating system
description
FBE +PP adhesive +MouldedPP
Type of protection Corrosion protection +thermal insulation
Typical coating
thickness
4-10 mm
Design temperature Up to 110 (130 with high temp. FBE)
Example of system FBE: Scotchkote 226N (3M)
Adhesive: BB 127E (Borealis) or HifaxEP5 10/60 (Basell)
Solid PP: EA 165E (Borealis) or CA 197 (Basell)
Overlap on parent
coating
70 mm
96
22/01/2014
49
6.2. Field joint coatings S-lay installation
S-lay:
Firing line is horizontal
Pipeline is support by a stinger to avoid high bending stress.
97
6.2. Field joint coatings S-lay installation
98
22/01/2014
50
6.2. Field joint coatings Subcontractors
Bredero
Shaw
Canusa CPS
PIH
OJ S
FBE, IMPU, IMPP
HSS, liquid epoxy, tape wrap
FBE, flame spray PP & PE, HSS, IMPU, IMPP, PU
foam infill
HDPUF, HSS
99
10
0
Summary
1. HSE moment
100
22/01/2014
51
7. Coating qualification
101
Painting
Pipe and field joint coatings
7. Coating qualification - Painting
Norsok M501 rev.6
CS surfaces operating <120
Ballast water tanks/ seawater filled
vessels
Anti-slip for walkways, escape
routes, lay down areas
Intumescent epoxy +cementitious
PFP
Splash zone and immersed surfaces
1
3B
4
5
7
102
22/01/2014
52
7. Coating qualification - Painting
Norsok M501 rev.6
Test (acc. to ISO 20340) Assessment method Acceptance criteria
Seawater immersion
- 4200h
- For system 3B, 7A, 7B, 7C and 1
when used in tidal or splash zone
ISO 4624- pull-off test
ISO 4628-3,4,5,6
5MPa
No defect
Ageing
- 4200h
- For system 1, 3B, 4, 5A, 5B, 7A
ISO 4624- pull-off test
ISO 4628
5MPa
No defect
Cathodic disbonding
- 4 weeks
- For system 3B, 7A, 7B, 7C, 1 when
used in splash or tidal zone
ISO 15711 Max. 20 mm
103
Shell systems that need to be qualified as per DEP
TSA (DEP 30.48.40.31)
DFT checking
Ballast water tanks/ seawater filled
vessels
Anti-slip for walkways, escape
routes, lay down areas
Intumescent epoxy +cementitious
PFP
Splash zone and immersed surfaces
104
22/01/2014
53
Test Assessment
method
Measurement Acceptance criteria
Visual examination
ISO 14918 100% surface Uniform appearance, no defect
or blisters
Coating thickness
ISO 2808 Min. 5 Min. 250 m
Coating adhesion
ISO 4624 Min. 3 >7 MPa
Overall quality
Bend test (DEP) Min. 3 Minor cracks
Sealer
Visual inspection 100% surface No open pores at the surface
Shell systems that need to be qualified as per DEP - TSA
Check every step of the ITP.
The process leads to qualificationof:
o operators (blasters, sprayers),
o equipment,
o subcontractor coatingprocedure.
Example of PQT done for Prelude FLNG
Microsoft Word
7 - 2003 Documen
Adobe Acrobat
Document
105
7. Coating qualification Pipe & FJC
Qualification of 3LPE and 3LPP as per ISO 21809-1: Adobe Acrobat
Document
Properties 3LPE 3LPP
Continuity Zero defect Zero defect
Impact strength >7 J /mm >10 J /mm
Indentation at 23
Indentation at max temp.
<0.2 mm
<0.4 mm
<0.1 mm
<0.4 mm
Elongation at break >400 % >400 %
Peel strength at 23
Peel strength at max. Temp.
>15 N/mm
>3 N/mm
>25 N/mm
>4 N/mm
Cathodic disbondment 23 , 28 d
Cathodic disbondment 65 , 24 h
Cathodic disbondment max. temp., 28 d
<7 mm
<7 mm
<15 mm
<7 mm
<7 mm
<15 mm
Hot water immersion test (80 , 48h) Average <2 mm and
max. <3 mm
Average <2 mm and
max. <3 mm
Flexibilitty No cracking at 2 angle No cracking at 2 angle
Curing of epoxy As per manufacturer As per manufacturer
106
22/01/2014
54
Sources
Bibliography:
[1] NACE CIP 1 Manual
[2] Encyclopedie de la peinture: formuler, fabriquer, appliquer, tome 1
[3] ISO 8501-1
[4] ISO 21809-1 to 5
[5] PPG PFP and Fouling release coating presentation
Websites:
[6] www.nace.com
[7] http://www.corrosion-doctors.org/Seawater/Fouling.htm
[8] www.brederoshaw.com
107
Thank you
108

Coating Presentation TP Bangkok - 23 Jan 2014

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Coating Presentation TP Bangkok - 23 Jan 2014

Diunggah oleh

Hak Cipta:

Format Tersedia

22/01/2014

eq. to SSPC SP10 50-75 m

eq. to SSPC SP10

Anda mungkin juga menyukai