“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

Typically several different types of coatings are used in a 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 .

Corrosion protection of the steel Flexibility Abrasion resistance 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 : 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

Pipeline Coatings 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 Increasing Technology - Operating Temperature Special

Review of Pipeline coatings used in Australia : 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: -1st Layer – FBE -2nd Layer – Tie adhesive -3rd Layer –PE jacket

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

FBE Performance Standards: 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)

Hot Water Soak Adhesion Slide 6/20 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: SP2888 cannot be removed even after exposure to 28 days @75C SP2888 Soak at 75°C - 28 days

Bend Flexibility Requirements of FBE Stds.: SP2888 LPE Results Slide 7/20 Requirements of FBE Stds.: NACE (at -18°C): > 2.5 degrees/pipe diam. 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 Note: AS3862 requirement of 3.75 degrees for Field Pipe bending is not relevant

Impact Resistance Requirements of FBE Stds. at 23°C Slide 8/20 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

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

Yes No *No **No Application Yellow Jacket( 2 layer HDPE) coating Slide 10/20 Application Coating Corrosion Protection HDD application Bends and fittings ? Field Joint coating? Remote application Yellow Jacket( 2 layer HDPE) coating Yes No FBE Powder coating *No **No 3LPE Liquid Polymer Epoxy *FBE as a single coating is not suitable for HDD applications ** FBE on the joints is expensive and not user friendly

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

Latest developments in LPE technology. 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

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

Transcanada Pipelines

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

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

Cost Savings of approx 29.11% Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x 69630 metres Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x 69630 metres Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x 69630 metres Bangkok Ring Mains ( Soi Noi Project ) 30"x 18.34WT Pipe x 69630 metres Comparison of coating Pipe in Thailand with SP2888 and 3LPE in Batam or Kuantan- Bangkok Ring Mains Soi Noi Project -30” x 18.34 Wt Pipe x 69630 metres Coating Batam /Kuantan Thailand 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 Metres 3.5mm $50.93 25mil $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 $167.43 $118.68 Cost Savings of approx 29.11%

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

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

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

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

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

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

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

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

SPC Brushgrade Application by Roller

SPC Brushgrade Brush Application

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