Role of Corrosion & Field Joint Coating System Selection Criteria in Submarine Pipelines Integrity

Transcription

1 Role of Corrosion & Field Joint Coating System Selection Criteria in Submarine Pipelines Integrity Nawin Singh McDermott International, Inc McDermott International, Inc. All rights reserved. February 2015

2 What is Covered? Pipeline System Pipeline External Corrosion & Impact External Corrosion Coating Systems Corrosion Coating Selection Criteria Field Joint Coating Systems and Alternatives Way forward Conclusion

3 Why Pipelines and what they offer? Lower cost More energy transportation capacity Feed different segments of the energy consumption Safer & environment friendly mode of transportation Negligible loss of product in transit

4 Pipeline External Corrosion When pipeline is either buried or submerged in water, corrosive environment constitute between metal surface and its environment. Corrosion is the damage of a substance which is usually a metal. The rate of corrosion depends on various parameters including Pipeline Operating Temp. Surroundings e.g. water quality Soil quality & burial status Interference with other facility

5 Pipeline Incident Statistics Construction Fault, 7.5 Ground Movement, 3.3 Incidental TP damage, 7.2 Malicious TP damage, 5 External Corrosion 26% Stress Cracking, 1.1 Internal Corrosion, 5.3 Materials Fault, 8.3 Accidental TP damage, 33.5 Source: Ref. 3 [ERM from CONCAWE ] Human Error, 2.5 Other Natural Hazards 0.3

6 Pipeline Integrity & Corrosion Impacts Cost of corrosion is upto 3% [2] of GDP for USA For Oil and Gas Pipeline alone, it is approx. $7billion [2] per year for USA Corrosion rated as 2 nd integrity [10 26% [4] ] most common threat for pipeline Coating cost is only 5 6% [19] of project cost but play very important role in integrity.

7 Pipeline Corrosion Coating Developments Coal Tar & Asphalt Enamel Powder Epoxy Two layer System Multilayer polyolefin [Source:

8 Coating Type and Market Share North America South America Middle East Europe North Africa Asia FBE PE/PP Other [Source: Ref. 10]

9 Industry Standards for External Coating AFNOR AWWA BS CSZ DIN ISO NF A (FBE) NF A (3LPE) NF A49 711(3LPP) AWWA C203 (CTE ) AWWA C213 (FBE) BS 4164 (CTE) BS 4147 (AE) CSA Z (FBE) CSA Z (Olefins) DIN (3LPE) DIN (3LPP) ISO (3LPE & PP) ISO (FBE) ISO (2L FBE) ISO (2LPE)

10 Coating Selection Criteria Material Application Repair Economics Past experience of End User Local Regulation Surroundings Environment External Corrosion coating Adhesion Cathodic Disbondment Holiday Application Rate Compatibility with FJC Easily repaired Ease of application Performance Mechanical Properties Electrical Properties Ageing/Design Life [Source: Ref. 15]

11 Coating Selection Criteria [Ref. 6, 7, 13, 18] Typical Properties Single Layer FBE 3LPE 3LPP Service Condition Upto 80 C (110 C) Upto 65 C (80 C) Typical Thickness 350 m 600 m 2.2mm to 4.0mm Upto 110 C (140 C) Impact Resistance [@23 C] Cathodic Disbonding [@approx. 23 c for 28days] Adhesion Strength [@23 C] Suitability for CWC application or HDD or similar >1.5J/mm >7J/mm >10J/mm <8.5mm < 7mm < 5mm Rating 1 to 3 > 100N/cm > 250N/cm Suitable with additional layer Suitable Suitable Damaged during Handling Moderate Low Very Low Cost [16] Comparatively lesser than PE High Relatively Higher than PE

12 Coating Selection Criteria Ranking considered on 1 to 3 Scale (based on 3 as superior) Ranking index Coating system FBE 3LPE 3LPP Current Generation Coating System Normal Temp. Limit Max. Temp Limit Impact Resistance Adhesion Disbondment Indentation Resistance Cost Performance

13 Field Joint Coating (FJC) System Why? Corrosion control To supplement CP System Mechanical protection FJC System Why? Design Codes specify e.g. DNV RP F102, ISO

14 Compatible FJC system Fusion Bonded Epoxy (FBE) FBE 100% solid liquids, epoxy, epoxy urethane Heat shrink sleeves (HSS) Cold and hot applied tapes Three layer polyethylene (3LPE) Three layer HSS Multilayer flame spray with PE Three layer polypropylene (3LPP) Three layer HSS Multilayer flame spray with PP FBE, spray applied adhesive, co extrudedpp [Source: Ref. 1]

15 FJC System Selection Technique Compatibility Pipelay geographical location Environment Complexity Ease of repair Cost

16 Field Joint Coating Possible Alternatives Protective Network Coating System (PNC) Solid Polyurethane Other alternative for fast curing Compensation with CP Example: System Injection Molded PP PNC Pre heat Temperature 230 C 230 C Cycle time on 24 joint 8 10 minutes < 6 minutes Operating Temp. rating 150 C Level of applicator expertise High Low Industry Compliance Yes Yes [Source: Ref. 5]

17 Impact of Improvement in FJC System Pipeline Details Marine duration for one joint with conventional FJC Marine duration for one joint with alternative for FJC Saving per joint on marine duration Total marine duration Saving on Marine Cost (assumed $400K/day) 24 OD, 100KM long 12 minutes (with 4 WS & 3 station for FJC) 8 10 minutes (e.g. with 5 WS or PNC or other alternatives) 2.5 minutes 341 Hrs / 14 Days 5.6 MM $ Girth Weld Shrink Wraps $ 75 /meter2 [Ref. 16] Total area (approx.) 4712 m 2 Cost on account of FJC Cost for additional anode Saving [Source: Ref. 5, 16] $ 354 K $ 225 K (lesser than FJC material cost*) It seem approx. 5 MM$ on account of marine duration can be realized per 100KM considering other aspect including specialized crew for FJC application

18 Way forward External Corrosion Coating and Pipeline Integrity Coating Failure mechanism and challenges Coating Specification Field Joint Coating Selection EPCI contractor engagement Interaction needs to be encouraged amongst the design engineer, coating material manufacturer, coating applicator, installation contractor and the end user to provide an economical solution and to enhance long term performance of external coating system for pipeline integrity.

19 Conclusion This presentation can be seen as the start of further discussion for the Specification authors, Standardization bodies and subsea industry as a whole to review The coating selection process in view of upcoming challenges in terms of high temperature pipeline, long lasting coating system, minimizing or eliminating the failure Requirement and compatibility for field joint coating system Incorporating the ongoing innovation & researches

20 Question What next of 3LPP for pipelines operating more than 140deg C?

21 References Sl No. References 1 [Online] / auth. A JPCL ebook Protecting and Maintaining Transmission Pipeline. Technology Publishing Company. January 10, [Online] / auth. NACE International. Corrosion costs and preventive strategies in the United States. January 11, [Online] / auth. Petitt Glenn // January 10, and Insight/Publications/ERM paper on cross country pipelines failure rates as presented at the IChemE Hazards XXIII Conference/. 4 8th EGIG report no. EGIG 11.R.0402 [Report] / auth. European Gas Pipeline Incident Data Group. Groningen : EGIG, A New 3LPP Offshore Field Joint Coating [Conference] / auth. Mallozzi Meghan and Perez Mario // Corrosion Conference & Expo. USA : NACE International, Vol. Paper No External coatings for buried or submerged pipelines used in pipeline transportation systems Part 1: Polyolefin Coatings [Book] / auth. International Organization for Standardization. Switzerland : ISO, Vols. ISO External coatings for buried or submerged pipelines used in pipeline transportation systems Part 2: Fusion bonded epoxy coating [Book] / auth. International Organization for Standardization. Switzerland : ISO, Vols. ISO Fast Set Polyurethane Coatings High performance, cost effective alternatives for field joint coating [Report] / auth. Schertzer Richard. Canada : [s.n.]. 9 International Experiences with Cathodic Protection of Offshore Pipelines and Flow lines [Report] / auth. TWI for Petroleum Safety Authority Norway. Norway : TWI Ltd., 2007.

22 References Sl No. References 10 New Challenges and Developments in Pipeline Coatings [Article] / auth. Guan Shiwei William // North American Pipelines. [s.l.] : January/February Offshore Pipeline Coating for Field Joints why? [Conference] / auth. Surkein Michael, Melot Denis and Eric Agel // Corrosion Conference & Expo. USA : NACE International, Vol. Paper no Performance of European cross country oil pipelines Statistical summary of reported spillages in 2012 and since 1971 [Report] /auth.concawe Conservation ofclean airand waterin Europe. Brussels : CONCAWE, Plant applied external fusion bond epoxy coating for steel pipe [Book] / auth. CSA Group. Toronto : Canadian Standards Association, Vol. CSA Standard Z Polypropylene Coatings for High Temperatures and Thermal Insulation of Pipelines [Conference] / auth. Turner Barry J. // Corrosion Conference & Expo. USA : Nace International, Vol. Paper no Review of Pipeline Coating Systems from an Operators Perspective [Conference] / auth. Thompson Ian and Saithala Janardhan Rao // Corrosion Conference & Expo. USA : Nace International, Vol. Paper No Thick Film Coating Systems Technology Trends [Conference] / auth. Osborne Michael // PDA Annual Conference. Houston : PDA, Trend in Pipe Coating Selection Process [Conference] / auth. Surkein Michael B. and LaFontaine John P. // International Offshore and Polar Engineering Conference. Beijing : ISOPE, June DIN German Standard for Polyethylene coatings on steel pipe and fittings requirement and testing DIN Germany : Deutsches Institute fur Nomung, [Online] / auth. Dasgupta Chanchal. January 12, in 3lpe coating for pipeline protection.html.