Surface Preparation for FBE/3LP Pipecoating Chris Bates Group Technical Coordinator, Pipecoating CHEMETALL PLC, UK
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1 Surface Preparation for FBE/3LP Pipecoating Chris Bates Group Technical Coordinator, Pipecoating CHEMETALL PLC, UK
2 Surface Preparation - Purpose To Clean the surface To provide a surface condition to which a coating can adhere AA Coating is only as good as the surface to which it is applied Poor preparation means poor performance
3 Pipecoating Procedures - Key Steps Surface Preparation Line : 1: Initial Cleaning and Drying 2: 1st Shot/Gritblast 3: 2nd Gritblast 4: Chemical Cleaning ACID WASH 5: Inspection Coating Line : 6: CHROMATE Treatment 7: Pre-Heat 8: Coating Application 9: Quenching 10: Inspection and Testing
4 Pipe Condition Questions to be asked Type, Grade and Hardness of the steel? Where from? Age? Storage and Transportation? Surface Condition? Yard Storage? Atmospheric conditions?
5 Pipecoating: : Plant, Materials & Services Design, Layout and Maintenance Air Quality Water Quality Heating methods Materials in contact with the pipe surface Housekeeping!
6 Gritblasting what, how & why? Abrasives choice and mix? To descale/deoxidise the steel surface To provide the correct surface profile for the chosen coating But, it does not clean
7 Gritblasting Specifications applying ISO 8501 part A1: minimum Sa2½ required ISO : Profile Amplitude of µm (60-80µm preferred) But, what about Profile Density? ISO : Dust level <2
8 NOT ready to coat - Why not? Not clean enough Residual contamination Chlorides! Inconsistent surface finish Unstable and Fragile All of which have a measurable impact on performance?
9 ACID WASHING - Why? Guarantees a surface Chloride level of LESS THAN 2µg/cm 2 Eliminates any concerns about the original received pipe condition Guarantees a clean surface all the time A measurable improvement in overall coating quality and performance But only using approved processes of known quality and source #
10 ACID WASHING - Method WHERE? - After Gritblasting WHAT? Oakite 31 and 33 - proven Acidbased cleaning systems HOW? - 3-Step Procedure - All-in-one Unit FROM WHOM? the approved supplier, using their expert advice and support $
11 Acid Washing - spray application & reaction
12 Acid Washing - high pressure water rinsing
13 ACID WASHING - Benefits A clean surface Improved coating quality Improved performance REDUCED surface preparation cost
14 CHROMATE Treatment - Why? The only proven means of ensuring: Maximum Coating application consistency and quality Maximum Coating adhesion and corrosion resistance Maximum Coating performance and durability But only using approved processes of known quality and source
15 CHROMATE Treatment - Why? Without Chromate With Chromate Properly applied, the Chromate Treatment will ensure the best possible coating adhesion and corrosion resistance (Cathodic Disbondment, Hot Water Soak, Strain, Peel tests, etc.) on well prepared pipe. Over the last 20+ years, this has been the proven result on countless pipecoating projects using FBE or FBE-primed 3-Layer Polyolefin coatings all over the world, totalling many 1000 s of Kms of buried & sub-sea pipelines.
16 CHROMATE Treatment - Method WHERE? - Immediately before the Pre-Heat WHAT? - Gardobond 4504PC and Accomet PC - proven Dry-in-Place Chromate pretreatment processes HOW? by even, thin film application and drying FROM WHOM? the approved supplier, using their expert advice and support
17 CHROMATE Application: Drip-feed & wipe method
18 CHROMATE Application: Brush/Roller method
19 CHROMATE Treatment the Chemistry The Chromate/Silica complex oxide conversion coating process: Reacts with: The clean, lightly oxidised steel surface To Form: a layer of complex mixed oxides of Chromium, Silicon and Iron, integral with the steel surface, ca 1µm thick. By: Chemical reaction, with the surface and internally within the applied film, AND Heat. #
20 Chromate Layer schematic FBE >150µm Si rich Oxide Layer Cr rich Oxide Layer 0.5-2µm Fe/Cr rich Oxide Layer STEEL >10mm, [60-80µm Profile]
21 CHROMATE Treatment Benefits Maximum Coating adhesion, performance and service life Consistently achieved coating quality and durability Faster, easier, reject-free surface preparation REDUCED surface preparation cost Reduced Pre-heat/cure energy costs
22 CHROMATE Treatment: Expectations WILL give total control over the final surface condition WILL provide maximum coating consistency and quality all the time WILL maximise coating performance and durability all the time WILL provide low cost insurance against failure
23 CHROMATE Treatment: Averaged Performance Averaged Cathodic Disbondment Performance (30 Day, ambient) 10 Shot/Gritblast only (SB) SB + "Acid Wash" SB + "Chromate" CD Rating (10-worst; 0-best) SB + "Acid Wash" + "Chromate" Surface Preparation
24 Summary Know what you are dealing with - pipe and its condition Prepare for the worst case Use the Shot/Gritblast procedure effectively - don t overestimate its capability Manage and control the abrasive type and mix carefully Concentrate on achievement of the right profile USE Acid Washing to ensure complete surface cleanliness, USE Chromate to ensure TOTAL surface consistency and quality - maximum performance will be the end result Manage and look after the plant and its physical impact Plan and implement easily manageable procedures, proved with PQT s, and stick to them! To get it right - first time, every time
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