1. Coating Description:
Internal Coated Pipes (Epoxy Coated)
A spraying nozzle has been used to spray the liquid epoxy inside the pipe as per the required thickness. Before applying the epoxy paint, internal surface of the pipe is cleaned. The liquid applied epoxy lining systems may consist of any of the following three types:
- A two-part, chemically cured epoxy primer and one or more coats of a different two-part, chemically cured epoxy topcoat;
- Two or more coats of the same two-part, chemically cured epoxy coating; or,
- a single coat of a two-part, chemically cured epoxy coating.
The typical coating thickness for gas pipelines varies between 60 to 100 μm and for water and other liquids it varies between 200 to 500 μm.
Features of Internal Epoxy Coating
- Increase flow of gas/water by 20%
- Suitable for Service Temperature up to 80°C
- Excellent Corrosion Resistance
- High Steel Adhesion
- Low mechanical & abrasion Resistance
- High Impermeability for water / gas
- Low Electrical Resistance
- Ease of cleaning the pipeline and ease of water
- Decrease line maintenance and up keep costs
FBE Coated Pipes
Fusion bonded epoxy (FBE) coated pipes are used for prevent steel pipes from corrosion and harmful chemicals. These are thin coatings of epoxy-resin powder materials formed in a film and applied on pipes by specialised coating facilities by electrostatic spraying. These FBE coated pipes can be used in temperatures up to 85oC in dry conditions.
FBE Coating has been used as a standard in industries for protection against corrosion. FBE coatings have good handling characteristics; they are flexible and resistant to soil pressure. These are used in pipeline projects that have normal requirements and do not have harsh conditions.
A dual-layer of fusion bonded epoxy can also be used for coating of pipelines for use in harsher conditions to make it more abrasion resistant. The second layer is also made of the similar fusion bonded epoxy with both the layers being sprayed successively. Depending on the application, the dual-layer FBE can also come with an Abrasion-Resistant Overcoat (ARO), to reduce damage to pipes.
Features of Fusion Bonded Epoxy (FBE) Coating
- Corrosion resistant and chemical resistant
- High resistance to cathodic disbondment
- Increases the life span of steel pipes providing a constant performance throughout its life span.
- High bond strength and bond firmly to mild steel pipe surface.
Dual Layer FBE Coating (UV Resistant Overcoat)
It is for above ground applications in diameter range from 25 mm to 3000 mm. This coating provides excellent corrosion resistance, resistance to cathodic disbondment and resistance to UV degradation.
Dual Layer fusion bonded epoxy coatings are thermoset hardening layers of epoxy resin applied to steel pipes using an electrostatic process, which protects them against corrosion.
The two coating layers in dual layer FBE coated pipe are as follows:
Layer 1: This is the corrosion protective layer. This layer is of fusion bonded epoxy which offers very good corrosion protection. The fusion bonded epoxy has a very good bonding with the blasted steel surface.
Layer 2: This layer is a coat of fusion bonded polyester. This layer absorbs the UV radiation that causes degradation and erosion of the FBE coating.
Features of Dual FBE Coating
- Base coat of Fusion bonded epoxy has excellent adhesion to steel & provides long term corrosion protection to steel pipelines operating over a wide range of temperatures.
- Provides excellent resistance to cathodic disbondment.
- Top coat of Fusion bonded polyester provides U V protection & protection from harsh weather conditions for the designed lifespan.
- Coating has been designed for good chemical resistance under various installation conditions.
- Ability to be stored & used in all climatic conditions.
- Resistance to UV radiation & rain.
3LPE Coated Pipes
3LPE Coated Pipes consist of 3 layers for pipeline coating.
Layer 1 consists of Fusion Bonded Epoxy. This later provides protection against corrosion and is fusion bonded with the blasted steel surface.
Layer 2 is a copolymer adhesive which has excellent chemical bonding to the inner layer and the top layer of polyethylene.
Layer 3 is the layer of polyethylene used for protection against any physical damage of the pipes.
The 3 layer polyethylene coated pipes are the preferred choice for transmission of oil and gas around the world. It can withstand varied temperatures and environments ranging from dessert dry lands to deep underwater regions. 3LPE coated steel pipes are used for transportation of drinking water, oil and gas and other fluids. The 3LPE coated pipes can be used in the high temperatures as high as 60o C to 80 oC.
Features of 3LPE coating
- Excellent chemical and corrosion resistance preventing steel pipes from any damage.
- Resistance to cathodic disbondment
- prevents any physical damages to either the pipes or the fusion bonded epoxy during handling
- High performance characteristics and an extended life cycle
3LPP Coated Pipes
3LPP Coated Pipes consists of multilayer anti-corrosion coatings consisting of an inner layer of fusion bonded epoxy layer, the middle layer is an adhesive layer and an outer layer of polypropylene. The inner layer is used for protection against corrosion and chemical damage while the outer layer is used for protection against any physical damage in laying and transportation.
The 3 layer polypropylene coated pipes are used in oil fields where the resources are drawn from deep reservoirs and at high temperatures (100oC to 140oC). It is highly abrasion resistant and is generally used where the chances of damage are high such as Rocky Mountains or for drilling operations.
Features of 3LPP coated pipes:
- Excellent chemical and corrosion resistance preventing steel pipes from any damage.
- Resistance to cathodic disbondment
- highly abrasion resistant and can withstand high temperatures.
- high performance characteristics and an extended life cycle.
Polyurethane Coating
The aromatic polyurethanes are 100% solids materials that contain no VOCs. Polyurethane linings are typically applied at 20 mils minimum thickness; however, thicker lining applications are possible.
Features of Polyurethane Coaitng
- Fast curing – ensures economy of high production rates and efficiency.
- Excellent adhesion to ferrous and properly prepared steel surfaces.
- High impact resistance
- Effectively protects pipe from corrosion
- Lower lining thickness is required compared to other technologies, and hence pipe design can be more efficient, reliable and economical as the wastage factor will be reduced, and pipeline capacity is higher for the same size of pipe.
- Reduced head loss and pumping losses due to a smoother internal surface of the pipes.
- Longer economic life as deterioration due to erosion cavitation is low.
Coal Tar Enamel Coating
The coal tar pitch, which forms the basis for the coal tar enamel (CTE), consists of stable molecules that are formed during coking operations at about 1,300°C. The fillers and coal add flexibility and strength to the product.
Features of CTE Coating
- Water resistant — negligible water absorption and vapor transmission.
- Stable chemical structure — resistant to acid and alkali
- Resistant to cathodic disbonding — most pipelines are protected using impressed current or sacrificial metal anodes; CTE is resistant to the alkaline environment formed at exposed metal surfaces.
- High electrical resistance — even after two years’ immersion in water, the electrical resistivity remains 1014-ohm cm3.
- Adhesion — forms a strong permanent bond to the steel surface.
- Resistant to attack by bacteria, marine organisms and root penetration.
BITUMEN COATING
To prevent rusting in pipes used for natural gas and petrol lines, this coating is applied to the outside of pipes by wrapping. All our applications are in accordance with the following applied standards: DIN 30673
Pipes can be coated externally with bitumen + reinforced glass as per DIN 30673 to maintain a higher corrosion strength.
The bitumen layer coated on the pipe surface can increase the anti-corrosion properties of the casting pipes. The coating of the equipment has the effect of flat and tidy surface, free of bubbles and the solid fixing between the coating layer and the coated body.
2. Reference Standards:
2.1 External Epoxy Coating
CAN/CSA-Z245.20 Standard for External Fusion Bond Epoxy Coating for Steel Pipe
API RP 5L9 External Fusion-Bonded Epoxy Coating of Line Pipe
AS 3862 Standard Specification for External Fusion-Bonded Epoxy Coating for Steel Pipes
AWWA C210 Standard for Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
AWWA C213 Standard for Fusion Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines.
BP GIS 06-402 Guidance on Industry Standard for Fusion Bonded Epoxy Powder External Pipeline Coatings
DEP 31.40.30.32 Technical Specification for External Fusion-Bonded Epoxy Powder Coating for Line Pipe
NFA 49-710 Standard Specification for External Fusion-Bonded Epoxy Coating
ISO 15741 Paints and Varnishes - Friction-Reduction Coatings for the Interior of On-and Offshore Steel Pipelines for Non-Corrosive Gas.
ISO 21809-2 Petroleum and natural gas industries-External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 2: Fusion-bonded epoxy coatings
NACE RP0394 National Association of Corrosion Engineers Standard Recommended Practice, Application, Performance, and Quality Control of Plant Applied, Fusion Bonded Epoxy External Pipe Coating.
NACPA 12-78 National Association of Pipe Coating Applicators External Application Procedure for Plant Applied fusion Bonded Epoxy (FBE) to Steel Pipe.
SAES-H-002 Internal and External Coatings for Steel Pipelines and Piping
09-SAMSS-089 Shop-Applied External FBE Coating
09-SAMSS-091 Shop-Applied Internal FBE Coatings
TransCanada TES-CO-FBE-GL: External Fusion Bond Epoxy for Steel Pipe Specification (CAN-US-MEX) Table 12-1 & Table 12-2 (Fusion-Bonded Epoxy Powder & Coating Qualifications).
2.2Polyethylene Coating
CAN/CSA Z245.21 External Polyethylene Coating for Pipe
DIN 30670 Polyethylene Sheathing of Steel Tubes and of Steel Shaped Fittings
NFA 49-710 External Three-Layer Polyethylene Based Coating, Application by Extrusion
DNV-RP-F106 Factory Applied External Pipeline Coatings For Corrosion Control
AS/NZS 1518 External Extruded High-Density Polyethylene Coating System for Pipes
AS 4321 Fusion Bonded Medium-Density Polyethylene coating and lining for pipes and fittings
EN 10288 Steel tubes and fittings for on and offshore pipelines - External two layer extruded polyethylene based coatings
ISO 21809-1 Petroleum and natural gas industries -- External coatings for buried or submerged pipelines used in pipeline transportation systems - Part 1: Polyolefin coatings (3- layer PE and 3- layer PP)
ISO 21809-4 Petroleum and natural gas industries -External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 4: Polyethylene Coatings (2-layer PE)
BP GIS 06-403 Guidance on Industry Standard for the Application of Three-Layer Fusion Bonded Epoxy-Polyethylene Coating and Three-Layer Polypropylene Coating System for Line Pipe
DEP 31.40.30.31-Gen. TECHNICAL SPECIFICATION FOR EXTERNAL POLYETHYLENE AND POLYPROPYLENE COATING FOR LINE PIPE
IPS-G-TP-335 Material and Construction Standard for Three Layer Polyethylene Coating System
NFA 49-710 External 3 layer Polyethylene Coating
PETROBRAS ET-200.03 Engineering Specification ("Piping Materials for Production and Process Facilities") for using low density linear polyethylene in carbon steel piping, as to appendix 13 of such specification.
09-SAMSS-113 External Renovation Coating for Buried Pipelines and Piping (APCS-113)
UNI 9099 Polyethylene Coating Applied by Extrusion
2.3 Polypropylene Coating
DIN30678 Polypropylene Sheathing of Steel Tubes and of Steel Shaped Fittings
EN 10286 Steel tubes and fittings for onshore and offshore pipelines –External three layer extruded polypropylene based coatings.
NFA 49-711 External Three-Layer Polypropylene Based Coating, Application by Extrusion
09-SAMSS-114 Shop-Applied Extruded, Three-Layer Polypropylene External Coatings for Line Pipe
2.4 Polyurethane Coating
AWWA C222 Polyurethane Coatings for the Interior and Exterior of Steel Water Pipe and Fittings
BS 5493 Polyurethane Coating
DIN 30677.2 Polyurethane Insulation of the fittings
EN 10290 PUR B3 steel pipes and fittings used in constructing sea and coastal pipelines. External coatings of liquid polyurethane and modified polyurethane - external coatings.
2.5 Polyolefin Coating
AWWA C225 Fused Polyolefin Coating Systems for the Exterior of Steel Water Pipelines
AWWA C215 Extruded Polyolefin Coatings for the Exterior of Steel Water Pipelines
AWWA C216 Standard for Heat-Shrinkable Cross-Linked Polyolefin Coatings for the Exterior of Special Sections, Connections, and Fitting for the Steel Water Pipelines
AWWA C224 Two-layer Nylon-11 Based Polyamide Coating System for Interior and Exterior of Steel Water Pipe and Fittings
AWWA C225 Fused Polyolefin Coating Systems for the Exterior of Steel Water Pipelines
2.6 Tape Coating
ISO 21809-3 Petroleum and natural gas industries-External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 3: Field joint coatings
AWWA C209 Standard for Cold-Applied Tape Coatings for the Exterior of Special Sections, Connections, and Fittings for Steel Water Pipelines
AWWA C214 Standard for Tape Coating Systems for the Exterior of the Steel Water Pipelines
AWWA C217 Standard for Cold-Applied Petrolatum Tape and Petroleum Wax Tape Coatings for the Exterior for Special Sections, Connections, and Fittings for Buried/Submerged Steel Water Pipelines
AWWA C218 Standard for Coating the Exterior of Aboveground Steel Water Pipelines and Fittings
AWWA C224 Two-layer Nylon-11 Based Polyamide Coating System for Interior and Exterior of Steel Water Pipe and Fittings
EN 12068 - DIN 30672 STANDARD-POLYETHYLENE SELF ADHESIVE TAPES
2.7 Bitumen Coating
DIN 30673 Bitumen coatings and linings for steel pipes, fittings and vessels
2.8 Coal-Tar Enamel Coating
AWWA C-203 Coal-Tar Protective Coatings and Linings for Steel Water Pipelines-Enamel and Tape-Hot-Applied
AWWA C205 Cement Mortar Protective Lining and Coating for Steel Water Pipe - 4 inch (100 mm) and Larger- Shop Applied
2.9 Concrete Weighted Coating
DNV-OS-F101 Submarine Pipeline System
DEP-31.40.30.30 Concrete coating of line pipe
ISO 21809-5 Petroleum and natural gas industries -External coatings for buried or submerged pipelines used in pipeline transportation systems - Part 5:External concrete coating.
2.10 Structure Coating
ISO 12944 Paints & Varnishes – Corrosion Protection of Steel Structures by protective paint system (parts 1 – 8)
ISO 20340 Paints and varnishes – Performance requirements for protective paint systems for offshore and related structures
ISO 15741 Paints and varnishes-Friction-reduction coatings for the interior of on- and offshore pipelines for non-corrosive gases
2.2. Internal Coating
2.2.1 Epoxy Coating
API RP 5L2 Recommended Practice for Internal Coating of Line Pipe for Non-Corrosive Gas Transmission Service.
DEP 31.40.30.35 Internal coating of line pipe for non-corrosive gas transmission service (amendments/ supplements to API RP 5L2)
AWWA C210 Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
NFA 49-709 Internal can be epoxy 80 microns
NFA 49-708 Recommended Practice for Internal Coating of Line Pipe
TransCanada TES-COAT-INT: Internal Coating of Line Pipe for Non-Corrosive Gas Transmission Service (Cdn-US).
TransCanada TES-COAT-EPU: External Multi-Component Liquid Coating Systems for Below Ground Facilities (Cdn-US-Mex).
TransCanada TES-EPU-TEST: External Multi-Component Liquid Coating Systems Test Requirements (Cdn-US-Mex).
2.2.2 Bitumen Lining
DIN 30673 Bitumen coatings and linings for steel pipes, fittings and vessels
UNI-ISO 5256/87 Bitumen coatings
2.2.3 Cement Mortar Lining
AS 1281 Cement mortar lining of steel pipes and fittings
AWWA C203 Coal-Tar Protective Coatings & Linings for Steel Water Pipelines, Enamel & Tape, Hot-pap. (Incl. add. C203a-99)
AWWA C205 Cement-Mortar Protective Lining and Coating for Steel Water Pipe- 4 In. (100 mm) and Larger-Shop application
AWWA C602 Cement-Mortar Lining of Water Pipelines - 4 inch (100 mm) and Larger - In Place
3. Brands of Coating Materials
3M™: SK 134, SK6233, SK6352 Toughkote, SK 314, SK 323, Scotchkote ™ 206N, SK 226N, SK 6251 DualKote SK-6171, SK 206P, SK226P,
3M Internal Coatings: Coupon EP2306HP
DuPont: 7-2500, 7-2501, 7-2502, 7-2508, 7-2514, 7-2803, 7-2504 Nap Gard Gold 7-2504, Nap Rock: 7-2610, 7-2617 FBE Powders
DuPont Internal Coatings: 7-0008, 7-0010, 7-0014, 7-0009SGR, 7-0009LGR, 7-2530, 7-2534, 7-2509
DuPont Repair Kits; 7-1631, 7-1677, 7-1862, 7-1851
Akzo Nobel: Interzone 485,Interzone 505,Interzone 954,Internline 876 Seal Coat
Hampel: 85448,97840
Denso: 7200, 7900 High Service Temperature Coatings
Internal Liquid Epoxy: Powercrete Superflow
