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5349
Journal of Applied Sciences Research, 8(11): 5349-5359, 2012
ISSN 1819-544X
This is a refereed journal and all articles are professionally screened and reviewed
ORIGINAL ARTICLES
Corresponding Author: Mohamed A Wahab A Halim Gaber, Egyptian Petroleum Research Institute, 1 Ahmed El Zomer,
Nasr City, Cairo, Egypt.
E-mail: mgaber01@hotmail.com
Impact of Anti-Corrosion Liquid Epoxy and Fusion Bond Epoxy Primer on Mechanical
Testing of Three Layers Polyethylene Pipeline Coating
Gaber, M. AW.
Egyptian Petroleum Research Institute, Nasr City, Cairo, Egypt.
ABSTRACT
Pipeline coatings have undergone dramatic technological changes over the past two decades. Coatings now
must perform at higher in-service operating temperatures, must not be damaged in handling during construction
or in operation by soil stress or soil movement, and must provide exceptional corrosion protection. Coatings also
must be user friendly and must be able to be applied in a mill or in the field. This paper examines the
performance of liquid epoxy and fusion bond epoxy coatings on mechanical testing of three layer polyethylene
coatings pipeline which utilized in transport oil, gas and water. This study shall compare the on line and
laboratory inspection during surface preparation, preheat and application of 3layer extruded polyethylene
coating to determine which type of anticorrosion primer is more efficiency and durable for pipeline coatings.
The two types were applied for underground pipeline for Egyptian petroleum production companies since last
30 years at PETROJET coating plant. The field application testing indicates that the FBE primer give excellent
results for adhesion, cathodic protection, but the liquid epoxy primer give acceptable results but still less than
fusion bond epoxy.
Key words: polyethylene, cathodic protection, fusion bond epoxy, liquid epoxy primer, disbondment, 3layer
polyethylene.
Introduction
Pipelines are particularly important for the world, for their multi –uses and vital role in transporting
Petroleum and its products, as well as carrying water and drainage works. The pipelines are suffering from
corrosion, cracking and other problems. External corrosion has been recognized for many years as one of the
main deterioration mechanisms that may reduce the structural life of buried transmission pipelines. Corrosion of
these pipes inflicts huge costs on countries, to protect their pipelines, and make them workable for the longest
possible time. Ghazay El Metary (2004).
One of the ways followed in pipelines protection, is by coating them with special material that protect them
from affecting corrosion factors, as the type of the soil, moisture, pH, temperature variations and other factors.
Organic coating is used to control corrosion by isolating the external surface of the underground or submerged
pipeline from environment. This organic coating should have a high electrical resistance and high dielectric
strength to provide a barrier against moisture reaching the pipelines surface.
The pipelines are laid under buried environments over long distances from source to destination. In the
United States there are about 2 millions km of buried natural gas pipelines and 280,000 km of petroleum
products pipelines, which contributes billions of dollars to the economy. The growing demand and importance
for pipelines in all over the world warrants special attention to protect it from the deteriorating effects such as
corrosion, external forces and others. Among these effects, corrosion contributes the majority of the pipe failure
cases. For example, a recent review indicates that corrosion of metals and alloys costs U.S companies a total of
approximately $300 billion per year, these corrosion failures shall be eliminated by the use of best available
corrosion prevention techniques and materials.
1. Process of 3 Layer Polyethylene Coating:
Three layer polyethylene coating provides excellent corrosion protection, based on the use of a fusion
bonded epoxy or liquid epoxy primer with the mechanical protection afforded by medium or high density
polyethylene. Suitable for application on oil, gas and water pipelines at service temperatures up to 85°C, 3LPE
has an excellent track record. Anees U. Malik (1999).
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
Organic coatings, applied on properly pretreated surfaces, are the most common and most effective mode of
corrosion protection for metallic objects and structures. The exterior surfaces of corrodible metals such as iron
and steel are effectively protected from their environment by applying a coating system.
Despite the fact that the pipeline coating represents only about 5% of the total cost, the choice of the most
effective coating is a key point to guarantee the life of the installed pipelines.
A large variety of organic polymeric materials belonging to different functional groups has been used as
external coatings for open air or buried pipelines. Asphalt mastic and asphalt enamel, coal tar epoxy, extruded
polyethylene, fusion bonded epoxy, multilayer polyolefin coating systems including polyethylene or
polypropylene and polyurethane are some of the most widely used organic pipe coatings for external
applications. Polyethylene coatings having an FBE primer or liquid epoxy resin and a 2-layer polyethylene
based material extruded over it has been used extensively throughout the world in recent years BSI 96/.
The 3layers PE coating system applied to steel pipes shall be divided as follows:
-Layer 1: Immediately after the abrasive blast cleaning the layer shall formed by film of liquid epoxy resin
or fusion bond epoxy powder.
-Layer 2: This layer shall be formed by a polymer intended to provide adhesion between layer 1 and layer 3
and be compatible with those layers.
-Layer 3: This layer shall be formed by the polyethylene or polypropylene coating
Fig.1 Schematic of three layers Polypropylene coating for pipes
Fig. 1: Schematic of three layers Polypropylene coating for pipes.
3- Experimental & Field methodology:
The laboratory and field testing of bare pipes surface preparation, heating, priming, and
adhesive/polyethylene coating for pipelines used for oil/gas transportation were carried out on PETROJET, Port
Said and Suez coating plants.
The present study aims to find the effect of both liquid epoxy primer and Fusion Bond Epoxy as anti-
corrosion primers on mechanical testing of 3 layers polyethylene coating used.
The following inspection procedure and testing were carried out to find the efficiency of both types liquid
epoxy and FBE primers.
1- Climatic condition "temperature, relative humidity, dew point"
The climatic condition parameter is measured before start coating work to ensure that the ambient
temperature, relative humidity, dew point and steel surface temperature is suitable to apply the 3 layer
polyethylene coating for pipelines.
2- Measurement of rust grade of bare pipes
Rust grades of bare pipes are divided to 4 grades (A,B,C,D) according to degree of pitting in steel surfaces.
The grade of rust need to define before start surface preparation to determine the blasting method can be
achieve the cleanliness and profile degrees
3- Inspection of abrasive material (shot & grit)
Physical and chemical analysis for abrasive material shall be measured before used in blasting machine
4- Cleanliness degree
The cleanliness degree achieved by blasting shall be at least Sa 2½ according to ISO 8501-1
5- Surface profile
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
The surface anchor is necessary for good bonding of steel surfaces and coating materials and shall be
measured according to ISO 8503 -2
6- Salt level
The coated surface shall be free of all hazard materials " salt level" and shall be tested according to ISO
8502- 6
7- Dust level
Dust level for coated surfaces shall be less than rate 2 as per coating specifications and ISO 8502-3
8- Pipe preheat and coating materials
The preheating temperature of the steel pipes, adhesive and polyethylene coating materials shall be
measured at the frequencies to insure that the application temperature is comply with the manufacturer
recommendation.
9- Dry film thickness of primer, adhesive and PE
The coating thickness of the 3 layers coating system (primer, Adhesive, polyethylene) shall be measured
according to petroleum companies specification and DNV-RP-F106 (2011)
10- Adhesion test
The pipe coating requires sufficient adhesion to prevent water ingress or migration between the coating and
the pipe, along with cohesion to resist handling and soil stress. Soil stress is the main cause of pipe coating
failure. "Soil stress effects can be seen on flexible PE coatings with elastomeric adhesives as a
characteristic wrinkling. A.W. Peabody (2001).
The adhesion of the coating shall be determined by measuring the peel-off resistance in accordance with
DIN 30 670 at 23 & 80° C
11- Impact test
To protect steel from corrosion, a coating film must be continuous. Breaks in the coating will allow the
environment to permeate to the steel substrate and initiate corrosive degradation. The Impact test shall
performed by dropping a known weight from a calculated height onto the coating. Failure is the point at
which holidays were observed.
A Hot Spark or Holiday Test is then used to determine if the coating has been damaged or broken.
The objective of this test is to evaluate the resistance of the coating to damage from impact by a blunt ended
object. J Banach (2004), ASTM G 14 and DIN 30678.
12- Cathodic disbondment
Cathodic disbonment of anticorrosion primer is very important to ensure the performance of organic types
(liquid and FBE epoxies) and the testing procedure completed as per ASTM G8 & G42.
A- The coated carbon steel pipeline "X52" sample has been prepared for measurement of cathodic disbonding
after 2 day, maintaining at temperature of 65 2°C ). The sample has been cut from carbon steel pipeline
coated by POLYETHYLENE 3 Layer system, and the coating system includes the following layers :
1-Layer of Epoxy-based powder FBE, with DFT = 80 - 100 m.
2- Layer of ethylene-based polmeric adhesive with DFT = 330 m.
3- Layer of Polyethylene ( top coat ) with DFT = 2.5 mm.
B- The coated carbon steel pipeline "X52" sample has been prepared for measurement of cathodic disbonding
after 2 day, maintaining at temperature of 65 2°C ). The sample has been cut from carbon steel pipeline
coated by POLYETHYLENE 3 Layer system, and the coating system includes the following layers:
1-Layer of Liquid Epoxy primer, with DFT = 70 - 90 m.
2- Layer of ethylene-based polmeric adhesive with DFT = 330 m.
3- Layer of Polyethylene (top coat) with DFT = 2.5 mm.
13- Hot water test
The degree of coating to resistance disbondment due to hot water with NaCl solution 3% immersion shall
be tested in accordance with as per GBE/CW6:part 1. The coating shall show good resistance to
disbondment 80°C for 2 days
14- Flexibility test
Flexibility of steel coated panel to ensure the full coating system when exposed to external forces as per
CAN/CSA Z 245.20- 98
15- Degree of cure for fusion bond epoxy powder and liquid epoxy
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
The degree of cure shall be determined on layer 1 of the coating. The cure of fusion bond epoxy powder
shall be determined by differential thermal analysis and the acceptance criteria are based on the value of ∆
Tg in accordance to CSA Z 245.20. On the other hand the degree of cure of the liquid epoxy shall be
determined by measuring the hardness in accordance with IOS 2815.
16- Holiday test for coated pipes
The test measure the isolation of coating system to steel surface with high voltage at 25 k.v as per NACE
RP 0274
Results and Discussion
The following laboratory and online inspection were conducted in Petrojet coating plant, and includes the
following testing using calibrated equipments to ensure which type of both liquid and fusion bond epoxy
primers has been positively affect the adhesion and cathodic properties.
1- Climatic condition
The climatic condition parameter is measured before start coating work to ensure that the ambient
temperature, relative humidity, dew point and steel surface temperature is suitable to apply 3 layer polyethylene
coating for pipelines. Dew point less than steel temperature by 3°C.
Fig. 2: Hygrometer.
Fig. 3: Dew point & RH % calculator.
2- Rust grade of bare pipe before blasting
Rust grades of bare pipes are divided into 4 grades (A,B,C,D) according to degree of pitting in steel
surfaces, the rust grade of coated pipes used in this work is grade B which mean more or less presence of rust
traces "pitting" start to appear. The grade of rust need to define before start surface preparation to determine the
blasting method can be achieve the cleanliness and profile degrees.
3- Abrasive material (shot & grit)
Physical and chemical analysis for abrasive material measured before used in blasting machine and found
free from contamination and the conductivity is 140 uS/cm which comply with coating specification
requirements, Total Fina Elf (2002).
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
Fig. 4: Rust grade B.
4- Cleanliness degree
The cleanliness degree achieved by blasting is Sa 2½ to Sa3 according to ISO 8501-1.
Fig. 5: Blasted pipe to Sa 3.
5- Surface profile
The surface anchor is measured using the Press-O-Film gauge and it's necessary for bonding of primer with
steel surfaces and polyethylene coating layers, the profile ranging from 65- 80 um as per to ISO 8503 -2.
Fig. 6: Profile Gauge.
Fig. 7: Measuring profile.
6- Salt level
The coated surface shall be free of all hazard materials, the results indicates that the salt level is 1 um/cm²
"10 - 15 mg/m²" for both pipes coated with liquid and powder primers.
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
Fig. 8: Attach paper to substrate.
Fig. 9: SCM salt tester.
7- Dust level
Dust level for coated surfaces indicates no trace of contamination and less than rate 2 as per coating
specifications and ISO 8502-3.
Fig. 10: Transparent tape indicate no trace of contamination.
Table 1: Surface preparation of bare pipes parameters.
Test Liquid Epoxy Primer Fusion Bond Epoxy
Rust grade B B
Abrasive Shot/Grit Shot/Grit
Primer type Prodopeen coat 12-04 3 M
Cleanliness Sa 3 Sa3
Profile 65-85 65-85
Salt level 10 - 15 mg/m² 10 - 15 mg/m²
Dust level < rate 2 < rate 2
8- Pipe preheat and coating materials
The preheating temperature of the steel pipes, adhesive and polyethylene coating materials shall be
measured at the frequencies to insure that the application temperature is comply with the manufacturer
recommendation and the reading illustrated in table (2).
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
Fig. 11: Induction heat for pipe.
Fig. 12: temperature of coating materials.
Table 2: Preheat of pipe and coating materials.
Test Liquid Epoxy Primer Fusion Bond Epoxy
Pipe 195°C 205°C
Primer 75°C 180°C
Adhesive 215°C 215°C
PE 235°C 235°C
9- Dry film thickness of primer, adhesive and PE layers
The coating thickness of the 3 layers coating system (primer. Adhesive, polyethylene), were measured
according to petroleum companies specification on and the results recorded in table (3).
Fig. 13: DFT for fusion bond epoxy primer.
Table 3: Dry Film Thickness for coating layers.
Test Liquid Epoxy Primer Fusion Bond Epoxy
Primer 60-80 um 80-100 um
Adhesive 250 um 250 um
PE 2.5 mm 2.5 mm
10- Adhesion test
The adhesion of the coating shall be determined by measuring the peel-off resistance in accordance with
DIN 30 670 at 20° C and 80° C. The results of liquid epoxy primer is 80 kg/5 cm and 39 kg/5 cm consecutively.
5356
J. Appl. Sci. Res., 8(11): 5349-5359, 2012
The fusion bond epoxy powder results is 100 kg/5 cm at 20 ° C and 45 kg/5 cm at 80° C. Accordingly, the FBE
primer gives more bonding between substrate and coating layers and shall positively affect on corrosion
resistance and extend the pipeline shelf life.
Fig. 14: Adhesion (peel off) test.
Fig. 15: Bonding between PE & primer layers.
11- Impact test
Impact test for coated system according to DIN 30670 is carried out using an impact rod ≥ 5 J and the
holiday conducted over the impacted points and found no pin holes on both samples coated with both types of
primers
Fig. 16: Impact test for coated pipes.
5357
J. Appl. Sci. Res., 8(11): 5349-5359, 2012
12- Cathodic disbondment
Cathodic disbonment of anticorrosion primer is very important to ensure the performance of organic liquid
and FBE epoxies resistance to corrosion. The results obtained after 2 days at 65°C indicates that the fusion bond
epoxy powder increase in radial defect is 0.99 mm , but the Liquid epoxy primer increase in radial defect is
1.74 mm under the same condition, it means the performance and efficiency of FBE is more than Liquid epoxy
primer as per illustrated in table (4&5).
Table 4: Cathodic disbondment results of samples coated with Liquid epoxy primer.
ITEM Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 AVG.
INITIAL DIA. (mm) 6.00 6.00 6.00 6.00 6.00 6.00
FINAL DIA. (mm) 8.70 9.70 8.90 10.30 9.80 9.48
DISBONDING DIA (mm) 2.70 3.70 2.90 4.30 3.80 3.48
Max. Increase in Radial Defect (mm) 1.35 1.85 1.45 2.15 1.90 1.74
Table 5: Cathodic disbondment results of samples coated with Fusion Bond Epoxy primer.
ITEM Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 AVG.
INITIAL DIA. ( mm) 6.00 6.00 6.00 6.00 6.00 6.00
FINAL DIA. (mm) 7.43 7.77 7.70 8.33 8.63 7.97
DISBONDING DIA (mm) 1.43 1.77 1.70 2.33 2.63 2.44
Max. Increase in Radial Defect (mm) 0.72 0.88 0.85 1.17 1.32 0.99
Fig. 17: Cathodic disbondment.
Fig. 18: CD measurement.
13- Hot water test
The degree of coating to resistance disbondment due to hot water immersion shall be tested in accordance
with GBE/CW6: part 1. The fusion bond epoxy primer coating show no change in disbondment areas after
immersed in potable water at 80°C for 2 days. The liquid epoxy primer indicates increasing in disbonment area
with 16 %.
14- Flexibility test for FBE
The results indicate no visible cracks seen in coating layers when bending over a mandrel at ambient
temperature.
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
Fig. 19: Bending machine.
Fig. 20: Microscopic examination.
15- Cure of FBE
The degree of cure of fusion bond epoxy primer is tested using Differential Scanning Calorimetry (DSC) to
determine the glass transition temperature and the acceptance criteria ∆ Tg = -2/+3° C as per NACE RP 0394 ,
ASTM D 3895 and CSA Z 245.20. The glass transition temperature ∆ Tg (Tg2 – Tg1) results is 0.3 as illustrated
in Fig.(32). In case of Liquid epoxy primer the curing measured directly during application of primer over pipe
substrate and found dry and suitable for applying the subsequent 2 layers of adhesive and polyethylene.
Fig. 21: Cure graph.
Table 6: Mechanical testing for two types of primer.
Test Liquid Epoxy Primer Fusion Bond Epoxy
Adhesion at 20°C 80 kg/ 5cm 100 kg/ 5cm
Impact No crack No crack
Cathodic
Disbondment 0.99 mm 1.74 mm
Bend test No crack No crack
Hot water 1 mm No change or disbondment
DSC N/A ∆ g 0.3
Holiday no pinhole no pinhole
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J. Appl. Sci. Res., 8(11): 5349-5359, 2012
16- Holiday test for coated pipes
The test measure the isolation of coating system to steel surface with high voltage at 25 k.v and no pin holes
found in both pipes coated with liquid and FBE primers with polyethylene layers as per NACE RP 0274.
Conclusions:
-The bare pipes type is X52, climatic condition, rust grade, surface preparation (cleanliness, profile, salt
level, dust level), preheat parameters is the same for both types of organic anticorrosion liquid and FBE
primers.
-The adhesion test of fusion bond epoxy results is more than liquid epoxy primer as indicated in table (6).
-The cathodic disbondment test of fusion bond epoxy indicates small radial defect area (0.99 mm), than
liquid epoxy primer (1.74 mm).
-The FBE primer has good mechanical properties, low water permeation, no chemical degradation and good
corrosion resistance.
-3Layer polyethylene showed good resistance to water and chloride permeation.
-The present search recommends using the FBE primer with 3layer polyethylene coating system to achieve
the optimum cathodic protection and long shelf life of pipe coating.
References
ASTM G 8, 1996. Standard Test method for Cathodic disbanding of pipeline coatings.
ASTM G 42, 1996. Standard Test method for Cathodic disbanding of pipeline coatings subjected to elevated
temperature.
ASTM G 14, 1988. Standard Test method for Impact resistance of pipeline coatings (Falling weight test).
Peabody, A.W., 2001. Control of pipeline corrosion. NACE International.
Anees. U. Malik, Shahreer Ahmed, Ismail Andijani, 1999. Corrosion protection evaluation of some organic
coatings in water transmission pipes. Research & development center, Kingdom of Saudi Arabia.
Canadian Standards Association -CSA Z 245.20, 1998. External fusion bond epoxy coatings for steel pipe.
DIN 30 670, 1992. Polyethylene Coatings for Steel Pipes and Fittings, Requirements and Testing.
DIN 30678, 1992. Polyethylene coating for steel pipes.
DNV-RP-F106, 2011. factory applied external pipeline coatings for corrosion control. Item 7.2.8.
Gazay El Metary, Ms.C., 2004. Corrosion study and evaluation of externally coated pipelines. King Saud
University.
Gas Business Engineering (GBE CW6 part1): Technical Specification for the External Protection of Steel Line
Pipe and Fittings Using Fusion Bonded Powder and Associated Coating Systems.
ISO 8501-1, 1994. Preparation of steel substrate before application of paints and related products – Visual
assessment of surface cleanliness.
ISO 8503-2, 1988. Preparation of steel substrate before application of paints and related products – Surface
roughness characteristics of blast cleaned steel substrates.
ISO – 6, 1995. Preparation of steel substrate before application of paints and related products- Extraction of
soluble contaminants for analysis- the Bresle method.
ISO 8502-3, 1993. Preparation of steel substrate before application of paints and related products- Assessment
of dust on steel surfaces prepared for painting (pressure sensitive tape method).
ISO 2815, 2003. paints and varnishes – Buchholz indentation test.
J Banach, 2004. Liquid epoxy coatings for today's pipeline coating challenges. NACE International.
NACE –RP-0274, 2004. High – Voltage electrical inspection of pipeline coatings.
NACE –RP-0394, 2002. Application, performance, and quality control of plant-applied, fusion-bonded epoxy
external pipe coating..
Total Fina Elf, 2002. External protection of off-shore and related structures and equipment by painting, page 11.
ResearchGate has not been able to resolve any citations for this publication.
- A.W. Peabody
This manual is a collection of information on practices, techniques, materials and equipment, and related material on basic corrosion, cathodic protection theory, measurement practices, construction details and typical methods of installation and operation tested in field applications. (P.J.B.)
- J Banach
Pipeline coatings have undergone dramatic technological changes over the past two decades. Coatings now must perform at higher in-service operating temperatures, must not be damaged in handling during construction or in operation by soil stress or soil movement, and must provide exceptional corrosion protection. Coatings also must be user friendly and must be able to be applied in a mill or in the field. Liquid epoxies have been developed to provide protection for pipelines operating at temperatures up to 150°C. Additionally, adva nces to epoxy technology allow epoxy to be applied on wet surfaces and to bond to polyethylene coating systems.
Corrosion protection evaluation of some organic coatings in water transmission pipes
- U Anees
- Shahreer Malik
- Ahmed
Anees. U. Malik, Shahreer Ahmed, Ismail Andijani, 1999. Corrosion protection evaluation of some organic coatings in water transmission pipes. Research & development center, Kingdom of Saudi Arabia.
Corrosion study and evaluation of externally coated pipelines
- Ms C Gazay El Metary
Gazay El Metary, Ms.C., 2004. Corrosion study and evaluation of externally coated pipelines. King Saud University.
External protection of off-shore and related structures and equipment by painting
- Fina Total
- Elf
Total Fina Elf, 2002. External protection of off-shore and related structures and equipment by painting, page 11.
Corrosion protection evaluation of some organic coatings in water transmission pipes. Research & development center
- . U Anees
- Shahreer Malik
- Ismail Ahmed
- Andijani
Anees. U. Malik, Shahreer Ahmed, Ismail Andijani, 1999. Corrosion protection evaluation of some organic coatings in water transmission pipes. Research & development center, Kingdom of Saudi Arabia.
Source: https://www.researchgate.net/publication/281782594_The_15th_International_Conference_on_Petroleum_Mineral_Resources_and_Development
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