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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"$*#+7’<=0%)#>
?)#1"17’1=*6’&)*+’0.0+"@0A
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2 G*4 ’&)*+%#,0’5C)+>*//6%"17’&)61’*//6%"1’@*0+%&0A
2 H.?$%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’."*$0A
GTI Soil Bed Construction
Total Ambient Systems: 48 (24 on both 8" and 24" and 24 on only 8") –
All 2 year and 5 year pipes.
Total Heated Systems: 12 (all on both 8" and 24") –
All 1 year only.
(6*.’I"10’5O7I7(7P73A
QQR
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5 Year Pipes
D2
E2
D4
E4
B4
B3
C3
(6*.’I"10’5O7I7(7P73A
(6*.’I"10 D*#1’I"10T)&E.’I"10
-)/’U%";’)<’O66’I"10N
C4
QQR SR
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VR
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-’H’3’T’W ’X ’(’X’M’B’Y’3’D
A1
A2
B1
B2
C2
C1
H)+
O%$
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
QQR
QR
QR
QR
KR
KR
S9R
QR
KR
QR
KR
5 Year Pipes
D2
E2
D4
E4
B4
B3
C3
(6*.’I"10’5O7I7(7P73A
(6*.’I"10 D*#1’I"10T)&E.’I"10
-)/’U%";’)<’O66’I"10N
C4
QQR SR
QR
VR
QR
QR
QR
KR
S9R
-’H’3’T’W ’X ’(’X’M’B’Y’3’D
A1
A2
B1
B2
C2
C1
H)+
O%$
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
QQR
QR
QR
QR
KR
KR
S9R
QR
KR
QR
KR
5 Year Pipes
D2
E2
D4
E4
B4
B3
C3
(6*.’I"10’5O7I7(7P73A
(6*.’I"10 D*#1’I"10T)&E.’I"10
-)/’U%";’)<’O66’I"10N
C4
QQR SR
QR
VR
QR
QR
QR
KR
S9R
-’H’3’T’W ’X ’(’X’M’B’Y’3’D
A1
A2
B1
B2
C2
C1
H)+
O%$
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
QQR
QR
QR
QR
KR
KR
S9R
QR
KR
QR
KR
5 Year Pipes
D2
E2
D4
E4
B4
B3
C3
(6*.’I"10’5O7I7(7P73A
(6*.’I"10 D*#1’I"10T)&E.’I"10
-)/’U%";’)<’O66’I"10N
C4
QQR SR
QR
VR
QR
QR
QR
KR
S9R
-’H’3’T’W ’X ’(’X’M’B’Y’3’D
A1
A2
B1
B2
C2
C1
H)+
O%$
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
GTI Field Applied Coatings Research Program
Presented to OPS Advanced Pipeline Coatings Workshop
June 9, 2005
Paul Beckendorf
GTI
847.768.0889