Coatings – Directional BoringCoatings – Directional BoringCoatings – Directional BoringCoatings – Directional Boring

Tim JenkinsTim Jenkins

Coatings – Directional BoringCoatings – Directional BoringCoatings – Directional BoringCoatings – Directional Boring

Design Considerations (data collection)Design Considerations (data collection) Contributed coating failuresContributed coating failures

Pre-Operation stepsPre-Operation steps Post-Operation stepsPost-Operation steps

Design – Directional Boring Coatings

Design – Directional Boring Coatings

Data Collection for coating selectionData Collection for coating selection Surrounding EnvironmentSurrounding Environment

Soil composite Soil composite LocationLocation

Foreign lines –Foreign lines –• Other pipelinesOther pipelines• AC Transmission towersAC Transmission towers

Timeframe Timeframe

Powercrete – Powercrete – 12 to 15 mils of FBE (Fusion bonded Epoxy) 3M 12 to 15 mils of FBE (Fusion bonded Epoxy) 3M

62336233 Concrete polymer base outer coat 20mils per Concrete polymer base outer coat 20mils per

application, two applications normally usedapplication, two applications normally used Typically 55 to 60 mils coating thicknessTypically 55 to 60 mils coating thickness

FBE – Dual coatFBE – Dual coat 12 to 15 mils of 3M 623312 to 15 mils of 3M 6233 20 mils of a Dual coat application of 3M 635220 mils of a Dual coat application of 3M 6352 Typically 35 mils total coating thicknessTypically 35 mils total coating thickness

Design – Directional Boring Coatings

Design – Directional Boring Coatings

Time frame considerations –Time frame considerations – Powercrete – hand applied, 4 joints per 2 Powercrete – hand applied, 4 joints per 2

hours can be coatedhours can be coated FBE – Dual coat – assembly line, 3000 feet FBE – Dual coat – assembly line, 3000 feet

in three hoursin three hours

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Durability –Durability – Powercrete – UV protected, more abrasive Powercrete – UV protected, more abrasive

resistance in comparison to the FBE dual coatresistance in comparison to the FBE dual coat Recommended practice – Recommended practice –

Abrasive environment use the Powercrete Abrasive environment use the Powercrete application, application,

In In well knownwell known normal soil application, FBE normal soil application, FBE dual coat acceptable and probably more cost dual coat acceptable and probably more cost effective effective

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Coatings Case history - FailuresCoatings Case history - Failures The most popular coating failure -The most popular coating failure -

Cathodic ShieldingCathodic ShieldingRock formationRock formation

• Pipe wedge next to a rock formation at the point Pipe wedge next to a rock formation at the point of coating holidayof coating holiday

Disbondment coatingDisbondment coating• Coating becomes disbondment from the surface Coating becomes disbondment from the surface

of the pipe, but shields the CP from the surface of of the pipe, but shields the CP from the surface of the metallic structure exposed under the coatingthe metallic structure exposed under the coating

Design – Directional Boring Coatings

Design – Directional Boring Coatings

Cathodic Shielding - RockCathodic Shielding - RockCathodic Shielding - RockCathodic Shielding - Rock

Cathodic Shielding – Coating Cathodic Shielding – Coating DisbondmentDisbondment

Cathodic Shielding – Coating Cathodic Shielding – Coating DisbondmentDisbondment

Coatings Case history - FailuresCoatings Case history - Failures Thickness of coating application –Thickness of coating application –

The thicker of the coating, less durable, The thicker of the coating, less durable, more brittlemore brittle

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Harlem RD Bore – Coating Harlem RD Bore – Coating FailureFailure

Harlem RD Bore – Coating Harlem RD Bore – Coating FailureFailure

Coatings Case history - FailuresCoatings Case history - Failures Powercrete –Powercrete –

Flexibility – Degrees per pipe diameterFlexibility – Degrees per pipe diameter 1.41.4° for 35 mils° for 35 mils .75° for 55 mils.75° for 55 mils

FBE – Dual Coat – FBE – Dual Coat – Flexibility – Degrees per pipe diameterFlexibility – Degrees per pipe diameter 2.82.8° for 35 mils° for 35 mils

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Coatings Case history – FailuresCoatings Case history – Failures

FBE Dual coat more flexible than FBE Dual coat more flexible than PowercretePowercrete

But,,, But,,, Powercrete more impact resistance than Powercrete more impact resistance than

FBEFBE

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Powercrete application adhesive bond to the Powercrete application adhesive bond to the FBE, and the dual coat 3M will result of FBE, and the dual coat 3M will result of complete pull out of coating application complete pull out of coating application from the metal surface due to, coating from the metal surface due to, coating flexibility angle being too greatflexibility angle being too great

In a normal pulling process, coating will be In a normal pulling process, coating will be disbondment by layers and normally does disbondment by layers and normally does not result in total removalnot result in total removal

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Girth Welds –Girth Welds – Two part Liquid Epoxy usedTwo part Liquid Epoxy used

Protal 7200 - 50Protal 7200 - 50° or greater° or greaterProtal 7125 - 50° or lessProtal 7125 - 50° or lessR95 – Powercrete J (new)R95 – Powercrete J (new)

Pipe Preparation – Pipe Preparation – Sand blasting – NACE 2 or SSPC-SP10Sand blasting – NACE 2 or SSPC-SP10

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Northern Loop – Hoover Bore Northern Loop – Hoover Bore Girth WeldsGirth Welds

Northern Loop – Hoover Bore Northern Loop – Hoover Bore Girth WeldsGirth Welds

Transmission Class pipelineTransmission Class pipeline ECDAECDA

Pipe thickness designPipe thickness design %SYMS%SYMS

ICDAICDA Internal CouponsInternal Coupons ProbesProbes Inclination angle considerationInclination angle consideration

Do not get greater than the Critical Inclination angleDo not get greater than the Critical Inclination angle Inline Inspection – smart piggingInline Inspection – smart pigging

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Design – Directional Boring Design – Directional Boring CoatingsCoatings

Pre-Operation StepsPre-Operation StepsPre-Operation StepsPre-Operation Steps

Columbia Gas needs to inspect all coated pipe line Columbia Gas needs to inspect all coated pipe line at the coating mill before the pipe is coatedat the coating mill before the pipe is coated

Corrosion Technicians are being trained, KTA Corrosion Technicians are being trained, KTA certifiedcertified

Communication should be placed to Corrosion Communication should be placed to Corrosion FLL by Supply chainFLL by Supply chain

Need to consider cost of technician or coating Need to consider cost of technician or coating inspector to work order budgetinspector to work order budget

Corrosion Department InspectingCorrosion Department InspectingPowercrete application for Powercrete application for Maumee River CrossingMaumee River Crossing

Corrosion Department InspectingCorrosion Department InspectingPowercrete application for Powercrete application for Maumee River CrossingMaumee River Crossing

Pipe Inspected in the field by the corrosion departmentPipe Inspected in the field by the corrosion department Determine any coating defects due to shipmentDetermine any coating defects due to shipment

Pipe and girth welds coatings inspected in the field by the Pipe and girth welds coatings inspected in the field by the corrosion technicianscorrosion technicians Dew point readingsDew point readings Pipe TemperaturePipe Temperature Chloride checkChloride check DFTDFT WFTWFT Observe Jeeping process – recommend voltage settingObserve Jeeping process – recommend voltage setting

Pre-Operation StepsPre-Operation StepsPre-Operation StepsPre-Operation Steps

Post Operation StepsPost Operation StepsPost Operation StepsPost Operation Steps

Survey – Coating and CPSurvey – Coating and CP CP – CP –

CIS – Close Interval surveyCIS – Close Interval surveyExternal Coupons usedExternal Coupons used

CoatingCoatingDCVG – Direct Current Voltage GradientDCVG – Direct Current Voltage GradientACVG – PCM – Alternate Current Voltage ACVG – PCM – Alternate Current Voltage

GradientGradient Cost of survey new steel pipe by corrosion department Cost of survey new steel pipe by corrosion department

should be considered on the work order budgetshould be considered on the work order budget