FIELD EXPERIENCE WITH HIGHLY EROSION AND CORROSION
RESISTANT ELASTOMER PIPE COATINGS AND LININGS
Michael Magerstädt, Thorsten Räth, Larry Lai, Dan Plourde,
Holger Rosenbleck-Schmidt
Calgary, Alberta, Canada
February 23rd-26th, 2015
1
AUTHORS
Michael Magerstädt
ROSEN Swiss AG
Obere Spichermatt 14
6370 Stans
Switzerland
Thorsten Räth, Larry K.L. Lai, Dan Plourde
ROSEN Canada Ltd.
5020 12a Street SE
Calgary, Alberta T2G 5K9
Canada
Holger Rosenbleck-Schmidt
ROPLAST GmbH
Am Seitenkanal 8
49811 Lingen
Germany
Please send correspondence relating to this presentation to:
mmagerstaedt@rosen-group.com
Calgary, Alberta, Canada
February 23rd-26th, 2015
2
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
3
EROSION, CORROSION, AND EROSION CORROSION IN SLURRY TRANSPORT
Slurry transport pipelines:
- the obvious threat to steel pipes is abrasive wear around the 6
o’clock position (gravity!).
- there often are wall thickness reduction, wear scars, and pipe
surface appearance changes, in the upper half of the pipe.
- particularly when the slurry pipeline runs under low pressure
and the slurry does not always fill the entire pipe.
- Most serious damage in these cases occurs at or near the
“water line”, the interface between the liquid and a gas phase
above it.
Calgary, Alberta, Canada
February 23rd-26th, 2015
4
EROSION, CORROSION, AND EROSION CORROSION IN SLURRY TRANSPORT
Slurry transport pipelines:
• Such damage cannot be explained by erosion alone. The
damaged areas of the pipe surface show signs of corrosion.
• The resulting effect, named erosion-corrosion, is stronger than
the sum of the effects of erosion and corrosion.
• Small-area, shallow surface damage by erosion will provide
attacking points for corrosion and vice versa, corroded surface
area is structurally weaker than un-corroded steel and thereby
provides easier access to abrasion.
Calgary, Alberta, Canada
February 23rd-26th, 2015
5
EROSION, CORROSION, AND EROSION CORROSION IN SLURRY TRANSPORT
Protective solutions:
Metallic Solutions:
• Induction Heating
• Material Alloying
• Weld Overlays, 6 to 20 times
• Wear Tiles, 5 to 10 times
Polymeric Solutions:
• HDPE Liners (in low-erosion cases)
• Rubber Liners
• Polyurethane Liners / Coatings
Other Solutions:
• Addition of Corrosion Inhibitor (in low-erosion cases)
• Ceramic Claddings
Calgary, Alberta, Canada
February 23rd-26th, 2015
6
HIGH PERFORMANCE POLYURETHANE
AND POLYUREA ELASTOMERS
What is Polyurethane (PUR)?
Up to 8 components: Isocyanate, polol, crosslinkers,
hardeners, chain extenders, etc.
„the Polyurethane“ does not exist –> millions of
permutations possible
Typical applications:
Soft foam (seats, matttresses)
Hard foam (insulation material)
TPU (injection moulded, automotive, houshold
appliances)
Elastomers (pipeline inspection tools, buffer,
rollers, etc.)
Adhesives and coatings
Calgary, Alberta, Canada
February 23rd-26th, 2015
7
HIGH PERFORMANCE POLYURETHANE
AND POLYUREA ELASTOMERS
Basic formulae of Polyurethane and Polyurea; the two main components only
Calgary, Alberta, Canada
February 23rd-26th, 2015
8
HIGH PERFORMANCE POLYURETHANE
AND POLYUREA ELASTOMERS
Pipeline Inspection Pigs, a Tough Challenge for Polyurethanes
Disks and cups made
from polyurethane
seal against the pipe
interior surface and
scrape along the steel
wall.
56“ pig
The world record for
in-line-inspection in a
single run holds at
1224 km (NordStream
pipeline).
3“ pig
Calgary, Alberta, Canada
February 23rd-26th, 2015
9
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
10
INTERIOR PIPE COATINGS MADE
FROM POLYURETHANE
Extensive Tests by Independent Laboratories:
• Higher adhesion to steel than any other polyurethane
elastomer tested;
• Extremely high abrasion and tear resistance;
• Very little swelling (almost no water uptake);
• Excellent chemical and mechanical resistance;
• Stable and very high adhesion even after long-term
hot water immersion, and
• No susceptibility to cold wall effect.
Calgary, Alberta, Canada
February 23rd-26th, 2015
11
INTERIOR PIPE COATINGS MADE
FROM POLYURETHANE
Calgary, Alberta, Canada
February 23rd-26th, 2015
12
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
13
CASE OIL SANDS TAILINGS
Long-term Performance
25 mm (1”) thick high performance polyurethane elastomer coating in oil
sands coarse tailings, 30” o.d., in Alberta:
•
•
•
•
•
•
•
•
In this location, carbon steel needs to be rotated after 2500-3000 hrs;
Tailings line, including rocks up to 5“ diameter;
Coating thickness: 1“;
Flow velocity approx. 5 m/s;
Temperature 45-65 °C, no thermal insulation on pipe;
Outside temperature down to -40 °C in winter;
Line cleaning with water @ 95° C at regular intervals;
High Performance Polyurethane Elastomer Coating after 20‘000 hrs. of
operation has lost 6 mm coating at and around the 6 o‘clock position
(highest wear area).
Calgary, Alberta, Canada
February 23rd-26th, 2015
14
CASE OIL SANDS TAILINGS
Long-term Performance
25 mm (1”) thick high performance polyurethane elastomer coating in oil
sands coarse tailings, 30” o.d., in Alberta:
Calgary, Alberta, Canada
February 23rd-26th, 2015
15
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
16
CASE OIL SANDS TAILINGS
Field Joining
• Principle: application of a metal sleeve around one end of the pipe, filet
welded in a way that a “female” pipe end is generated.
• The coating is cast to stand out over the end face of the steel pipe. At the
other, male end of the pipe, the coating also covers the end face.
• When the joints are brought together in the field, a second filet weld is applied
where the outer sleeve ends over the male pipe end.
• This way, the end face coating areas are pressed together firmly and the fillet
weld holds the pipes together.
• Overheating and damage to the coating during welding is prevented by an
insulating layer and a steel heat dissipation ring.
• This connection has been pressure tested to 3000 PSI and complies with ASME
B31.11 The welding process complies with ASME Sec. IX.
Calgary, Alberta, Canada
February 23rd-26th, 2015
17
CASE OIL SANDS TAILINGS
Field Joining
Female Pipe End with Sleeve
Calgary, Alberta, Canada
February 23rd-26th, 2015
18
CASE OIL SANDS TAILINGS
Field Joining
Field joining process and 250 bar / 3000 PSI
pressure test
Calgary, Alberta, Canada
February 23rd-26th, 2015
19
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
20
CASE EROSION-CORROSION IN COARSE TAILINGS
• High turbulence area of a coarse oil sands tailings line
behind elbow and pump.
• Chromium-carbide overlay (CCO) cladded pipe needs to
be rotated every 2’500 to 3’000 hours of operation.
• With a 25 mm thick high performance polyurethane
coating , at the highest wear point, after 11’000 hours,
6 mm of coating thickness was left.
This can only be explained by erosion-corrosion on the CCO.
-- increased turbulence, increased oxygen content (pump)
Calgary, Alberta, Canada
February 23rd-26th, 2015
21
CASE EROSION-CORROSION IN COARSE TAILINGS
Actual spool and measurements
taken after 11‘000 hours
Note:
The readings above 25 mm at position
0 mm is caused by the compressed
Polyurethane covering the entire
end-face (coating and steel thickness).
Calgary, Alberta, Canada
February 23rd-26th, 2015
22
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
23
PIPE STRIPPING AND RE-USE
The very strong adhesion to steel of High Performance
Elastomer Coatings makes removal of such coatings by
standard methods difficult.
A proprietary process was developed combining mechanical,
thermal, and chemical means.
In a new coating plant in Alberta coming on stream these
days, the removal process will be routinely applied thereby
providing another means of cost reduction for operators.
Calgary, Alberta, Canada
February 23rd-26th, 2015
24
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
Continuous Interior Coating Wear Measurement From Outside The Pipe
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
25
CONTINUOUS INTERIOR COATING WEAR
MEASUREMENT FROM OUTSIDE THE PIPE
A novel wear monitoring system was presented at last year’s conference3.
An update on first field experience
with this system in an Alberta
oil sands tailings line will be given
at this conference.
This system is able to continuously
monitor internal polyurethane
wear from the outside of the
pipe without the need for placing
a hole through the pipe wall.
Calgary, Alberta, Canada
February 23rd-26th, 2015
26
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
27
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Two new
high performance
polyurea coating
recipes were tested
by independent
laboratories
according to
numerous
international
standards, e.g.:
AWWA C222-99:
“Polyurethane Coatings for the Interior and Exterior of
Steel Water Pipe and Fittings”
DIN EN ISO 10290:2002:
“Steel tubes and fittings for onshore and offshore pipelines External liquid applied polyurethane and polyurethanemodified coatings”
ISO 21809:2007
Petroleum and natural gas industries – External coatings
for buried or submerged pipelines used in pipeline
transportation systems (Part 1: 3L-PE/PP, Part 2: FBE, Part
3: Field Joint Coating)
ISO 12944:1998:
„Paints and varnishes - Corrosion protection of steel
structures by protective paint systems”
Calgary, Alberta, Canada
February 23rd-26th, 2015
28
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
29
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Subkha
Subkha soils contain a high salt concentration. During seasonal high water and
sometimes even with tidal fluctuations, water levels in this ground rise so high
that the pipes are actually immersed in water from time to time, posing a very
high corrosion threat.
Subkha environment and Subkha damage to coating on steel pipe
Calgary, Alberta, Canada
February 23rd-26th, 2015
30
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Subkha
Pipe rehabilitation in Subkha soil
Field test pipe (operating pipeline) before and after
rehabilitation with high performance polyurea coating.
Calgary, Alberta, Canada
February 23rd-26th, 2015
31
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Subkha
Manual application
of high performance
polyurea coating
during field trial
Field test pipe showed neither defects nor deterioration
after more than one year in buried operation.
Calgary, Alberta, Canada
February 23rd-26th, 2015
32
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Subkha
Core unit of
automated
spray equipment
for multi-km
in-field
external coating
rehabilitation
Calgary, Alberta, Canada
February 23rd-26th, 2015
33
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
34
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Thrust Boring
Today, instead of tunneling underneath roads and rivers to lay a pipeline, often
the pipe is laid by thrust boring. The pipe is attached to a bore head and
pushed through the ground into its final position.
Calgary, Alberta, Canada
February 23rd-26th, 2015
35
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Thrust Boring
In a comparative trial, 18 different exterior coatings were subjected to a thrust
boring trial in rocky terrain by an operator. As opposed to thrust boring for
pipeline construction, in this trial, the pipes were pulled back out at the other
end to evaluate damage to the coatings.
Calgary, Alberta, Canada
February 23rd-26th, 2015
36
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Thrust Boring
High performance
polyurea elastomer
reached the best
rating by the operator;
all other coatings
showed severe
damage;
the polyurea coating
was rated
“minor damage” only.
Calgary, Alberta, Canada
February 23rd-26th, 2015
37
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Thrust Boring
High performance
polyurea elastomer
reached the best
rating by the operator;
all other coatings
showed severe
damage;
the polyurea coating
was rated
“minor damage” only.
Calgary, Alberta, Canada
February 23rd-26th, 2015
38
EXTERNAL CORROSION PROTECTION BY HIGH
PERFORMANCE POLYUREA COATING
Thrust Boring
High performance
polyurea elastomer
reached the best
rating by the operator;
all other coatings
showed severe
damage;
the polyurea coating
was rated
“minor damage” only.
Calgary, Alberta, Canada
February 23rd-26th, 2015
39
CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
Erosion, Corrosion, and Erosion-Corrosion in Slurry Transport
High Performance Polyurethane and Polyurea Elastomers
Interior Pipe Coatings made from Polyurethane
Case Oil Sands Tailings
1. Long-Term Performance
2. Field Joining
Case Erosion-Corrosion in Coarse Tailings
Pipe Stripping and Re-Use
External Corrosion Protection by High Performance Polyurea Coating
1. Subkha
2. Thrust Boring
Conclusions
Calgary, Alberta, Canada
February 23rd-26th, 2015
40
CONCLUSIONS
High Performance Polyurethane Elastomers have proven their excellent
abrasion and erosion-corrosion protective properties in oil sands tailings
and in other slurry applications.
Extension of life times by a factor of 10 or more translates into
enormous savings for operators; mostly by saving down time due to
much less frequent replacement and maintenance.
A proprietary weld joining system requiring only one field weld per joint,
pressure tested up to 3000 PSI, is widely applied in the field.
Under erosion-corrosion conditions, high performance polyurethane
elastomers can even beat the life time of chromium-carbide overlays.
Calgary, Alberta, Canada
February 23rd-26th, 2015
41
CONCLUSIONS
High abrasion resistance, high adhesion to steel and fast curing time
make high performance polyurea spray coatings ideal protective
coatings for thrust boring applications.
In addition, they provide long-term corrosion protection for buried
pipelines even in challenging environments. Particularly in salt-rich, salt
water exposed soils.
Application of polyurea spray coatings made from high performance
elastomer recipes can be done manually as well as by automated
equipment. The process lends itself to in-factory as well as in-field
applications.
The building-kit chemistry of polyurethanes and polyureas enables
manufacturers to design interior and exterior pipe coatings with
specific properties tailored to specific applications.
Calgary, Alberta, Canada
February 23rd-26th, 2015
42
THANK YOU FOR JOINING
THIS PRESENTATION.
www.rosen-group.com
Calgary, Alberta, Canada
February 23rd-26th, 2015
43