1. “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

2. 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 .

3. 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

4. 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

5. 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

6. 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

7. 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 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)

8. 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
SP2888
Soak at 75°C - 28 days

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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
                    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

16. Transcanada Pipelines

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

19. Cost Savings of approx 29.11%
Bangkok Ring Mains ( Soi Noi Project )
30"x 18.34WT Pipe x metres
Bangkok Ring Mains ( Soi Noi Project )
30"x 18.34WT Pipe x metres
Bangkok Ring Mains ( Soi Noi Project )
30"x 18.34WT Pipe x metres
Bangkok Ring Mains ( Soi Noi Project )
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)
37840 metres 2.5mm $ mil $38.23
31280 metres 3.5mm $ mil $40.23
Metres 3.5mm $ mil $40.23
Bare Pipe receiving $ $0
At Batam/Kuantan
Coated Pipe Loadout $ $0
Coated Pipe Freight $ $0
Total Cost $ $118.68
Cost Savings of approx 29.11%

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

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

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

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

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

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

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

27. 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

28. SPC Brushgrade
Application by Roller

29. SPC Brushgrade
Brush Application

30. Slide 20/20