COATING OF UNDERGROUND STEEL PIPE IS USED IN CONJUNCTION WITH FACTORY COATED PIPE, SUCH AS, BUT NOT LIMITED TO: TAPE, COAL TAR ENAMEL, EXTRUDED POLYETHYLENE, OR FUSION BONDED EPOXY. THE PROCEDURES OUTLINED COVER THE FOLLOWING AREAS: 1> WELDED JOINTS 2>
COATING OF UNDERGROUND STEEL PIPE IS USED IN CONJUNCTION WITH FACTORY COATED PIPE, SUCH AS, BUT NOT LIMITED TO: TAPE, COAL TAR ENAMEL, EXTRUDED POLYETHYLENE, OR FUSION BONDED EPOXY. THE PROCEDURES OUTLINED COVER THE FOLLOWING AREAS: 1> WELDED JOINTS 2>
COATING OF UNDERGROUND STEEL PIPE IS USED IN CONJUNCTION WITH FACTORY COATED PIPE, SUCH AS, BUT NOT LIMITED TO: TAPE, COAL TAR ENAMEL, EXTRUDED POLYETHYLENE, OR FUSION BONDED EPOXY. THE PROCEDURES OUTLINED COVER THE FOLLOWING AREAS: 1> WELDED JOINTS 2>
COATING OF UNDERGROUND STEEL PIPE IS USED IN CONJUNCTION WITH FACTORY COATED PIPE, SUCH AS, BUT NOT LIMITED TO: TAPE, COAL TAR ENAMEL, EXTRUDED POLYETHYLENE, OR FUSION BONDED EPOXY. THE PROCEDURES OUTLINED COVER THE FOLLOWING AREAS: 1> WELDED JOINTS 2>
FIELD SPECIFICATION FOR THE COATING OF UNDERGROUND STEEL PIPE
1.0 SCOPE OF WORK 1.1 THIS SPECIFICATION IS USED IN CONJUNCTION WITH FACTORY COATED PIPE, SUCH AS, BUT NOT LIMITED TO: TAPE, COAL TAR ENAMEL, EXTRUDED POLYETHYLENE, OR FUSION BONDED EPOXY.. THE PROCEDURES OUTLINED COVER THE FOLLOWING AREAS: 1> WELDED JOINTS 2> BENDS, ELBOWS, TEES 3> FIELD FABRICATED PIPE 4> COMPRESSORAND PUMP STATION PIPING 5> OFF-SHORE JOINTS! PIPING 6> PATCHING OF FACTORY APPLIED COATINGS 7> RECONDITIONING OF INSTALLED PIPELINES 8> PATCHING OF" OVER-THE-DITCH" COATINGS ~ 1.2 IN ADDITION, AN APPENDIX COVER THE METHOD OF COATING IRREGULAR SURFACES SUCH AS BOLT STYLE MECHANICAL COUPLINGS, VALVES, ANODE CONNECTIONS AND OTHER DIFFICULT SURFACES. 2.0 REFERENCES 2.1 THIS WORK SHALL COMPLY WITH THE APPLICABLE PROVISIONS OF THE FOLLOWING: 2.1.1 STEEL STRUCTURES PAINTING COUNCIL (SSPC) 1> SP-1 SOLVENT CLEANING 2> SP-2 HANDTOOL CLEANING 3> SP-3 POWER TOOL CLEANING 2.1.2 OPTIONAL 1> SP-6 COMMERCIAL BLAST CLEANING 2.1.3 ANSIIAWWA C203 --- ~ 3.0 MATERIALS 3.1 TC OMNIPRIME 3.2 TAPECOAT20 (58 MILS) 3.3 TAPECOATTERRASHIELD(1/2") 4.0 SURFACE PREPARATION 4.1 ALL BARESTEEL SHALLBE FREE OF DUST, DIRT, GREASE, OILANDOTHER FOREIGNMATTER. PRACTICALREMOVALCANBE DONE j3Y EITHER POWER OR HANDWIRE BRUSHING. GREASE ANDOILCAN BE REMOVED BY USE OF A SOLVENTTHATLEAVESNO OILYOR DUSTY FILMREMAININGON THE STEEL SURFACE. 4.2 WELDS SHALL BE CLEANED OF ALL WELDING SLAG, SPLATTER, AND SCALE. SHARP EDGES OR BURRS SHALL BE REMOVEDBY GRINDING OR FILING. 4.3 THE WELD SHALL BE NO MORE THAN "WARM TO THE TOUCH" BEFORE PRIMINGANDTAPING. 4.4. MOISTURE, IF PRESENT, SHALL BE REMOVED BEFORE PRIMINGANDTAPING. 5.0 PRIMER APPLICATION 5.1 AFTER PROPER SURFACE PREPARATION, TC OMNIPRIME SHALL BE STIRRED AND APPLIED SPARINGLY IN A UNIFORM CONTINUOUS METHOD TO THE STEEL SURFACE AND AT LEAST 4" ONTO THE FACTORY COATING, OBTAININGA 1-2 MILDFT. 5.2 APPLICATIONMAY BE BY BRUSH OR ROLLER. 5.3 PRIMER SHALL DRY TO TOUCH BEFORE APPLYING TAfPECOAT 20. I 5.4 NO FOREIGNMATTERSHALLCOME IN CONTACT WITH THE PRIMEDSURFACES PRIOR TO APPLYING TAPECOAT 20. I 5.5 PRIMING APPLICATION SHALL BE LIMITEDTO THAT AMOUNT OFf PIPE THAT CAN BE WRAPPED DURING THE SAME WORKDAY; --- --- OTHERWISE THE STEEL MUST BE REPRIMED. REPRIMING MAY NOT TAKE PLACE UNTIL ALL DUST. DIRT AND OTHER FOREIGN MATTER HAS BEEN REMOVED. IN ADDITION THE SURFACE MUST BE DRY BEFORE REPRIMING. 6.0 TAPE APPLICATION 6.1 TAPE SHALL BE USED TO COAT ALL MISCELLANEOUS PIPE DELIVERED BARE TO THE FIELD SUCH AS, BUT NOT LIMITED TO, BENDS, ELBOWS, CUTOUTS, STRAIGHT RUNS, WELDED JOINTS AND PATCHING OF THE FACTORY APPLIED COATING. 6.2 PROPER APPLICATION OF TAPECOAT 20 IS OBTAINED BY USE OF A PROPANE TORCH WITH A WIDE MOUTH BURNER HEAD. A C68-B WELDIT TORCH IS RECOMMENDED. TAPECOAT 20 IS APPLIED AFTER PROPER SURFACE PREPARATION AND PRIMING BY HEATING THE COATING SIDE -NOT THE FILM SIDE- LIGHTLY WITH THE PROPANE TORCH TO OBTAIN A SOFTENING OF THE PITCH, CAUSING THE TAPE TO HAVE A SMOOTH GLOSSY FINISH. ONLY ENOUGH TAPE SHOULD BE HEATED THAT WILL REMAIN IN A SEMI-LIQUEFIED STATE DURING APPLICATION. APPLICATION PROCEEDS, ALTERNATELY HEATING THE COATING SIDE AND WRAPPING WITH MINIMUM OVERLAP UNTIL THE ENTIRE SURFACE IS COATED. 6.2.1 IF A 55% OVERLAP OF MATERIAL IS REQUIRED (FOR A TOTAL OF APPROXIMATELY 116 MILS - 2 LAYERS) THE APPLICATION PROCEEDS, ALTERNATELY HEATING AND FLASHING WITH THE TORCH TO THE FILM OF THE FIRST LAYER OF TAPE THAT HAS BEEN APPLIED AND WRAPPING WITH A 55% OVERLAP UNTIL THE ENTIRE SURFACE IS COATED. 6.2.2 WHERE THE PLASTIC FILM HAS BEEN FLASHED OUT (REF: 6.2.1) THE FIRST LAYER MAY HAVE RESIDUAL MELTED PLASTIC FILM ON THE SURFACE OF THE TAPE - THIS IS ACCEPTABLE. IN ADDITION, AS THE PLASTIC FILM IS FLASHED OFF, HEAT BUBBLES WILL OCCUR - THIS IS NORMAL. IT IS NOT NECESSARY TO FLASH OFF THE FINAL LAYER OF PLASTIC FILMON THE SECOND LAYER OF TAPE. 6.3 FOR WELDED JOINTS THE TAPING SHALL START AND STOP AT LEAST 4" ONTOTHE FACTORY WRAP. 6.3.1 CARE SHALL BE TAKEN THAT THE TAPE CONFORMS TO THE "CUTBACK" OF THE FACTORY COATING AND THE WELD AREA. NO VOIDS OR WRINKLES CAUSED BY IMPROPER APPLICATION IS -- --- ALLOWED. STRETCH AND TENSION WRINKLES DURING APPLICATION ARE ACCEPTABLE. 6.4 THE REPAIR AND PATCHING OF THE FACTORY COATING IS MADE BY REMOVING ALL LOOSE OR DISBONDED MATERIAL FROM AROUND THE AREA OF THE "HOLIDAY". NO SHARP POINTS, BURRS, OR ROUGH EDGES SHALL APPEAR AROUND THE FACTORY COATING EDGES. THESE EDGES SHALL BE "FEATHERED" SMOOTH, PRIOR TO APPLICATION OF THE PRIMERAND TAPE. 6.4.1 REFER TO SECTIONS 4.0 AND 5.0 FOR PROPER SURFACE PREPARATIONAND PRIMERAPPLICATION. 6.4.2 THE EXPOSED AREA OF STEEL SHALL BE REPAIRED USING THE SAME SYSTEM OF PRIMERAND TAPE AS REFERRED TO IN SECTIONS 5.1 AND 6.2. 6.4.3 PATCHED AREAS SHALL OVERLAP THE ADJACENT UNDAMAGED FACTORY COATING A MINIMUMOF 2 INCHES. 6.4.4 THE TAPE SHALL BE WORKED DOWN ONTO THE SURFACE OF THE STEEL, SO AS TO LEAVE NO WRINKLES OR VOIDS APPEARING ON THE NEW PIECE OF TAPE THAT IS IN CONTACT WITH THE STEEL. 6.4.5 PINHOLES SHALL BE TAPE OVER WITHOUT PRIMING WITH A MINIMUM OF 4 SQUARES INCHES OF TAPE. 7.0 HOLIDAY DETECTION 7.1 TINKER & RASOR MODEL A-P HOLIDAY DETECTOR WITH BRUSHES OR COIL SPRINGS SHALL BE USED IN ACCORDANCE WITH THE MANUFACTURES RECOMMENDATIONS. VOLTAGE SHALL NOT EXCEED 7,000 VOLTS IN A SINGLE LAYER APPLICATION AND 12,000 VOLTS IN A 55% OVERLAP OR DOUBLE LAYERAPPLICATION. 7.2 HOLIDAY DETECTION SHALL TAKE PLACE ONLY ONCE, JUST PRIOR TO BACKFILLING AND AFTER ALL WELDED JOINTS AND OTHER MISCELLANEOUS PIPE AS REFERRED TO IN SECTION 6.1 HAS BEEN COATED WITH TAPECOAT 20. 7.3 AN EXCEPTION TO 7.2, IS WHEN PIPE HAS BEEN WRAPPED IN A "SHOP" OR "PLANT" SET-UP AND SHIPPED TO ANOTHER LOCATION. IN THIS CASE, HOLIDAY DETECTION MAY TAKE PLACE PRIOR TO LEAVING THE SHOP OR PLANT. AFTER THE PIPE REACHES ITS FINAL DESTINATION, SECTION 7.2 WILL PROCEED. ---- ------- 7.4 ALL HOLIDAYS DETECTED SHALL BE REPAIRED IN ACCORDANCE WITH SECTION 6.4. 8.0 STORAGE, HANDLING AND SHIPPING 8.1 COATED PIPE SHALL BE HANDLED AND STORED IN SUCH A MANNER AS TO PREVENT DAMAGETO THE COATING. 8.2 ALL BOOMS, HOOKS, FORKS, SUPPORTS, SKIDS AND OTHER DEVICES USED TO MOVE AND HANDLE COATED PIPE SHALL BE PADDED TO PREVENT DAMAGE TO THE COATING. 8.3 PIPE SHALL BE SHIPPED USING SUFFICIENT PADDING AND DUNNAGE TO ADEQUATELY PROTECT THE PIPE COATING. CHAINS AND STEEL BANDS SHALL NOT BE USED. 9.0 BACKFILL 9.1 BACKFILL ADJACENT TO THE COATED PIPE SHALL BE FREE OF SCRAP, STICKS, LARGE STONES, ROCKS OR OTHER DEBRIS WHICH WOULD TEND TO DAMAGE THE COATING. 10.0 ROCK SHIELD 10.1 TERRA-SHIELD SHALL BE USED OVER THE FINAL COATING, WHERE IT HAS BEEN DETERMINED THAT THE BACKFILL, HANDLING OR INSTALLATION WILL BE DETRIMENTAL TO THE COATING. ~ APPENDIX THIS SECTION COVERS THE WORK TO BE DONE ON IRREGULAR SURFACES AS REFERRED TO IN SECTION 1.2. SURFACE PREPARATION AND PRIMING IS INACCORDANCE WITH SECTION 4.0 AND 5.0. A.O MATERIALS A.1 TAPECOAT TC MASTIC (LIQUID) A.2 TC OMNIPRIME A.3 TAPECOAT 20 B.O IRREGULAR SURFACES-TC MASTIC ~ DEFINED AS, BUT NOT LIMITED TO, TEES, VALVES, AND MECHANICAL COUPLINGS. TC MASTIC IS APPLIED BY BRUSH WITHOUT PRIMER. APPLY ONE LAYER OF TC MASTIC TO OBTAIN A MINIMUM DFT OF 12 MILS. MINIMUM WAITING TIME FOR BACKFILLING IS 24 HOURS. C.O ANODEITEST ST ATION- TAPECOA T TAPECOA T 20 USING THE PROPANE TORCH TO SOFTENING THE TAPECOAT20 . THE TAPECOAT 20 SHALL BE MOLDED TO COMPLETELY COVER THE EXPOSED ANODE WIRE AREA AND ONTO THE UNDAMAGED COATING AT LEAST 2" AND CONFORMING AROUND THE ANODE WIRE. A SLIT WILL BE MADE IN THE TAPECOAT 20 TO ACCOMMODATE THE ANODE WIRE CONNECTION. THE SLIT AREA WILL OVERLAP ON TO ITSELF TO ASSURE A TIGHT SEAL AROUND THE WIRE. TAPE COATING SYSTEM FOR PIPELINE CORROSION PROTECTION
Abboud L. Mamish, Director oI Research & Development, Berry Plastics Corp., Lexington, MA
Abstract
The need to protect underground pipes Irom corrosion started over 60 years ago. The evolution oI such protective pipeline coatings started with the use oI asphalt, coal tar to cold applied tapes which were Iollowed shortly thereaIter with Iusion bonded epoxies and more recently 3-layered systems. The cold applied tape system, which is one oI the two leading coating systems in the U.S., is used on new or reconditioned pipelines carrying oil, gas and water. Their main Iunction is to provide long term corrosion protection Iorm underground elements as well as mechanical protection. This paper is an overview describing the system`s composition, perIormance, beneIits and application methods.
History
PE tape was Iirst introduced into the pipeline oil and gas industry in the early 1950s Ior the purpose oI providing long lasting in-ground corrosion protection. These tapes were Iirst applied in the Iield by the technique reIerred to as Over-The-Ditch which was later extended to in-plant application. Since its Iirst introduction, this technology has advanced Ior mainline application and girth weld protection Ior new pipelines as well as Ior reconditioning oI older pipelines. Today PE tape market has undergone Iurther growth to protect pipelines that transmits and distributes potable water. Pipe diameter in this application can typically range Irom 24 144 inches.
Market
Oil, gas and water transmission and distribution pipelines are considered an essential part oI the inIrastructures worldwide. Construction activity has undergone unprecedented increases in the last Iew years due to demand and population growth. Last year`s Iigures are a clear reIlection oI this trend which indicated that over 107,000 miles oI new crude oil and natural gas (excluding water) pipelines are either being built, planned or being studied globally, a 17.8 growth over 2007 (1). Investment in constructing a pipeline can be quite high. For example, a planned 42 inch diameter gas transmission line stretching Irom Wyoming to Oregon (680 miles) is estimated to cost $2 billion. Thus, protecting such valuable assets against corrosion presents a technical challenge. The coating must demonstrate long term perIormance to maintain: ! Consistent adhesion ! Mechanical protection under high soil loading ! Cathodic protection ! Resistance to soil stress and low moisture and gas permeation at the pipe`s operating temperatures and over the expected coating liIe span oI 30 years.
267 Coating Types
There are many coating types that are employed in corrosion protection oI steel pipes. This protection can be broken down into 2 areas. First, main line coating where this coating is applied to every pipe section with the exception oI the last 6 oI both ends and second, girth weld where the pipe ends are coated in the Iield and aIter the pipe joints are welded. Main line coating types include: ! Cold applied tapes ! Fused tapes ! Fusion bonded epoxy ! 2 part Urethane ! 2 and 3 layer Polyethylene
The total tape system components consist oI a primer applied directly to the pipe surIace, an inner-wrap tape layer that provides a corrosion barrier and an outer-wrap tape layer that provides mechanical protection (Figure 1).
1. Primer The primer is an integral part oI the cold applied tape system. It is mainly composed oI butyl rubber along with tackiIiers, stress corrosion inhibitors and other additives that will Iacilitate good adhesion to the blasted pipe surIace as well as maximize bonding oI the inner-wrap tape layer to the pipe. These components are typically dispersed in a high evaporating solvent matrix and sprayed at controlled thickness on the blasted pipe surIace, allowed to adequately dry prior to the application oI the inner- wrap tape layer. Due to recent state and Iederal regulations mandating solvent emission controls, 100 solids hot melt adhesive 'primers have been developed and introduced recently to the market as an alternate solution. They are also Iormulated with a butyl rubber and applied to the pipe surIace using more specialized spray equipment.
2. Backing The inner and outer wrap layers backings are primarily composed oI Polyethylene (PE). The PE backing is Iormulated to the demands oI the coating Ior a speciIic application on pipe, or Ior a speciIic application as a coating. The PE composition oI the anti- corrosion layer product is diIIerent than the mechanical layer, due to the Iunction oI the respective layers. The anti-corrosion layer generally has more medium and low density PE composition which provide strength and conIormability, while mechanical layers require the use oI select high and low density PE that provide higher mechanical strength, toughness and resistance to stress cracking. A typical Iormula would include low and high density PE, antioxidants, UV inhibitor and colorant.
268 3. Adhesive The adhesive in both tape layers are elastomeric based. Butyl rubber (BR) is predominantly used as opposed to other elastomers. BR`s molecular structure oI low unsaturation levels yields unique characteristics oI chemical and moisture resistance, thermal stability, weathering and gas permeability, all essential properties required Ior long term in-ground perIormance. In addition to BR, a typical Iormula would include a tackiIier, oil, Iiller, antioxidant, biocide and a colorant. Cross-linkers may also be used in applications requiring high, long term resistance to excessive soil stress and continuous heat exposure (up to 125 C).
The adhesive works in conjunction with the primer to Iorm a strong bond to the steel substrate, providing the corrosion protection and long term perIormance that the pipe requires as well as imparting high cathodic disbonding resistance, high shear and soil stress resistance. DiIIerent adhesive Iormulas are used depending on the surIace to be applied to. There is the steel pipe surIace and the PE backing layer oI the anti-corrosion layer and the backing layer oI the mechanical layer. Each layer oI the PE Tape system must have a speciIic adhesive composition to insure achievement oI a good adhesion at each interIace.
Figure 1.
Manufacturing Processes
PE backings are manuIactured by either a Calendering or Co-extrusion process whereby, the Polyethylene resins with additives are blended and processed to Iorm a PE sheet or Iilm. The calendering process by the nature oI the methodology orients the molecular chains oI the Polyethylene to provide some machine direction orientation oI the PE Iilm. This orientation provides some unique application advantages relative to the yield point oI the PE Iilm when stressed and stretched during application on pipe. Co-extrusion on the other hand does not impart the same degree oI orientation, resulting in diIIerent tensile properties requiring diIIerent application parameters during application on pipe. AIter the application oI the adhesive to the PE backing or Iilm, the product is rolled into master rolls, slit to width and packaged as required by in-use application in the industry.
Primer Inner-wrap Outer-wrap CoId AppIied Tape System 269 Tape Application to Pipe
The pipe coating process consists oI the Iollowing steps, (Figure 2): ! Drying and cleaning using a grit or sand blasting to remove mil scale ! Phosphoric acid wash and drying, iI required ! Primer spray and drying ! Inner-wrap application continuously and spirally using precision tension control ! Outer-wrap application continuously and spirally using precision tension control ! Holiday Detection ! Cut backs at both pipe ends
Figure 2.
The above steps are carried out using detailed speciIics to conIorm to industry and tape manuIacturer application standards under the watchIul eyes oI a certiIied inspector. For example, the sand blasting step requires achieving a well deIined cleanliness and anchor pattern Ior the primer/inner-wrap to achieve expected adhesion, primer dryness and thickness, tape tension, temperature and overlap control are among many application conditions that are required to be practiced. Both tape layers are applied with recommended tension to insure good application to the pipe, to insure good conIormability at the overlap and to achieve the mechanical and chemical adhesion oI the coating system to the pipe. With machine application using tension, the coating experiences tension and necking down oI the coatings by 2. This tension eIIect creates a 'gasket eIIect or Ilow oI the adhesive at the overlap sealing the adhesive to the overlap and Iurther creating mechanical adhesion oI the coating to the substrate and to the multiple interIaces within the PE tape coating system.
Some oI the industry standards include DIN 30672, EN 12068, AWWA C-209, C-214 and C-225.
Performance Requirements and Testing Methods
As stated above, the expectation that the system is required to perIorm at and long term in-ground perIormance, 30 years, are quite demanding. Thus, design parameters, Iunctionality long term heat aging and in-ground testing and exposure to the most corrosive soil environment is the Iirst critical stage oI development prior to any new product launch. 2 Layer Tape AppIication MuItiIayer PE Tape AppIication - PIant Coating Primer Spray Pin HoIe Detection Grit BIasting 270
First, the inner-wrap must Iorm a continuous and permanent bond to the primer providing adhesion, soil stress and resistance to cathodic disbondment as well as bond to itselI at the overlap regions. Second, the outer-wrap must bond to the inner-wrap and to itselI, provide mechanical strength to resist damage during shipping, handling backIilling and long term rock penetration damage under load. Other requirements include UV exposure oI coated pipes during yard storage, low temperature Ilexibility down to -40 C and good ductility and Ilexibility during bending over a wide temperature range. Table 1 is an example oI some oI the critical properties Ior the inner wrap tape layer.
Table 1: Physical Properties of an Inner-Wrap Tape, (2)
Property Requirement
Width deviation - 5 oI width or - /, whichever is smaller Thickness 19-22 mils Adhesion (with Primer) 200 oz/in Water Absorption (24 hrs.) 0.2 , maximum Water vapor transmission 0.2 perm |1.15x10 -11 kg/(Pa.s.m 2 )| maximum Dielectric Strength 6000 volts/tape thickness Insulation resistance 500,000 megaohms Tensile Strength 20 lb/in Elongation 100 minimum Non-polyoleIinic content 3.5 maximum
Field Installation
PE tape coating systems Ior pipe reconditioning are applied using traditional 'Line Travel or Over-The- Ditch techniques which are strictly Iield applied methods. This method is less used today than in the 1960-1990s.
For new pipe construction, the plant coated pipes are transported to the installation site where the 40` joint sections are Iirst welded, Iollowed by sand blasting the cut back area to the proper anchor proIile and then either hand wrapped with tape or a shrink sleeve is applied prior to burial on a speciIied backIill (pea stone/sand mix). Here again these steps are carried out taking special care to avoid coating damage that may go unnoticed or require repair that would slow down the construction progress.
References
1) BeauboueI, B., Pipeline and Gas Technology Journal, page 16, (May 2008). 2) ANSI/AWWA C-214-07 standard, Tape Coating System Ior the Exterior oI Steel Water Pipelines. 271
TECH 32 Technical Seminar Speaker
Tape Coating System Ior Pipeline Corrosion Protection Abboud L. Mamish, Berry Plastics Corp.
Abboud L. Mamish is director oI research & development at Berry Plastics Corporation and Subsidiaries. He has 28 years oI experience in research and new product development in various PSA tape applications such as automotive, corrosion protection and industrial. Mamish holds nine US patents and has published Iour technical papers.
Mamish has both a B.S. and M.S. in plastics engineering Irom the University oI Massachusetts Lowell. His master`s thesis was 'Co-extrusion Coating oI Woven Fabrics.
He can be reached at abboudmamishberryplastics.com.