Coating Failure at a Gas Compressor Facility Robert Lanterman JPCL Webinar 15 November 2018

Topics Discuss typical process of a failure investigation. Examine the details of an F-Files failure investigation article to be published in the December edition of JPCL.

Typical Failure Analysis Steps 1. Background Information 2. Site Visit 3. Laboratory Investigation 4. Final Report

Background Information Coating Specification Construction Sequence 3. Painting History 4. Inspection Documents

Site Visit 1. Visual Examination 2. Pattern of Failure 3. Adhesion 4. Substrate Condition 5. Coating Thickness 6. Sample Removal 7. Photographs 8. Additional Tests

Laboratory Investigation 1. Microscopic Examination 2. FTIR 3. SEM/EDS 4. Mix Ratio

Final Report 1. Relevant Background Information 2. Findings of Site Visit 3. Laboratory Findings 4. Conclusions 5. Recommendations

Failure Location Natural gas compressor facility, new construction. Large diameter piping to have been shop blasted and painted. Small diameter piping to have been blasted and painted in field.

Failure Background 1. Coating Specification Surface Preparation Coating Materials 2. New Construction a. Shop Painting b. Field Painting 3. No Inspection Documents

Visual Large diameter piping was in generally good condition. Areas of mechanical damage during installation.

Visual Small diameter piping was in generally fair to poor condition. Painted over OEM coating.

Coating Thickness Item Spec Field Tooke Large Diameter Piping 9 mils 1 coat tan / white primer with tan top coat Small Diameter Piping 2-3 mils 1 coat tan Specification required 3 coats

Adhesion Large diameter piping had generally good adhesion. Small diameter piping had generally fair to poor adhesion.

Substrate Large diameter piping was abrasive blasted. Small diameter piping had OEM coating.

Laboratory Findings 1. Epoxy coatings, no urethane coat 2. Only one layer of coating 3. Abrasive blasting was performed on large diameter pipe section

Conclusions Small diameter piping was not abrasive blasted in the field prior to painting as required by specification. The required 3 coat system was not applied. Typically only one coat was observed. The required urethane top coat was not applied.

Recommendations The large diameter piping should be abrasive blasted and coated. Overcoating could be an option. The small diameter piping should be abrasive blasted and coated in accordance with the specification.