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EXTERNAL PIPE Coating PDF
EXTERNAL PIPE Coating PDF
COATINGS
Cross Country Petroleum Pipelines External Pipe Coatings
Adherence to pipe
Non-porous
Free of defects, pores, flaws, holidays
Should act as an insulating barrier
Should be inert to environment
Coefficient of thermal expansion of the coating film > that of pipe metal
High resistance to abrasion
Resistance to UV degradation
Following types of coatings are mainly used for coating of line pipes:
Reference Codes
BS 4164 : Specification for coal-tar based hot applied coating materials for
protecting from iron and steel, including suitable primer.
AWWA C-203-86 : AWWA standard for Coal Tar Protective coatings & linings for steel
water pipelines, enamels and tape-hot applied.
Materials
Coal Tar : The coal tar enamel shall consist of a uniform mixture of a
specially modified coal tar and inert non-fibrous filler.
Wrapper
Inner Wraps : The inner wrap glass fibre reinforcement material shall conform
to AWWA C-203. The glass fibre reinforcement material is
reinforced in the longitudinal direction.
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Cross Country Petroleum Pipelines External Pipe Coatings
Outer Wraps : The outer wrap material shall conform to AWWA C-203. The
outer wrap material is coal tar impregnated asbestos felt or glass
fibre felt.
1) Surface Preparation
Oil, grease or other contaminants are removed by solvent cleaning prior to
blasting. Exterior surfaces of the pipes to be coated are blast cleaned by
sand blasting to near white metal finish to Grades 2 1/2, SIS 0550900.
Prior to primer application, the pipe is cleaned to remove any wetness or
other contamination.
2) Priming
Primer material compatible with the enamel coating is used. Primer is
applied on sand blasted pipe in an uniformly thick film to completely
cover the circumference of the pipe and all surfaces which are to be
coated. The freshly primed pipes are dried on racks until they are no
longer wet, sticky or tacky.
4) Coating of Pipes
The coating system consists of applying over the primed pipe, a coat of
coal tar enamel having a minimum thickness of 2.4 mm and one wrap of
glass-fibre mat, followed by a second coat of coal-tar enamel having
minimum thickness of 2.4 mm and wrap of glass fibre mat followed
immediately by an outer wrap of coat tar impregnated asbestos felt/glass
fibre felt.
Glass fibre mat is applied simultaneously with the first coat of coal tar
enamel. The roll of glass fibre mat is maintained under sufficient tension
to embed the mat in the enamel before the latter sets or cools. The second
coat of hot coal tar enamel is then applied simultaneously with the second
layer of glass fibre mat. The impregnated outer wrap is then applied
immediately behind the glass fibre reinforcement in a tight uniform spiral.
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Cross Country Petroleum Pipelines External Pipe Coatings
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Cross Country Petroleum Pipelines External Pipe Coatings
Reference Codes
Materials
Polyethylene compound
Epoxy powder
Adhesive
Properties of Polyethylene Compound
Melt index. Test conducted at g/10 min. 0.25 min. ASTM D 1238
2. a temperature of +190°C
under a total load (including
piston weight of 2.16 Kg)
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Cross Country Petroleum Pipelines External Pipe Coatings
Epoxy powder shall be chosen such that it complies with the functional
requirements and properties of coating system.
Properties of Adhesive
Adhesive shall be chosen such that it complies with the functional requirements
and properties of coating system.
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Cross Country Petroleum Pipelines External Pipe Coatings
1) Surface preparation
Solvent cleaning is done in accordance with SSPC - SP 1. Prior to
abrasive blast cleaning, the pipes are preheated to 65°C to 85°C for
removal of any moisture, raising of silvers, laminations etc. The external
surface of the pipe is cleaned by abrasive blast cleaning machine for white
metal finish to SA 2 ½ of Swedish Standard SIS 055900.
2) Coating application
The external surface of the pipe shall is heated to about 190°C followed
by application of following three layers:
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Cross Country Petroleum Pipelines External Pipe Coatings
Peel test: Peel test is carried out as specified in DIN 30670 for testing
adhesion. The system shall fail only in the adhesive layer. Failure of either
adhesive to steel or adhesive to backing is not acceptable.
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Cross Country Petroleum Pipelines External Pipe Coatings
COMPARISON OF COATINGS
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Cross Country Petroleum Pipelines External Pipe Coatings
The FBE is an electrostatically changed powder, which is pneumatically sprayed onto the
hot pipe, and contains excellent passive corrosion protection properties.
The system was developed for the protection of pipelines operating at elevated
temperatures where coating adhesion and resistance to soil stresses and cathodic
disbondment are required. It consists of a single layer of cured thermosetting epoxy resin
powder as the corrosion barrier (no other mechanical protection) applied by electrostatic
charge to a preheated pipe. As per CSA Z245-20, the thickness requirement for Single
Layer Coating shall be 350 - 500 micron.
Advantages
Disadvantages
Dual layer fusion bonded epoxy is a 2-component powder coating designed to provide
long term corrosion resistance and mechanical protection to steel pipe. The system was
principally developed for road/river crossing and HDD (Horizontal Directional Drilling)
applications where resistance to abrasion and gouging are considered important. It
consists of:
ii) A secondary layer of abrasion and impact resistant epoxy resin powder to provide
mechanical protection
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Cross Country Petroleum Pipelines External Pipe Coatings
As per CSA Z245-20, the thickness requirement for Dual Layer Coating shall be 750 -
800 micron.
Advantages
Disadvantages
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Cross Country Petroleum Pipelines External Pipe Coatings
Field joint coatings are carried out using Heat Shrinkable Sleeves.
Reference Code
DIN-30672-1991 : Coating of Corrosion Protection Tapes & Heat Shrinking Products for
Pipelines - Operational Temperatures upto 50º C.
Materials
The thickness of field joint coating material is such that an average thickness of 2.0 mm
is guaranteed on the complete finished field joint coating.
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Cross Country Petroleum Pipelines External Pipe Coatings
@ 50ºC.
With Metal Surface >4
With Mill Coating > 2.5
At Layers Overlap >4
3. Cathodic Disbondment (after 30 mm <30 ASTM G-42
days) Test Method A, @ 60ºC.
4. Resistance to Indentation, @ 50ºC. mm 0.3 max. DIN 30672
5. Lap Shear Strenth @ 50ºC. Between N/ cm2 >6 DIN 30672
Wrapping & Metal Surface and Mill
Coating.
1) Surface Preparation
Oil, grease, salts and other contamination are removed from steel surface
by wiping with rags soaked with suitable solvents such as naphtha or
benzene. Solvent cleaning procedure is in accordance with SSPC-SP 1.
Surface is then blast cleaned to a finish equivalent to SA 2½ of Swedish
Standard SIS-055900. The ends of existing pipe protective coating are
inspected and chamfered prior to application and cleaned as necessary.
Joint coating shall be applied immediately after completion of surface
preparation.
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Cross Country Petroleum Pipelines External Pipe Coatings
3) Inspection
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Cross Country Petroleum Pipelines External Pipe Coatings
4) Testing
From each test sleeve, one or more strips of size 25 mm x 200 mm is cut
perpendicular to the pipe axis and slowly peeled off. The required peel
strength shall meet the requirements of DIN 30672 as applicable for 230 C
or 500 C. For qualification, peel test must be carried at 230 C. and 500 C.
After removal of strip the bulk of adhesive shall remain adhered to the
pipe showing no bare metal, otherwise, test is considered to have failed.
The adhesive layer that remains on the pipe surface shall be free of voids
resulting from air or gas inclusion.
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