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EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016
ZOR#5 Subsea Pipeline Team
Corrosion Coating & CP System For Oil &Gas Pipeline
Date : 8th Jan. 2017
Prepared by : Quan PH
Issued For : Internal Training
Al-Zour Refinery Project Package #5,
Kuwait Date : Jan. 2017 0
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016
CONTENTS
Al-Zour Refinery Project Package #5,
Kuwait Date : Jan. 2017 1
1. Introduction
2. Rate of Corrosion
3. Corrosion Coating System
4. Cathodic Protection System
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
This presentation aims to give the basis information for corrosion coating system of
pipeline and application of Cathodic Protection system for onshore and offshore in
Oil & Gas Sector .
Subsea pipelines and structure shall be protected from corrosion using a combination
of coatings and CP. The CP system shall be designed to maintain the electrochemical
potential of exposed metal surfaces within a range that controls corrosion within
acceptable limits and without causing material damage for the specified design life of
the asset.
This presentation covers some technical points from detailed design until completion
of site installation by necessary testing. The relationship between corrosion coating
system and CP system for anticorrosive property to be analyzed as well.
1. Introduction
2
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
1. Introduction
3
The guideline for testing and criteria presented is referred to DEPs as following:
- DEP 31.40.30.31 External Polyethylene And Polypropylene Coating For Line Pipe:
Applied for factory corrosion coating
- DEP 31.40.30.37 External Field Joint And Rehabilitation Coating Systems For Line:
Applied for field coating
For Cathodic Protection:
- Project Variation P4049N-0000-DE10-VAR-0091_Design Cathodic Protection System
- ISO 15589-2:2012 Petroleum, petrochemical and natural gas industries — Cathodic
protection of pipeline transportation systems
- DEP 30.10.73.32 Design Of Cathodic Protection Systems For Offshore Pipelines
(Amendments/Supplements To Dnv Rp B401)
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
When pipeline is either buried or submerged in water, corrosive environment
constitute between metal surface and its environment. The corrosion is the damage of
a substance which is usually a metal material.
The rate of corrosion depends on various parameters including:
- Type of applied corrosion coating and CP system
- Pipeline operating temp.
- Surrounding condition (electrolytic property)
- Soil quality and burial status
- Interface with other facility
To avoid corrosion of pipeline in design life, the corrosion coating shall be
appropriately selected and the CP system to be supplement in compensation of
electrochemical potential.
4
2. Rate of Corrosion
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Selection Criteria
5
The type of corrosion coating to be selected based on below various considerations:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Selection Criteria
6
On design point of view, the most important aspect for selection of corrosion coating
is performance ability which shall be in compliance with project specification, applied
standard and to satisfy the CP designed. Below are main points for consideration:
- Project requirements
- Environmental service exposure (seawater, soil, etc.)
- Service temperature (depend on max. conveyed fluid temperature)
- The anticorrosive property of coating system (As shown in page 17)
For application in Oil & Gas pipeline, there are 3 most popular corrosion coating
systems that were qualified & certified through many projects:
- FBE
- 3LPE
- 3LPP
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – FBE
7
FBE is a high performance anti-corrosion coating that provides excellent protection
for small and large diameter pipelines with moderate operating temperatures.
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – FBE
8
Typical Properties:
- Min. pipe diameter : 3.5”
- Max. pipe diameter : 48”+
- Min pipe length : 18’
- Max. pipe length : 82’
- Min. recommended handling& construction temperature : -30C
- Max. recommended operating temperature : 110 C
Application:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – FBE
9
Product Application Process:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – 3LPE
10
This anti-corrosion system consists of a high performance fusion bonded epoxy
(FBE) followed by a copolymer adhesive and an outer layer of polyethylene which
provides tough, durable protection.
First layer: primer (liquid or powdered fusion
bonded epoxy (FBE)). Continuous thin layer resistant
to the corrosive agents. Guarantee a suitable
adhesion of the coating to the steel.
Second layer: co-polymer or modified polyethylene
adhesive. Guarantee a suitable adhesion between the
upper polyethylene layer and the primer.
Third layer: polyethylene. It provides good
mechanical strength, mechanical protection and
electric insulation.
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – 3LPE
11
Typical Properties:
- Min. pipe diameter : 2”
- Max. pipe diameter : 48”+
- Min pipe length : 18’
- Max. pipe length : 80’
- Min. recommended handling& construction temperature : -40C
- Max. recommended operating temperature : 85 C
Application:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – 3LPE
12
Product Application Process:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – 3LPP
13
This anti-corrosion system consists of a high performance fusion bonded
epoxy (FBE) followed by a copolymer adhesive and an outer layer of polypropylene
which provides the toughest, most durable pipe coating solution available.
First layer: primer (liquid or powdered fusion
bonded epoxy (FBE)). Continuous thin layer resistant
to the corrosive agents. Guarantee a suitable
adhesion of the coating to the steel.
Second layer: co-polymer adhesive. Guarantee a
suitable adhesion between the upper polypropylene
layer and the primer.
Third layer: polypropylene. It provides very good
mechanical strength, mechanical protection and
electric insulation.
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – 3LPP
14
Typical Properties:
- Min. pipe diameter : 3.5”
- Max. pipe diameter : 48”+
- Min pipe length : 18’
- Max. pipe length : 80’
- Min./Max. recommended handling& construction temperature : -20C to 110 C
- Max. recommended operating temperature : -20C to 140 C
Application:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – 3LPP
15
Product Application Process:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Comparison Table
16
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Comparison Table
17
Affection of coating system to CP design:
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Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Internal coating
18
Epoxy Lining (Application Example):
This lining is applied by layering one or several coats of paint or by spraying epoxy powder.
1. The pipe is preheated to eliminate humidity
2. The interior surface is shot-blasted to remove mill scale and rust, obtaining a metal surface
which facilitates the adhesion
3. When epoxy powder is fused, the pipe is preheated to 238°C, in order to quickly cure the epoxy.
4. The pipe is rotated and the lining is sprayed from a set of nozzles which moves inside the pipe.
5. When paint is used, it is dried by blowing hot air through the pipe.
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Compatible FJC System
19
Fusion Bonded Epoxy (FBE)
FBE
100% solid liquids, epoxy, epoxy‐urethane
Heat‐shrink sleeves (HSS)
Cold and hot‐applied tapes
Three layer polyethylene (3LPE)
Heat‐shrink sleeves (HSS), Optional for FBE
Multilayer flame spray with PE
Three layer polypropylene (3LPP)
Heat‐shrink sleeves (HSS), Optional for FBE
Multilayer flame spray with PP
FBE, spray applied adhesive, co‐extruded PP
FJC system selection:
Corrosion Control
To supplement CP system
Mechanical protection
Design codes specify
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – FJC - HSS Installation guide
20
Example for installation of HSS (Refer [Att-1] for full document)
Example for HSS product (Refer [Att-2] for full document)
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Qualification and Testing
21
With reference to DEP 31403037, various
testing is required for qualification of
corrosion material (both factory and
field application). For FJC procedure
qualification:
- Surface finishing after blast cleaning
- Coating thickness
- Holiday test
- Coating adhesion
- Impact resistance
- Indentation
- Flexibility
- Hot water soak
- Cathodic disbonding resistance
- Thermal ageing
- Lap shear
- Degree of cure of FBE (if any)
- Microscopic examination
- Self-healing
- Drip resistance
- Peel to outer layers
- Destructive testing
EPC of New Refinery Project Package #5,
Kuwait
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Date: February 2016Date : Jan. 2017
3. Corrosion Coating – Testing Frequency for FJC (DEP 31403037)
22
As Salt test
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System - General
23
The principle of cathodic protection is in connecting an external anode to the metal
to be protected and the passing of an electrical DC current. To that all area of the
metal surface become cathodic and therefore do not corrode.
There is fundamental difference between CP system for offshore side and onshore
side consideration the surrounding electrolytic environment (water vs particular soil).
For offshore side, the CP system is sacrificial anode that is made by Indium
activated aluminium alloy or Zinc alloy normally (External anticorrosion system).
Type of offshore anode: 1. Bracelet, half-shell (Squared or tapered) 2. Long Slender
Stand-off or Flush-mounted
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Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System - General
24
Anode Typical Drawing – concrete coated pipe
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Project Information
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4. Cathodic Protection System - General
25
Anode Typical Drawing –coated pipe
EPC of New Refinery Project Package #5,
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Project Information
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4. Cathodic Protection System - General
26
For onshore side, the CP system is either galvanic anode
(sacrificial type), where the current is a result of the
potential difference between the two metals [Att-3.1] &
[Att-3.2] or it may be an impressed current anode,
where the current is impressed from an external DC
power source. The isolation joint may be omitted if the
onshore impressed current CP system is designed to
ensure that there is no current drain from the offshore
pipeline sacrificial anodes to onshore (As per ISO 15589-
2:2002)
Type 2:
Type 1:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System - General
27
If sacrificial anode to be used for buried onshore pipeline, the soil condition surround
anode shall be electrolytic activation.
Example from NSRP project and current design of Al-Zour Refinery Project.
NRP project:
NSRP project:
Anode Installation Sketch
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System - General
28
The above type CP system can be applied for offshore side, but due to installation
restriction, it is not used for offshore pipeline other than structure, e.g. platform.
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP system design
29
With reference to ISO 15589 -2:2012 (as specified by specification P4045ZOR-93-10-
43-908)
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP system design
30
With reference to ISO 15589 -2:2012 (as specified by specification P4045ZOR-93-10-
43-908)
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP system design
31
Affection of coating system to CP design:
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP Survey
32
After pipeline installation, the anode shall be surveyed against potential criteria.
The potential are referenced to an SCE reference electrode, which are equivalent to a
silver/silver chloride reference electrode (Ag/AgCl/seawater) in 30.cm seawater.
CP survey applied at NSRP Project (by HHI/Geometra)
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Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP Survey - Discussion
33
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP Survey & Anode Spacing
34
Following PV P4049N-0000-DE10-VAR-0091_Design Cathodic Protection System
Anode Spacing: as per section 8.1 of ISO 15589-2:2012
Anode Spacing: as per P4049N-0000-DE10-VAR-0091_0 Design Cathodic Protection
System
EPC of New Refinery Project Package #5,
Kuwait
Project Information
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4. Cathodic Protection System – CP Survey - MIJ
35
Monolithic Isolation Joint
The purpose of insulating joints installation on gas and oil pipelines, it is to ensure
electrical isolation among sections of pipelines preventing detrimental electrochemical
interaction among the sections themselves. Insulating joints are also used to ensure
effective current spreading on cathodic protection systems. Monolithic Isolation Joints
are coated to prevent corrosion and are 100% tested hydrostatically, electrically and for
weld performance.
Monolithic Isolation Joints provide electrical sectioning and passive protection against
corrosion, they are installed in inlet and outlet pipes, on meters, tanks, pumping
station, etc.
Monolithic Isolating Joints do not require maintenance, and they improve the cathodic
protection of gas, water and petroleum pipelines with important savings in operation
and maintenance cost.
EPC of New Refinery Project Package #5,
Kuwait
Project Information
Date: February 2016Date : Jan. 2017
4. Cathodic Protection System – CP Survey - MIJ
36
Monolithic Isolation Joint
Example for MIJ [Att-4.1] and NSRP [Att-4.2]