EROSION-CORROSION PREVENTION BY HIGH PERFORMANCE POLYURETHANE ELASTOMER COATINGS. Michael Magerstädt, Gunther Blitz, Thorsten Räth, Larry Lai

Transcription

1 EROSION-CORROSION PREVENTION BY HIGH PERFORMANCE POLYURETHANE ELASTOMER COATINGS Michael Magerstädt, Gunther Blitz, Thorsten Räth, Larry Lai 1

2 Michael Magerstädt ROSEN Swiss AG Obere Spichermatt Stans Switzerland Gunther K. Blitz and Thorsten Räth ROPLAST GmbH Am Seitenkanal Lingen Germany Larry K.L. Lai ROSEN Canada Ltd a Street SE Calgary, Alberta T2G 5K9 Canada AUTHORS Please send correspondence relating to this presentation to: mmagerstaedt@rosen-group.com 2

3 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 3

4 EROSION Wear depends on: Flow characteristics (turbulence, quasi-turbulence) Flow Velocity Doubling velocity increases wear-rate 4-6 times Settling slurries, bed loads Particle concentration Slurry particle size distribution Particle hardness and shape Impingement angle Excessive wear on elbows, reducers, etc. Other factors: Lifetime? Maintenance effort? Downtime? Others? our hosts here at Edmonton can tell you much more about this 4

5 EROSION Wear depends on: Others? Contact surface» Surface material type» Surface structure» Surface properties Chemical environment Liquid media used (e.g., naphtha and bituminous components in a hydrotransport stream can act as lubricant, thereby reducing wear) ph, chemical stream composition (e.g., dissolved gases or salts) influence on abrasive wear via erosion-corrosion 5

6 Recap from last year: EROSION 2 wear reducing philosophies A) The harder the solids in the slurry and the harder the internal pipe surface, the less the wear. Material alloying, e.g. by increasing C- and Mn-content Steel hardening, e.g. induction heating Wear tiles, e.g. cemented carbides Double wall pipes Bimetallic pipes, e.g. weld overlays B) The harder the solids in the slurry and the more elastic the internal pipe surface, the less the wear. PE liners Rubber liners Polyurethane liners High-Performance Elastomer Liners (Coatings!) 6

7 Recap from last year: EROSION Both philosophies are justified, depending on the conditions of the application. A) Metallic Solutions: 1. High to very high cost 2. Life time increase in comparison to mild steel: Material alloying, e.g. AR200 piping 1.5 to 2 times Induction heating, 3 to 8 times Wear tiles, 5 to 10 times Weld overlays, 6 to 20 times B) Polymer Liner Solutions: 1. Moderate cost 2. Life time increase 5 to 20 times 7

8 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 8

9 CORROSION Corrosion in steel pipelines occurs in all aqueous media. The corrosiveness of aqueous streams is higher than that of water if the stream has a high or low ph; the stream temperature is high; the stream contains medium or higher concentrations of salts, even if the ph is neutral; there is a multiphase stream that contains corrosive gases, in particular H 2 S or CO 2. 9

10 CORROSION Corrosion in steel pipelines occurs in all aqueous media. Since there is no way to provide cathodic protection on the pipe inside (as is customary for external steel pipe protection), the following countermeasures are applied for internal corrosion protection: Anticorrosion additives in the product stream Use of alloyed / galvanized steel Nonmetallic interior pipe coatings or liners Pros and cons of these countermeasures are somewhat similar to those described for erosion. 10

11 CORROSION Pros and cons of these countermeasures are somewhat similar to those described for erosion. Pros and cons of anticorrosion additives in the product stream: The protective effect depends on additive dosage and stream composition Additive is an additional compound contaminating the product stream High operating cost since the additive needs to be added continuously Pros and cons of the use of alloyed / galvanized steel: The protective effect very much depends on stream composition There is a strong correlation between protective effect and price of the steel type used; generally, these are very expensive materials This means: high investment, lower operating cost 11

12 CORROSION Pros and cons of these countermeasures are somewhat similar to those described for erosion. Pros and Cons of nonmetallic interior pipe coatings or liners: The protective effect is depending on the type of material used Generally, the coating itself cannot corrode This can mean: low investment AND low operating cost The nonmetallic material must provide a complete barrier against corrosive media, otherwise, steel corrosion can occur under the coating. In addition, in cases where HDPE liners are used and liquid or gaseous components of the stream are able to penetrate the HDPE, these components will accumulate between liner and pipe wall. Once the pressure inside the pipe fluctuates, this accumulation can create back pressure which which in turn can lead to liner collapse. 12

13 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 13

14 EROSION - CORROSION Definition ( The Multimedia Corrosion Guide, INSA, Lyon, France): Erosion-corrosion is caused by the relative movement between a corrosive fluid and a metal surface. The mechanical aspect of the movement is important and friction and wear phenomena can be involved. This process leads to the formation of grooves, valleys, wavy surfaces, holes, etc., with a characteristic directional appearance. Generally, polymeric pipe coatings do not suffer from erosioncorrosion - as long as a polymer is selected that is stable against and impenetrable by these agents. 14

15 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 15

16 HIGH PERFORMANCE POLYURETHANE ELASTOMER COATINGS + + Polyol Isocyanate Crosslinkers Chain Extenders, Catalysts, other ingredients Polyurethane A construction kit system, adjustable to the application. Millions of possible permutations ( = product properties). R N O C O R H 16 Slide 16

17 HIGH PERFORMANCE POLYURETHANE ELASTOMER COATINGS 17 Slide 17

18 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 18

19 LABORATORY TESTING ASTM B and ASTM G75-LB06/58 Wet Slurry Abrasion Testing 19

20 LABORATORY TESTING Adhesion to Steel most essential for interior coatings 20

21 LABORATORY TESTING Salt Brine Corrosion Resistance No change in adhesion after bending of the steel sample No penetration of the elastomers by salt brine after more than 20 test cycles The elastomer coating prevented spread of corrosion (CUI) from an artificial damage (cut) 21

22 LABORATORY TESTING Cold Wall Effect Atlas Cell Test If an elastomer swells from continuous water exposure, this means that water is being absorbed by the elastomer. This in turn means that water is able to penetrate the polymeric material. When the water reaches a cold steel pipe wall (outside temperature below 0 C), it will freeze and hence expand. This volume expansion leads to mechanical coating disbondment at the location where the water is expanding. The Atlas Cell Test simulates this situation. An oil sands operator tested under conditions that are more extreme than in the standard test to simulate a situation as it occurs in Northern Alberta: 17 weeks; coating side temperature +50 C; steel side temperature -20 C. 22

23 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 23

24 FIELD EXPERIENCE Oil Sands Tailings and Hydrotransport Field trial experience: 1 coating thickness, i.d. of 30 oil sands tailings 3½ years Result: life time extension by a factor of approx vs. uncoated carbon steel to hours without rotation (steel rotated every to h). High Performance Polyurethane Elastomer Coatings are now commercially applied in a number of oil sands tailings as well as hydrotransport lines in Alberta. 24

25 FIELD EXPERIENCE Oil Sands Tailings and Hydrotransport Welded Joints: Single-weld system Features Just one weld per pipe joint to be performed in field No in-field backfilling, no filling holes No cutback 25

26 FIELD EXPERIENCE Oil Sands Tailings and Hydrotransport The welding process complies with ASME Sec. IX. The field joints in field tests now in Canada comply with ASME B31.11 Pressure tested up to 250 bar (3 000 PSI) 26

27 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 27

28 FIELD EXPERIENCE Phosphate Slurry 28

29 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 29

30 FIELD EXPERIENCE Water Injection Lines for Enhanced Oil Recovery In a trial for water injection for EOR, a 5 mm coating was applied due to the smaller (12 ) pipe diameter. The pipes in question usually contain chromium carbide overlays (CCO) for abrasion protection. In the trial, High Performance Polyurethane Elastomer coating lasted as long as the overlay; an end point has not yet been determined. 30

31 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 31

32 FIELD EXPERIENCE High Performance Elastomers and Erosion-Corrosion The test spool after 1500 hours of operation in this high turbulence area In an oil sands tailings line, a high turbulence area was chosen for a field test of High Performance PUR Elastomer coating. In this location, steel pipe with CCO pipe needs to be rotated every to hours of operation Although in tests ASTM G75 and ASTM B 611, CCO shows a significantly lower wear than High Performance PUR Elastomers, in this field trial, the Elastomer has reached hours of operation without rotation at the time of this presentation. The most likely explanation is erosioncorrosion of the CCO. High oxygen content exists in this area. Further investigation is under way. Erosion-Corrosion Prevention by High Performance Polyurethane Elastomer Coatings ROSEN Group January

33 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 33

34 FIELD EXPERIENCE OUTLOOK: Low-erosion slurry lines / erosion-corrosion conditions For conditions of mild wear and / or potential of erosion-corrosion, often HDPE liners are used. E.g., for long-distance slurry transport. For an 18 steel pipe ID, minimum structural thickness of an HDPE liner has to be 13 mm. For the same pipe ID, a High Performance PUR Elastomer coating thickness of 3 mm is sufficient. Material cost similar or lower than with HDPE liner Installation cost lower due to field welding process Higher safety against penetration of erosive components Higher wear resistance longer design life 34

35 FIELD EXPERIENCE OUTLOOK: High Performance PUR Elastomer Wear Protection in Mining Ball mill lifters in copper mines 35

36 FIELD EXPERIENCE OUTLOOK: High Performance PUR Elastomer Wear Protection in Mining Intelligent ball mill lifters in copper mines 36

37 FIELD EXPERIENCE Outlook: High Performance PUR Elastomer Wear Protection in Mining Hydrocyclone Apex, Slurry Pump Liner, Chute Wear Plates, Tailings Channel Cladding 37

38 FIELD EXPERIENCE The manufacturing process 38

39 CONTENT 1. Erosion 2. Corrosion 3. Erosion-Corrosion 4. High Performance Polyurethane Elastomer Coatings 5. Laboratory Testing 6. Field Experience a. Oil Sands Tailings and Hydrotransport b. Phosphate Slurry c. Water Injection Lines for Enhanced Oil Recovery d. High Performance Elastomers and Erosion-Corrosion e. Outlook 7. Conclusions 39

40 CONCLUSIONS High Performance Polyurethane Elastomers provide excellent wear protection in slurry and tailings pipelines. These materials exhibit a very strong adhesion to steel which is not compromised by cold-wall conditions. In Alberta oil sand operations, these elastomers are running in tailings lines and in hydrotransport. A proprietary weld joining system requiring only one field weld per joint has proven its applicability in the field. In phosphate and water injection applications, indications were found that High Performance Polyurethane Elastomers are particularly advantageous vs. metallic solutions when there are erosion-corrosion conditions present. A trial in a high wear area of an oil sands tailings line with high oxygen content shows equal or better wear performance of High Performance Polyurethane Elastomers compared to chromium carbide overlays providing additional support to the postulated correlation between erosion-corrosion conditions and this wear performance ratio. 40

41 THANK YOU FOR JOINING THIS PRESENTATION. 41