GTI Field Applied Coatings Research Program · GTI Field Applied Coatings Research Program Presented to OPS Advanced Pipeline Coatings ... Paul Beckendorf Gas Technology Institute

GTI Field Applied Coatings Research Program

Presented to OPS Advanced Pipeline Coatings

Workshop

June 9, 2005

Paul Beckendorf

Gas Technology Institute

Pipeline Integrity and Coatings

> Maintaining pipeline integrity: Critical for continued safe

operation of gas distribution and transmission systems

> Accomplished through a comprehensive corrosion control

program which includes correctly specified and applied coatings

used in conjunction with cathodic protection

> Large selection of coating systems on the market

– Endless new product introductions

– Many product reformulations

> Improvements

> Changes to meet new regulations

– The multiple choices present a challenge for Corrosion Engineer

and Integrity Managers

> To thoroughly test the full range of available coating systems

– Determine which coating systems are most suitable for various

environments and situations

– Provide pipeline operators with information needed to make critical

decisions regarding coating systems

> Project results to date will be issued in 3Q05

– Gas Transmission Company funders - comprehensive results

– Manufacturers

> Overall generic results

> Product-specific results to each manufacturer for their products

only

GTI’s Project

Pipeline Coatings Evaluations

Underway at GTI

> In 2002 – FBE Compatible Test – Over 700 applications of

70+ pipeline coating systems made to 24" & 8" welded pipe

sections

– The pipe sections, except for the weld joints, coated with FBE

– Weld joints coated with the full range of available coating

systems

– Manufacturers applied their respective coatings

– Samples excavated and analyzed in 2004 and early 2005

– All work performed per agreed-to specifications (handouts)

Pipeline Coatings EvaluationsUnderway at GTI

> In 2004 – 3-Layer PE Compatible Test - Over 300 applications of 30+ pipeline coating systems made to 8” welded pipe sections

– Pipe sections, except for the weld joints, coated with 3-

layer PE

– Weld joints coated with full range of available coating

systems that are compatible with 3-layer PE

– Manufacturers applied their respective coatings

– All work performed per agreed-upon specifications

Pipeline Coatings EvaluationsUnderway at GTI

> !"#"$%&’()*+%#,’-./"0’-"0+"12 3/)4%"0’5&)*6’+*$7’899:’0)6%107’;*+"$’+)6"$*#+7’<=0%)#>

?)#1"17’1=*6’&)*+’0.0+"@0A

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0C$%#E*?6"7’C)+>*//6%"17’;*4>+./"A

2 G*4 ’&)*+%#,0’5C)+>*//6%"17’&)61’*//6%"1’@*0+%&0A

2 H.?$%1’0.0+"@0’2&)@?%#*+%)#0’)<’+;)’)$’@)$"’)<’+C"’

*?)F"

Phase One – FBE Parent Pipe

> 3#F%$)#@"#+’’

2 -C$""’"4+$"@"’0)%6’+./"0’5$)&E.’0)%67’&6*.7’0*#1A

2 I)+C’*@?%"#+’*#1’"6"F*+"1’+"@/"$*+=$"0’5J’K8K’LA

2 M#1"$’0C)$+’*#1’6)#,>+"$@’?=$%*6’5K’+)’N’."*$0A

GTI Soil Bed Construction

Total Ambient Systems: 48 (24 on both 8" and 24" and 24 on only 8") –

All 2 year and 5 year pipes.

Total Heated Systems: 12 (all on both 8" and 24") –

All 1 year only.

(6*.’I"10’5O7I7(7P73A

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5 Year Pipes

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2Year

Pipes

1 year Pipes

Total Ambient Systems: 48 (24 on both 8" and 24" and 24 on only 8") –

All 2 year and 5 year pipes.

Total Heated Systems: 12 (all on both 8" and 24") –

All 1 year only.

(6*.’I"10’5O7I7(7P73A

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2Year

Pipes

Total Ambient Systems: 48 (24 on both 8" and 24" and 24 on only 8") –

All 2 year and 5 year pipes.

Total Heated Systems: 12 (all on both 8" and 24") –

All 1 year only.

(6*.’I"10’5O7I7(7P73A

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5 Year Pipes

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Total Ambient Systems: 48 (24 on both 8" and 24" and 24 on only 8") –

All 2 year and 5 year pipes.

Total Heated Systems: 12 (all on both 8" and 24") –

All 1 year only.

(6*.’I"10’5O7I7(7P73A

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QR

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KR

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5 Year Pipes

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B3

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(6*.’I"10 D*#1’I"10T)&E.’I"10

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2Year

Pipes

2Year

Pipes

1 year Pipes

Geotextile & Geomembrane Installation –

Moisture & Washout Control

Installation of Drainage System

Pipeline Coatings Evaluation

Cutback Mark Off

Pre-grooving and Welding

of Cut Back Areas

Test Joints As Welded and Feathered

Surface Preparation of Pipes

Fusion Bonded Epoxy Field Applications

Liquid Applications – Brush,

Sponge, and Roller

Liquid Applications – Poured into

Casting

Flame Spray and Shrink Sleeve

Applications

Polymer Concrete and Tape

Applications

Airless and Plural Component

Applications

Heat Shrink Sleeve Applied by

Torch Over 3-Layer PE

Comprehensive Inspection

Report on Every Joint

FBE Coated Pipes Covered in

Tyvek and Awaiting Final Holiday

Testing

Controlled Placement of Coated

Pipe in Test Facility

Triangulation, SensorPlacement, and CP Hook Up

Backfill Operation

Internal Pipe Heating System

Field Applied Coatings Research – Soil Moisture Data

Sand Pit - Soil Moisture (SM)

January - June 2003

0

5

10

15

20

25

30

0 720 1440 2160 2880 3600 4320

Time (hours)

Mo

istu

re(%

)

SM_1

SM_2

SM_3

SM_4

SM_5

SM_6

SM_7

SM_8

SM_9

SM_10

Field Applied Coatings Research –

Soil Temperature Data

Clay Pit - Soil Temperature (STemp)

January - June 2003

0

20

40

60

80

100

120

140

0 720 1440 2160 2880 3600 4320

Time (hours)

So

ilT

em

pe

ratu

re(d

eg

F)

STemp-1

STemp-2

STemp-3

STemp-4

STemp-5

STemp-6

STemp-7

STemp-8

STemp-9

STemp-10

Field Applied Coatings Research –

Pipe Surface Temperature Data

Clay Pit - Pipe Temperature for Heated Pipes

October 2002 - June 2003

0

50

100

150

200

250

0 720 1440 2160 2880 3600 4320 5040 5760 6480

Time (hours)

Pip

eT

em

pe

ratu

re(d

eg

F)

TC Heated

24"

TC Heated

8"

Field Applied Coatings Research

Sand Pit - Soil Pressure (Press)

4th Quarter 2002

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

0 720 1440 2160

Time (hours)

So

ilP

res

su

re(p

sig

)

Press-1

Press-2

Press-3

Press-4

Pipeline Coatings QuantitativeTesting – Control and FieldSamples

> Impact Resistance (ASTM G-14).

> Adhesion (ASTM D-4541).

> Hardness (ASTM D-2240, 2583).

> Penetration Resistance (ASTM G-17).

> Abrasion Resistance (Tabor)

> Cathodic Disbondment (ASTM G-8, 42, 95).

Visual Inspection of Excavated Coating Systems

> Indentions

> Abrasions

> Deformations

> Rust

> Blistering

> Wrinkles

> Peeling

> Delamination

Post-Excavation Hardness andHoliday Testing

> All joints tested for pinholes and cracks

> Hardness testing measurements taken to compare to

original hardness

Adhesion Testing

> Adhesive and cohesive failures

> Adhesion strength measured

up to 3,000 psi

Peel Testing

> Some field-joint systems, such as the heat shrink sleeves,

tapes, wraps and composites were not suitable for

adhesion testing due to their composition

> For these systems, a specially modified GTI peel test

protocol was established and used.

Failure Analysis

> In some cases, the failure investigation revealed serious

deficiencies in the coating system that resulted in severe rusting

and pitting on the substrate, under the coating

> During failure investigation, the condition of the underlying

substrate was documented and photographed for future

reference and evaluation

Next Steps

> 3Q05 – Issue Report of Findings to Date

> 2007 – Excavate 5 year FBE Compatible Coating Systems for Failure Analysis and Testing

> 2007-2008 – Excavate 3 year 3-Layer PE Compatible Coating Systems for Failure Analysis and Testing

GTI Field Applied Coatings Research Program

Questions ???

For further, detailed information, contact

Daniel Ersoy

GTI

R&D Manager

847.768.0663

daniel.ersoy@gastechnology.org

GTI Field Applied Coatings Research Program

Presented to OPS Advanced Pipeline Coatings Workshop

June 9, 2005

Paul Beckendorf

GTI

847.768.0889

paul.beckendorf@gastechnology.org