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Presenting Author:

Christopher P. DorseySenior Manager, U.K. Middle East & Asia

TIB-Chemicals AG, Germany

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Economical and, Ecological Solution Two component solvent free Polyurethane's have been used as

a single protective coating for steel pipes, valves fittings and

other steel structures for over forty years.

Many internationally recognized examples where polyurethane

systems have been selected as the most cost effective and best

suited, for pipeline rehabilitation projects

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Excellent Chemical Mechanical Properties:

Excellent Adhesion Capacity High Impact & Abrasion resistance.

Corrosion protection with good chemical resistance.

Extremely Short Curing Time.

Advantages of easy application and control on-site.

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Surface PreparationManual

Automated Equipment

Requires

SA 2 (ISO 8501-1)

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Manual Surface Preparation In The Trench Project: IOCL Vadinar

Pipeline Rehabilitation:

42 Parallel Pipes

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Automated Surface Preparation

Uniform surface preparation

Faster

High quality

Good Anchor pattern

More Expensive

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Coating Application:100% Solids polyurethane coating technology allows

several application techniques including:

Manual two component heated airless spray machine

Automated Rotary Spraying Ring (In-Situ)

Automated Line Travel Equipment (Out of the Trench)

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Coating Application:100% Solids polyurethane coating technology allows several application

techniques including:

Manual (two component heated airless spray machine)

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Coating Manual Application

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Manual ApplicationCan be completed in open areas and areas with difficult access

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Manual Application Manual application in

Compressor Station

Operating pipeline(operating @ +40oC)

Tenting used to protectspray area and surfacepreparation

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Manual ApplicationIOCL 42 Pipeline Vadinar

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Manual ApplicationPossible Problems Encountered:

Slower (Than Automated Spraying Equipment)

Can be inconsistent with thickness

Over consumption can run @ 40% to 100% over

theoretical Qualified skilled labour can prove hard to find

More Economical than Automatic line travel equipment

method

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Rotary Automatic Spray System(In the Trench) Automatic spray ring system can be employed when speed

of application is an important requirement.

When short distances (Bell hole) Automatic rotary sprayring apparatus, offers the advantages that manual sprayingmethod cannot.

Speed of application. (0.5 meters-to-1 meter per minute)

Consistent & Uniformed thickness. Reduced overspray.

Reducing material costs.

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Automated Application In-Situ

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Automated Line Travel

Removal of the existing coating. (CTE, Tapes etc,) using

high pressure water jetting.

Abrasive blast cleaning (Sa 2.5 - ISO 8501-1)

Application of Two Component Polyurethane

Providing a single (Homogeneous) coating.

Multi-step Operation

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Coating RemovalCTE coating 38 Gas Pipeline Texas USA (1994)

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Surface Preparation Abrasive Blast

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Automated ApplicationLine Travel

Single Pass Application of Two Component Polyurethane Coating38 @ DFT 800 m/100m

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HighBuild CharacteristicsBy

Automated or Manual Application

1.7 mm in 1 pass

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Typical Alternative Liquid Systems:Two Component Liquid Epoxy :

Slower curing,

Low build thickness characteristics,

Less flexibility; and

Approximately 15% more expensive.

Two Component Liquid Epoxy Offers High operating temperatures (90oC+)

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Typical Testing Results:S/F Epoxy S/F Polyurethane

These typical testing values illustrate why, solvent free polyurethanes are

selected as the preferred coating system for pipeline rehabilitation

programmes.

Test Standard Solvent Free Epoxy Solvent Free P.U.Sag Resistance Typically 1mm Typically 2mm

Hard dry time

(Fast Setting)

4 Hours 1 Hour

Flexibility: ASTM-D522 Typically < 5% Typically < 40%

Impact Resistance: ASTM-G14 Typically: 3-4 Joules > 8.8 Joules

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Application Temperatures and Curing Time100% Solvent Free Polyurethane

Application Temp. Substrate > 10CComp. A 50C 80C

Comp. B 40C 60C

Pot Life Approx. 40 sec. At 60CCuring Time At 20C At 50C At 90C

touch dry 10 min. 2 min. * < 1 min. *

stackable 8 hours 30 min. * Immediately

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Holiday Testing - Within 2 Hours

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Solvent Free PolyurethaneTypical Performance Properties

Test Standard ResultsAdhesion: ASTM-D4541 Greater than 150 kg/cm onto blast

cleaned steel.

Chemical Resistance: - Good in most solutions other than,

aromatic solvents.

Flexibility ASTM-D522 Average 30% - 50% elongation tobreak, with cold bend resistance

down to 12.7mm mandrel.

Hardness: ASTM-D2240 Typically 70-80 Shore D

Abrasion Resistance: ASTM-D4060 Typically 70 mg loss (Taber

abrader, 1000 cycles, CS 10 wheels, 1kg loading)

Tensile Strength: ASTM-D638 13 N/mm

Penetration Resistance: ASTM-G17 Less than 10% of the thickness

penetrated

Impact Resistance: ASTM-G14 > 8.8 Joules

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Conclusions

Appointment of qualified approved applicators /contractors.

Experience and proven track record in theapplication of, Multi Component Liquid CoatingSystems. Results, Surface preparation, application of the newcoating and final testing, completed to thespecification requirements / criteria.

Which ever method of application selected forpipeline rehabilitation. The most important factorsare: