RoleofCorrosion&FieldJoint

CoatingSystemSelectionCriteriain
SubmarinePipelinesIntegrity
NawinSingh

McDermott International, Inc.

2014 McDermott International, Inc. All rights reserved. February 2015

 WhatisCovered?

PipelineSystem
PipelineExternalCorrosion&Impact
ExternalCorrosionCoatingSystems
CorrosionCoatingSelectionCriteria
FieldJointCoatingSystemsandAlternatives
Wayforward
Conclusion
 WhyPipelinesandwhattheyoffer?

Lowercost
Moreenergytransportationcapacity
Feeddifferentsegmentsoftheenergyconsumption
Safer&environmentfriendlymodeoftransportation
Negligiblelossofproductintransit
 PipelineExternalCorrosion

When pipeline is either buried or submerged in water,

corrosive environment constitute between metal surface and
its environment. Corrosion is the damage of a substance
which is usually a metal.

The rate of corrosion depends on various parameters

including
Pipeline Operating Temp.
Surroundings e.g. water quality
Soil quality & burial status
Interference with other facility
 PipelineIncidentStatistics

GroundMovement,3.3
ConstructionFault,7.5

IncidentalTPdamage,
7.2

ExternalCorrosion
MaliciousTPdamage,5 26%

StressCracking,1.1

InternalCorrosion,5.3

MaterialsFault,8.3

HumanError,2.5
AccidentalTPdamage,
33.5 OtherNaturalHazards
Source: Ref. 3 [ERM from CONCAWE 1971-2010] 0.3
 PipelineIntegrity&CorrosionImpacts

Cost of corrosion is upto 3%[2] of GDP for USA

For Oil and Gas Pipeline alone, it is approx. $7billion[2] per

year for USA

Corrosion rated as 2nd most common threat for pipeline

integrity [1026%[4] ]

Coating cost is only 56%[19] of project cost but play very

important role in integrity.
 PipelineCorrosionCoatingDevelopments

CoalTar&Asphalt
Enamel

PowderEpoxy

TwolayerSystem

Multilayerpolyolefin
[Source: www.brederoshaw.com]
 CoatingTypeandMarketShare

100

80

60

40

20

0
NorthAmerica SouthAmerica MiddleEast Europe NorthAfrica Asia

FBE PE/PP Other

[Source: Ref. 10]

 IndustryStandardsforExternalCoating

AFNOR AWWA BS CSZ DIN ISO

ISO218091
NFA49 (3LPE&PP)
706(FBE) AWWA BS CSA DIN
C203 4164 Z245.20 30670
ISO218092
(CTE) (CTE) (FBE) (3LPE)
(FBE)
NFA49
710(3LPE) ISO218096
(2LFBE)
AWWA BS CSA DIN
NFA49 C213 4147 Z245.21 30678
(FBE) (AE) (Olefins) (3LPP) ISO218094
711(3LPP) (2LPE)
 CoatingSelectionCriteria

Material
Application
Repair
Economics

PastexperienceofEndUser
LocalRegulation Cathodic
Surroundings Disbondment
Holiday
Environment Adhesion

External
Corrosion
coating

MechanicalProperties
Easeof ElectricalProperties
ApplicationRate Performance
application Ageing/DesignLife
CompatibilitywithFJC
Easilyrepaired

[Source: Ref. 15]

 CoatingSelectionCriteria [Ref.6,7,13,18]

TypicalProperties SingleLayerFBE 3LPE 3LPP

ServiceCondition Upto 80C Upto 65C(80C) Upto 110C(140C)

(110C)
TypicalThickness 350m 600m 2.2mmto4.0mm

ImpactResistance >1.5J/mm >7J/mm >10J/mm

[@23C]
CathodicDisbonding <8.5mm <7mm <5mm
[@approx.23cfor28days]
AdhesionStrength Rating 1to3 >100N/cm >250N/cm
[@23C]
Suitability forCWCapplicationor Suitablewith Suitable Suitable
HDDorsimilar additionallayer

Damaged duringHandling Moderate Low VeryLow

Cost[16] Comparatively High RelativelyHigherthan PE

lesserthanPE
 CoatingSelectionCriteria

Rankingindex Coatingsystem
25
Rankingconsideredon1to3Scale(basedon3assuperior)

20

15

10

0
FBE 3LPE 3LPP
CurrentGenerationCoatingSystem

NormalTemp.Limit Max.TempLimit ImpactResistance Adhesion

Disbondment IndentationResistance Cost Performance
FieldJointCoating(FJC)System Why?

Corrosioncontrol

TosupplementCPSystem

Mechanicalprotection

DesignCodesspecifye.g.
FJCSystemWhy? DNVRPF102,ISO218093
 CompatibleFJCsystem

Fusion Bonded Epoxy (FBE)

FBE
100%solidliquids,epoxy,epoxyurethane
Heatshrinksleeves(HSS)
Coldandhotappliedtapes
Three layer polyethylene (3LPE)
Three layer HSS
Multilayer flame spray with PE
Three layer polypropylene (3LPP)
Three layer HSS
Multilayer flame spray with PP
FBE, spray applied adhesive, coextruded PP

[Source: Ref. 1]
 FJCSystemSelection

Technique
Compatibility
Pipelay geographical location
Environment
Complexity
Ease of repair
Cost
 FieldJointCoating PossibleAlternatives

Protective Network Coating System (PNC)

Solid Polyurethane
Other alternative for fast curing
Compensation with CP
Example:
System InjectionMoldedPP PNC
PreheatTemperature 230C 230C
Cycletimeon24joint 810minutes <6minutes
OperatingTemp.rating 150C
Levelofapplicatorexpertise High Low
IndustryCompliance Yes Yes
[Source: Ref. 5]
 ImpactofImprovementinFJCSystem
PipelineDetails 24OD,100KMlong
Marine durationforonejointwithconventionalFJC 12minutes(with4WS &3stationforFJC)
Marine durationforonejointwithalternativeforFJC 810minutes(e.g. with5WSorPNCor other
alternatives)
Saving perjointonmarineduration 2.5minutes
Totalmarine duration 341Hrs /14Days
Saving onMarineCost 5.6MM$
(assumed$400K/day)
GirthWeldShrinkWraps $75/meter2 [Ref.16]
Totalarea(approx.) 4712m2
CostonaccountofFJC $354K
Costforadditionalanode $225K(lesser thanFJCmaterialcost*)
Saving Itseemapprox.5MM$onaccountofmarine
durationcanberealizedper100KM
consideringotheraspectincludingspecialized
crewforFJCapplication
[Source: Ref. 5, 16]
 Wayforward

External Corrosion Coating and Pipeline Integrity

Coating Failure mechanism and challenges
Coating Specification
Field Joint Coating Selection
EPCI contractor engagement
Interaction needs to be encouraged amongst the design
engineer, coating material manufacturer, coating applicator,
installation contractor and the end user to provide an
economical solution and to enhance long term performance
of external coating system for pipeline integrity.
 Conclusion

This presentation can be seen as the start of further discussion for

the Specification authors, Standardization bodies and subsea
industry as a whole to review

The coating selection process in view of upcoming challenges

in terms of high temperature pipeline, long lasting coating
system, minimizing or eliminating the failure

Requirement and compatibility for field joint coating system

Incorporating the ongoing innovation & researches

 Question

Whatnextof3LPPforpipelinesoperatingmorethan140degC?
 References
Sl No. References

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http://www.nace.org/uploadedFiles/Publications/ccsupp.pdf.
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 References
Sl No. References

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[s.l.] :www.napipelines.com. January/February2010.
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Conference&Expo. USA :NACEInternational,2013. Vol.Paperno.2258.
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