EXTERNAL PIPE

COATINGS
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EXTERNAL PIPE COATINGS

To protect the buried line pipes from external corrosion, the line pipes are coated. A good
quality pipeline coating shall have following characteristics:

Adherence to pipe
Non-porous
Free of defects, pores, flaws, holidays
Should act as an insulating barrier
Should be inert to environment
Coefficient of thermal expansion of the coating film > that of pipe metal
High resistance to abrasion
Resistance to UV degradation

Following types of coatings are mainly used for coating of line pipes:

Coal Tar Enamel Coating
3 Layer Polyethylene Coating
Fusion Bonded Epoxy Coating

COAL TAR ENAMEL COATING

Reference Codes

BS 4164 : Specification for coal-tar based hot applied coating materials for
protecting from iron and steel, including suitable primer.

AWWA C-203-86 : AWWA standard for Coal Tar Protective coatings & linings for steel
water pipelines, enamels and tape-hot applied.

Materials

Primer : Fast drying synthetic primer Type B for cold application.

Coal Tar : The coal tar enamel shall consist of a uniform mixture of a
specially modified coal tar and inert non-fibrous filler.

The primer & coal tar enamel shall conform to BS 4164.

Wrapper

Inner Wraps : The inner wrap glass fibre reinforcement material shall conform
to AWWA C-203. The glass fibre reinforcement material is
reinforced in the longitudinal direction.
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Outer Wraps : The outer wrap material shall conform to AWWA C-203. The
outer wrap material is coal tar impregnated asbestos felt or glass
fibre felt.

Coal Tar Enamel Coating Process


1) Surface Preparation
Oil, grease or other contaminants are removed by solvent cleaning prior to
blasting. Exterior surfaces of the pipes to be coated are blast cleaned by
sand blasting to near white metal finish to Grades 2 1/2, SIS 0550900.
Prior to primer application, the pipe is cleaned to remove any wetness or
other contamination.

2) Priming
Primer material compatible with the enamel coating is used. Primer is
applied on sand blasted pipe in an uniformly thick film to completely
cover the circumference of the pipe and all surfaces which are to be
coated. The freshly primed pipes are dried on racks until they are no
longer wet, sticky or tacky.

3) Heating of Coal Tar Enamel
The chopped Coal Tar Enamel is heated in kettles to maintain a
continuous supply of hot enamel. When the enamel is in a molten
condition in the kettle, it is continuously agitated.

4) Coating of Pipes
The coating system consists of applying over the primed pipe, a coat of
coal tar enamel having a minimum thickness of 2.4 mm and one wrap of
glass-fibre mat, followed by a second coat of coal-tar enamel having
minimum thickness of 2.4 mm and wrap of glass fibre mat followed
immediately by an outer wrap of coat tar impregnated asbestos felt/glass
fibre felt.

Enamel is applied by pouring on pipes and spreading to the specified
thickness. Enamel is applied so that each spiral resulting from the
spreading operations overlaps the preceding spiral producing a continuous
unbroken film.

Glass fibre mat is applied simultaneously with the first coat of coal tar
enamel. The roll of glass fibre mat is maintained under sufficient tension
to embed the mat in the enamel before the latter sets or cools. The second
coat of hot coal tar enamel is then applied simultaneously with the second
layer of glass fibre mat. The impregnated outer wrap is then applied
immediately behind the glass fibre reinforcement in a tight uniform spiral.
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5) Inspection & Testing

Holiday Detection: Coated and wrapped pipes which have been
supported on racks or skids are subjected to a test with an electric holiday
detector to detect all coke particles and other inclusions such as pinholes,
voids, holidays, air bubbles, cracks and other breaks.

Measuring coating thickness: The thickness of the coating is measured
by Elcometer.

Testing the adhesion of the coating: The adhesion of the coating is
determined at three points of the coated surface, one in the centre and two
at about 500 mm from the bevelled ends. After the coating has cooled
sufficiently two parallel incisions, at least 25 mm apart, are made in the
coating right down to the metal and two more incisions at right angles to
and intersecting the first two incisions. An attempt shall then be made with
the aid of a stopping knife or similar tool to peel the coating off the pipe
by applying a uniform force on the coating directed away from the pipe.
The adhesion is unsatisfactory if the layers of coating part from the primer
coat or if the primer coat parts from the steel.

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3 LAYERS POLYETHYLENE COATING

Reference Codes

i. DIN 30670 Polyethylene-Coatings For Steel Pipes And Fittings
Requirements And Testing
iv. ASTM D - 543 : Standard Method of test for Resistance of Plastics to
Chemical Reagents.
v. ASTM D - 570 : Standard Method of Test for Water Absorption of
Plastics.
vi. ASTM D - 638 : Standard Method of test for Tensile Properties of
Plastics.
vii. ASTM D - 792 : Standard Test Method for Specific Gravity and
Density of Plastics by Displacement.
viii. ASTM G - 42 : Tentative Methods for Cathodic disbonding of
Pipeline coatings subjected to Elevated or Cyclic
temperatures.
x. DIN 53735 Testing of Plastics: determination of Melt Index of
Thermoplastics.

Materials

Polyethylene compound
Epoxy powder
Adhesive
Properties of Polyethylene Compound

S. No Properties Unit Requirement Test Method
1. Tensile Strength at +25C Psi 2900 min ASTM D 638

2.
Melt index. Test conducted at
a temperature of +190C
under a total load (including
piston weight of 2.16 Kg)
g/10 min. 0.25 min. ASTM D 1238
3. Specific Gravity at +25C - 0.945 min. ASTM D 792
4. Hardness at +25C Shore D 60 min. ASTM D 2240
5. Water Absorption, 24 hours,
+25C
% 0.01 max. ASTM D 570
6. Volume Resistivity at +25C Ohm-cm 10
15
ASTM D 257
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S. No Properties Unit Requirement Test Method
7. Dielectric withstand, 100
Volt/sec rise at +25C
Volts 30,000 min. ASTM D 149

Properties of Epoxy Powder

Epoxy powder shall be chosen such that it complies with the functional
requirements and properties of coating system.

Properties of Adhesive

Adhesive shall be chosen such that it complies with the functional requirements
and properties of coating system.

Properties of Coating system

S. No Properties Unit Requirement Test Method
1. Resistance to indentation at
70 2C
mm 0.3 max. DIN 30670
2. Resistance to Impact (Min.
of 30 impacts at 70C. No
holiday allowed when
tested at 25 Kv)
NM per
mm of
coating
thickness
5 min. (for dia
<200 mm, 6 min
(for dia 200 mm)
DIN 30670
3. Resistance to Peeling. Test
Method at 50C
Kg/cm 7.0 min. DIN 30670
4. Elongation due to tearing % 500 DIN 30670
5. Water Soak Test. Sample
immersed 100%, at 80C
for 7 days
- No de-lamination,
No loss of peel
strength tested at
50C
Modified
British Gas
BGS PS/CW6,
Part 1, App. E
6. Resistance to thermal aging - Retain 70% of Melt
index
DIN 30670
7. Resistance to Exposure to
Light
- Retain 70% of Melt
Index
DIN 30670
8. Cathodic Disbondment
after 28 days, at +70C
mm
radius of
disbond
ment
30 max. ASTM G 42
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3 Layer Polyethylene Coating process

1) Surface preparation
Solvent cleaning is done in accordance with SSPC - SP 1. Prior to
abrasive blast cleaning, the pipes are preheated to 65C to 85C for
removal of any moisture, raising of silvers, laminations etc. The external
surface of the pipe is cleaned by abrasive blast cleaning machine for white
metal finish to SA 2 of Swedish Standard SIS 055900.

2) Coating application

The external surface of the pipe shall is heated to about 190C followed
by application of following three layers:

I. Electrostatic application of epoxy powder (100 - 175 micro meter
thick or as recommended by the manufacturer)

II. Crystalline Co-polymer Adhesive applied by extrusion (min. 0.20 mm
thick)

III. Polyethylene coating by extrusion.




The coated pipe is subsequently quenched and cooled in water for a
period, which shall sufficiently lower the temperature of pipe coating to
permit handling and inspection.

The copolymer adhesive is applied by extrusion within 15 seconds of the
fusion bonded epoxy (FBE) powder application and before the
solidification of the FBE so that the two materials will interact by
chemically bonding.

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3) Inspection and Testing

Visual inspection: of finished coating for colour, blisters, sags, porosity,
burns and handling damage during coating, stacking and loading.

Thickness: The coating thickness is measured by Elecometer.

Holiday Detection: Each coated pipe is checked over 100% of coated
surface by means of a holiday detector for pinholes, voids, holidays, air
bubbles, cracks and other breaks.

Peel test: Peel test is carried out as specified in DIN 30670 for testing
adhesion. The system shall fail only in the adhesive layer. Failure of either
adhesive to steel or adhesive to backing is not acceptable.

Indentation Resistance: Indentation resistance test is carried out as
specified in DIN 30670.

Impact Resistance: Impact resistance test is carried out as specified in
DIN 30670. Impacts, located equidistant along the length of coated pipe
are performed. Immediately after testing, the test area is subjected to
holiday detection. The pipe is rejected if any holiday is noted in the test
area.


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COMPARISON OF COATINGS

Description Coal Tar Enamel coating 3 Layer PE coating
Service Conditions
Temperature Suitable up to 45C Suitable up to 60C
Anti-corrosion Properties
Resistance to Moisture Good Very good
Cathodic Disbondment Fair Good
Volume Resistivity Fair Good
Electrical Properties
Coating Resistance 1200 Ohms-m 12000 Ohms-m
Mechanical Properties
Impact Resistance Fair Excellent
Elongation Fair Excellent
Indentation Resistance Poor Very good
Penetration Resistance Poor Good
Abrasion Resistance Fair Good
Resistance to Peel Fair Excellent
Resistance to Soil Stresses Poor Excellent
Long Term ageing
Heat and Light ageing Fair Very Good
Application and Field Handling
Application Easy to apply at yard Easy to apply at yard
Damages during handling
and transportation
High Low
Ease of repair Easily repairable Easily repairable
Cathodic Protection Design
Current Density 500 micro A/m 50 micro A/m
CP Stations At every 15-20 km At every 30-40 km
Cost
Coating Relatively Low Relatively High
Cost of CP Stations Approx. 3 times 3LPE Normal
Cost of Transportation/
Repair
High Low
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EXTERNAL FBE (FUSION BONDED EPOXY) COATING
The FBE is an electrostatically changed powder, which is pneumatically sprayed onto the
hot pipe, and contains excellent passive corrosion protection properties.
Single Layer Coating

The system was developed for the protection of pipelines operating at elevated
temperatures where coating adhesion and resistance to soil stresses and cathodic
disbondment are required. It consists of a single layer of cured thermosetting epoxy resin
powder as the corrosion barrier (no other mechanical protection) applied by electrostatic
charge to a preheated pipe. As per CSA Z245-20, the thickness requirement for Single
Layer Coating shall be 350 - 500 micron.

Advantages

Service temperature up to 90C maximum (110C intermittent in dry soil
conditions)
Excellent corrosion resistance
Excellent flexibility
Excellent adhesion to steel and extremely resistant to soil stresses
Compatible with most known field joint protection systems
Does not shield cathodic protection

Disadvantages

Susceptible to damage during handling, transportation & pipeline construction
Limited impact resistance
Hydroscopic material leading to increased cathodic protection demand as
pipeline ages


Dual Layer Coating

Dual layer fusion bonded epoxy is a 2-component powder coating designed to provide
long term corrosion resistance and mechanical protection to steel pipe. The system was
principally developed for road/river crossing and HDD (Horizontal Directional Drilling)
applications where resistance to abrasion and gouging are considered important. It
consists of:

i) A primary layer of thermosetting epoxy resin powder as the corrosion barrier
applied by electrostatic charge to a preheated pipe and

ii) A secondary layer of abrasion and impact resistant epoxy resin powder to provide
mechanical protection
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As per CSA Z245-20, the thickness requirement for Dual Layer Coating shall be 750 -
800 micron.

Advantages

Service temperature up to 90C maximum (110C intermittent in dry soil
conditions)
Excellent corrosion resistance
Provides excellent abrasion resistance
Excellent adhesion to steel and extremely resistant to soil stresses
Compatible with most known field joint protection systems
Does not shield cathodic protection

Disadvantages

Poor flexibility at higher coating thicknesses
More expensive than most coating systems
Limited impact resistance
Hydroscopic material leading to increased cathodic protection demand as
pipeline ages
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FIELD JOINT COATING

Field joint coatings are carried out using Heat Shrinkable Sleeves.


Reference Code

DIN-30672-1991 : Coating of Corrosion Protection Tapes & Heat Shrinking Products for
Pipelines - Operational Temperatures upto 50

C.

Materials

Heat shrinkable wraparound sleeve consists of radiation cross-linked, thermally
stabilised, ultraviolet resistant semi-rigid polyolefin backing with a uniform thickness of
high shear strength thermoplastic/copolymer hot melt adhesive. The joint coating system
may consist of a solvent free epoxy primer applied to the pipe surface prior to sleeve
application. The backing is coated with thermochrome paint which will change colour
when the desired heat during shrinking is attained. The wraparound sleeve is supplied in
pre-cut sizes to suit the pipe diameter and the requirements of overlap.

The thickness of field joint coating material is such that an average thickness of 2.0 mm
is guaranteed on the complete finished field joint coating.


Properties of Joint Coating Material


Sr.
No.
PROPERTY UNIT REQUIRE
MENT
TEST
METHOD
1. Tensile Strength @ 25 C. Psi 2200 ASTM D-638
2. Ultimate Elongation % @ 25 C. % 400 min DIN 30672
3. Dielectric withstand with 1000
Volt/Sec
KV > 30 ASTM D-1249
OR
DIN 30672
4. Water absorption 24 hours % < 0.05 ASTM D-570
5. Volume Resistivity @ 25C. Ohm-cm > 1x10/15 ASTM D-257
6. Resistance to Thermal Aging @
100 C.
% Change in
Elongation,
<25%
DIN 30672
7. Hardness (25 C.) Shore D 50 min ASTM D-2240




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Properties of Joint Coating System (As applied)

Sr.
No.
PROPERTY UNIT REQUIRE
MENT
TEST
METHOD
1. Resistance to impact @ 23C Class
C, 30 Blows
- No Holidays DIN 30672
2. Resistance to peel Class C
@ 23 C.
With Metal Surface
With Mill Coating
At Layers Overlap

@ 50C.
With Metal Surface
With Mill Coating
At Layers Overlap
N/cm
Width


>19
>10
>19


> 4
> 2.5
> 4
DIN 30672
3. Cathodic Disbondment (after 30
days) Test Method A, @ 60C.
mm <30 ASTM G-42
4. Resistance to Indentation, @ 50C. mm 0.3 max. DIN 30672
5. Lap Shear Strenth @ 50C. Between
Wrapping & Metal Surface and Mill
Coating.
N/ cm
2
> 6

DIN 30672

Field Joint Coating procedure

1) Surface Preparation
Oil, grease, salts and other contamination are removed from steel surface
by wiping with rags soaked with suitable solvents such as naphtha or
benzene. Solvent cleaning procedure is in accordance with SSPC-SP 1.
Surface is then blast cleaned to a finish equivalent to SA 2 of Swedish
Standard SIS-055900. The ends of existing pipe protective coating are
inspected and chamfered prior to application and cleaned as necessary.
Joint coating shall be applied immediately after completion of surface
preparation.


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2) Application of Joint Coating
The wrap around sleeve of size such that a minimum overlap of 100 mm is
ensured (after shrinking) on both sides of the yard applied corrosion
coating of pipe is selected. Before centering the wraparound sleeve, the
bare steel surface shall be preheated over the surface to remove the
moisture. The minimum preheat temperature as recommended by the
manufacturer and shall be checked by means of pyrometer or temperature
crayons. The solvent free epoxy primer (if applicable) is applied prior to
sleeve application.

The wraparound sleeve is then entirely wrapped around the pipe
positioning the closure patch off to one side of the pipe in 10 oclock or 2
oclock position, and the edge of the undergoing layer facing upward. A
heat shrinking procedure is applied to shrink the sleeve in a manner such
that all entrapped air is removed using gloved hands and hand rollers.
Heating is carried out until the thermochrome paint has completely
changed its colour. Resulting coating must be free of wrinkles, cold spots
and weld profile visible on the sleeve.



3) Inspection

A visual inspection is carried out for the following:
Mastic extrusion on either ends of the sleeve.
Punctures or pinholes or bend failure. The external appearance of
the sleeve shall be smooth, free of dimples, air entrapment or void
formation.
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Weld bead profile shall be visible through the sleeve.
The entire closure patch shall have changed colour uniformly.

Holiday Inspection: The entire surface of the joint section is inspected by
a full circle holiday detector after the joint has cooled below 50C.



4) Testing
From each test sleeve, one or more strips of size 25 mm x 200 mm is cut
perpendicular to the pipe axis and slowly peeled off. The required peel
strength shall meet the requirements of DIN 30672 as applicable for 23
0
C
or 50
0
C. For qualification, peel test must be carried at 23
0
C. and 50
0
C.
After removal of strip the bulk of adhesive shall remain adhered to the
pipe showing no bare metal, otherwise, test is considered to have failed.
The adhesive layer that remains on the pipe surface shall be free of voids
resulting from air or gas inclusion.