Michael Magerstadt Rosen Group Stans. Switerland

Michael Magerstädt

4th Annual Slurry Pipeline Conference · Perth · 12-Nov-2014

CASE STUDY: OIL SANDS AND PHOSPHATES SLURRY TRANSPORT

DESIGN LIFE EXTENSION BY ELASTOMER LINING OF STEEL PIPES

Slide 2

AUTHORS

Michael Magerstädt

ROSEN Group

Obere Spichermatt 14

6370 Stans

Switzerland

Thorsten Räth, Larry K. Lai, Holger Rosenbleck-Schmidt

ROSEN Group

Am Seitenkanal 8

49811 Lingen

Germany

Please send correspondence relating to this presentation to:

mmagerstaedt@rosen-group.com

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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UPDATE HIGH PERFORMANCE POLYURETHANE

ELASTOMERS

What is Polyurethane (PUR)?

Up to 8 components: Isocyanate, polol, crosslinkers,

hardeners, chain extenders, etc.

„the Polyurethane“ does not exist –> millions of

permutations possible

Typical applications:

Soft foam (seats, matttresses)

Hard foam (insulation material)

TPU (injection moulded, automotive,

houshold appliances)

Elastomers (pipeline inspection tools, buffer,

rollers, etc.)

Adhesives and coatings

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Experimental results from abrasion, adhesion, and tear resistance tests at independent laboratories demonstrate that these materials are ideally suited for internal protection of steel pipes.

very high abrasion resistance very high tear strength

UPDATES HIGH PERFORMANCE

POLYURETHANE ELASTOMERS

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UPDATE HIGH PERFORMANCE POLYURETHANE

ELASTOMERS

Extensive tests have been performed determining key properties

• All tests on RoCoat were carried out by independent laboratories or

by operators

• Abrasion tests ASTM G 75; ASTM B611; DIN EN ISO 53516;

EN ISO 598; ASTM D4060/7;

• Adhesion tests EN10290; ASTM D 4541

• Flexibility, bending, gouge tests CSA Z245.20-10, Clause 12.11;

CSA Z245.20-10 , Section 12.15 ;

• Cold wall effect: Atlas Cell Test

• Slurry Jet Test

• Hot water immersion adhesion test ASTM D 870; EN 10290

• Various other tests

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UPDATE HIGH PERFORMANCE POLYURETHANE

ELASTOMERS Adhesion to Steel – most essential for interior coatings

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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CASE OIL SAND TAILINGS

20‘000 hrs. of operation without rotation; still 20 mm coating @6 o‘clock

carbon steel needs to be rotated after 2500-3000 hrs

Tailings including rocks up to 5“ diameter

Coating thickness: 1“

Flow velocity approx. 5 m/s

Temperature 55-65 °C, no thermal insulation on pipe

Outside temperature down to -40 °C in winter

Line cleaning with water 95° C at regular intervals

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CASE OIL SANDS TAILNGS

hydrotransport lines:

- similar life times as tailings; in some cases longer since bitumen acts as lubricant -

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CASE OIL SANDS TAILNGS

Tailings lines and pipe storage yard and field test array

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CASE OIL SANDS TAILNGS

Cold wall effect….

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CASE OIL SANDS TAILINGS

Cold wall effect: Atlas Cell test

Tinternal (coating) = 50°C

Texternal (Stahl) = -20°C ΔT = 70°C, 17 Weeks

Results: no disbondment, cracks,

holes etc.

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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CASE OIL SANDS / EROSION-CORROSION

Erosion-Corrosion in Oil Sands Tailings

- Straight pipe after an elbow behind a pump

- High turbulence, high oxygen content

- At this location, steel pipe with chromium

carbide overlay (CCO) needs to be rotated

every 2’500 to 3’000 hours of operation

- First rotation of high performance elastomer

spool at 11‘000 hours with 5 mm elastomer

left at the 6 o‘clock position

Wear measurements taken during shutdown

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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CASE PHOSPHATE SLURRY STATION PIPING

Phosphate Slurry:

• pump station piping

• high turbulence

• flanged connections, customer-specific

• 12 mm coating

• selected areas 15 mm coating

• in operation for 18 months now

• Excellent performance

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CASE PHOSPHATE SLURRY STATION PIPING

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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HIGH PERFORMANCE POLYURETHANE

ELASTOMERS VS. HDP LINERS

Low-erosion slurry lines / erosion-corrosion conditions

• HDPE Liners are not chemically bound to the interior wall of the steel pipe.

• They require a minimum thickness to have enough structural strength to prevent

liner collapse in low pressure situations.

• Material cost per kg is lower for HDPE than for high performance

polyurethane elastomers; but a much thinner layer is required:

• For an 18“ steel pipe ID, minimum structural thickness of an HDPE liner

has to be 13 mm.

• For the same pipe ID, a High Performance PUR Elastomer

coating thickness of 3-5 mm is sufficient.

• At similar or lower total cost as HDPE:

• longer design life due to higher wear resistance;

• higher safety against penetration of erosive components;

• No danger of liner collapse;

• Installation cost significantly lower due to field welding process.

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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FIELD JOINING

RECAP: Welded Joints: Single-weld syetem

Features

Just one filet weld per pipe joint to be performed in field

No in-field backfilling, no filling holes

Factory-prepared one-sided weld

No cutback

Firmly installed insulating layer under weld

Patent pending

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FIELD JOINING

•Entire pipe sections joined by this system

are in continuous operation

•The welding process complies with ASME

Sec. IX.

•The field joints in field tests now in

Canada comply with ASME B31.11

•Pressure tested up to 250 bar (3‘000 PSI)

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FIELD JOINING

left: weld joint – female end // right: expansion barrel

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CONTENT

1. Update High Performance Polyurethane Elastomers

2. Case Oil Sands Tailings

3. Case Oil Sands / Erosion-Corrosion

4. Case Phosphate Slurry Station Piping

5. High Performance Polyurethane Elastomers vs. HDP Liners

6. Field Joining

7. Outlook

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Intelligent RoCoat™ Allowing Remote Wear Measurement:

Unique, patent-pending system that measures wear of interior high performance elastomer coating

• No hole in the pipewall is required for data transmission.

• First system to go on stream in Alberta oil sands in January 2015

OUTLOOK

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Intelligent RoCoat™ Allowing Remote Wear Measurement:

Unique, patent-pending system that measures wear of interior high performance elastomer coating

• Differentiation in the single-mm range

• Two readout modes:

• Firmly installed instrument at the

outside of the pipe with wireless

data transmitter and central

• Water – and dirt protected contact

points at the outside of the pipe for

attachment of portable readout

equipment by inspector

OUTLOOK

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Intelligent RoCoat™ Allowing Remote Wear Measurement:

Unique, patent-pending system that measures wear of interior high performance elastomer coating

• No batteries or other energy source

inside the pipe

• number of individual sensors around the

pipe circumference can be selected to

fit the rotation requirements o the operator

(to assure that there is a sensor in or near

the 6 o°clock position after rotation)

OUTLOOK

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OUTLOOK

Selected References Mining

www.rosen-group.com

THANK YOU FOR JOINING

THIS PRESENTATION.