Pipeline Coatings Research Articles

Wear and Corrosion Resistances of Arc-Sprayed FeCr Alloy and Fe-Based Coatings for Boiler Heat Exchanger Pipelines

Wear and Corrosion Resistances of Arc-Sprayed FeCr Alloy and Fe-Based Coatings for Boiler Heat Exchanger Pipelines

Uniform and local degradation of epoxy-based powder coatings: Salt transport and accelerated exposure analysis

The barrier performance of epoxy-based powder coatings for pipelines was evaluated through salt transport measurements through free-standing coating films and via cyclic testing of coated steel panels. The permeability of salt through the free-standing coating films was measured using reverse osmosis techniques under hydraulic pressures relevant to industrial use. These tests showed that fusion bonded epoxy (FBE) and high-performance powder coating (HPPC) have low salt permeability. Accelerated exposure tests were then conducted on the coated steel panels, subjecting them to humidified environments, ultraviolet (UV) light, and salt/fog conditions, all in accordance with ASTM D5894. Some of the exposure conditions (e.g., intensity of UV light and humidity) were modified to examine the impact of each parameter on the relative performance of these coating systems. The reversibility of the coating properties was characterized by a thermal cycling protocol and adhesion performance analysis. Alternative exposure to dry- and wet-cycles (at 60 °C and 50 °C, respectively), salt/fog conditions and UV light results in irreversible damage to the coatings as early as two weeks. However, coated panels exposed to a lower UV intensity (one tenth of the value defined by the standard) showed minimal degradation of FBE, meaning that the most critical parameter was the UV radiation exposure. For one 336-h ageing sequence under UV exposure, the HPPC exhibited superior performance compared to FBE. More importantly, our extended exposure sequences showed that while the FBE coating structure undergoes a slow ablation process, indicating significant surface damage, it still retains its effectiveness as a barrier. However, the osmotic pressures around coated pipes and the pre-existing, unavoidable porosity throughout the coating thickness can facilitate local through-thickness pinholes, which could potentially serve as areas susceptible to cathodic disbondment.

ANTICORROSION PROTECTION OF PIPELINES AND KEY TRENDS IN THIS FIELD

This study examines the significance of protective coatings for pipelines in hydropower and thermal power plants. It covers the role of primers in establishing strong bonds and explores the use of various coatings, including bituminous, epoxy, vinyl, and chlorinated rubber coatings. Key findings include the impact of environmental factors on coating durability, the adaptability of epoxy resins, and the efficacy of vinyl coatings in marine atmospheres. The study provides valuable insights for selecting appropriate coatings based on specific conditions and requirements. Keywords: Protective coatings, pipelines, hydropower, thermal power plants, epoxy coatings, vinyl coatings

Analyzing the Efficacy of Nickel Plating Coating in Hydraulic Pipeline Drag Reduction

This study delves into the drag-reducing properties of nickel plating coatings applied to hydraulic pipelines. To investigate the drag reduction characteristics of pipeline coatings, we designed a specialized experimental apparatus to conduct deceleration experiments. The primary objective was to systematically assess the drag reduction effect of varying coating thicknesses on liquid flow within the pipeline. Chemical nickel plating was employed for preparing drag reduction coatings with diverse thicknesses, achieved through precise adjustments in the composition and operating conditions of the plating solution. In the design of the experimental apparatus, careful consideration was given to crucial parameters such as the inner diameter of the pipeline, the inlet flow rate, and the control of experimental variables. It quantitatively assesses how varying coating thicknesses, flow velocities, and pipeline diameters impact the pipelines’ resistance to flow. By meticulously measuring the pressure differential across the pipeline, the research evaluates the extent of drag reduction afforded by the coatings and simultaneously elucidates the underlying mechanisms. Findings indicate a peak drag reduction rate of 5% under conditions of a 20 µm-thick nickel coating, 5 m/s flow velocity, and a 10 mm pipeline diameter. This study aims to comprehend how coatings affect linear losses along the pipeline, thereby establishing the groundwork for optimizing drag reduction technology. These outcomes highlight the coatings’ potential to mitigate linear losses due to shear stress during fluid transport, offering a viable solution to enhance hydraulic pipeline efficiency with significant industrial implications.

Machine Learning Assisted Early-Corrosion Detection System for Pipeline Coatings

Machine Learning Assisted Early-Corrosion Detection System for Pipeline Coatings

APPLICATION OF INTERNAL COATINGS IN ORDER TO INCREASE THE EFFICIENCY OF NATURAL GAS TRANSPORTATION AND REDUCE CORROSION DAMAGE TO THE PIPELINE WALL

With the development of the fuel and energy complex of the Russian Federation, new problems and challenges are emerging that require new scientific and technical solutions. At the moment, the length of pipelines through which various types of hydrocarbons are transported is growing. At the same time, the number of easily recoverable hydrocarbon reserves decreases every year, and at the same time their quality characteristics deteriorate, there is a need for a higher degree of their preparation for further transportation and additional purification. As a result, the corrosion effect on the pipe wall increases, leading to a decrease in the service life of the pipeline. Along with this, the share of heavy components in hydrocarbon mixtures transported through pipeline systems increases, which leads to an increase in energy costs for their transportation. These factors lead to a qualitative change in transportation conditions and, accordingly, to the need for additional technical solutions to protect pipes from corrosion and ensure the efficient operation of pipeline systems due to the increase in pressure losses along the length of the pipeline. As a result, it is necessary to achieve a reduction in energy costs for the transportation of natural gas. The problems of reducing pressure losses during natural gas transportation, as well as preventing corrosion wear of the internal cavity of the main gas pipelines are very relevant and require serious research to solve them.One of the effective ways to reduce energy loss during natural gas transportation and protect the inner wall of the pipeline from corrosion damage is the use of internal smooth polymer coatings of steel pipelines. At the same time, due to the growing influence of the negative factors listed earlier, there is a need for a critical analysis of existing technical solutions for their compliance with the current state and prospects for the development of the oil and gas complex.The article discusses existing and promising developments in the field of application of internal coatings in order to increase the efficiency of natural gas transportation and reduce the amount of corrosion damage to the pipeline wall.

Effective Protective Coating of Pipe Metal with High-Strength Corrosion-Resistant Material Based on Low-Molecular Oligodiene

Statement of the problem. A significant number of PJSC «Gazprom» main gas pipelines were built thirty or more years ago. At that time ineffective insulating materials were used for protecting steel pipes, applied mainly in the conditions of the route, which led to their extremely unsatisfactory condition in the future. Thus, at present there is a need to develop effective protective coatings for steel pipelines using domestic materials and equipment. Results. As a result of a series of experiments the composition of the composite material of the insulating coating based on the rubber concrete (Kauton) optimized to the state of the rubber mastic of the usable consistency has been determined. By carrying out a series of search experiments, rational temperature-time regimes of rubber mastic heat treatment have been determined for the formation of an effective layer of protective coating on the surface of pipe metal isolating it from harmful influences. Experimental device for providing modes of structure formation of pipe metal insulating coating material has been designed. Vulcanization of the rubber-containing mastic on the surface of a steel tube is performed by induction heating of the tube metal maintaining the necessary temperature-time modes of structure formation of the protective coating material. The physical and mechanical characteristics of the insulating coating for steel pipes on the basis of rubber mastic have been determined experimentally. Conclusions. The results of the research allow us to draw a conclusion about expediency, efficiency and significance of application in various areas of industrial production of coatings based on synthetic rubber to protect steel pipes from various negative influences and aggressive environments.

ANALYSIS OF THE PROPERTIES OF COATINGS USED TO PROTECT THE INNER SURFACE OF PIPELINES

The paper considers the main properties of protective coatings applied to the inner surface of pipes and pipe products. The main factors affecting the durability of coatings during the operation of pipelines are indicated, groups of test media and test parameters for the gradation of coatings to different operating conditions are identified. The influence of various aggressive media on pipeline coatings is described, as well as test media and test parameters of protective coatings are considered. The main methods for determining the physical and mechanical characteristics of coatings are given, brief informational and descriptive references for each of them are given. Recommendations are given for testing the protective coatings of the inner surface of pipes for compliance with technical requirements, which, ultimately, will allow the selection of materials most resistant to aggressive field environments.

Applied Insulating Coatings for Gas Distribution Pipelines in the Republic of Belarus and Their Characteristics

Gas distribution system is a production complex, which is part of the gas supply system and consists of organizational and economically interconnected facilities designed to organize the supply of gas directly to consumers. On the national basis of the gas distribution system is formed by about 67.0 thousand km of external distribution gas pipelines, 28.0 thousand km of which are underground steel pipelines. As potentially hazardous objects, steel underground distribution pipelines are subject to higher requirements for corrosion protection. As a rule, they are provided with complex anticorrosion protection, an obligatory component of which is insulation coatings. Taking into account the above mentioned, the definition of general indicators characterizing condition of insulation, the degree of its wear is an actual task. To solve it, for the first time, we have analyzed an array of long-term statistical data on defects of protective coatings of distribution gas pipelines, detected by instrumental method. The values of specific defect density Dd and damageability Ad have been determined for all types of applied protective coatings. The best values have been found for insulation on the basis of heat-shrinkable tapes. The characteristic damage of the protective coating on the basis of bituminous mastics (microcracks), which can be used as an indicator of aging of this type of insulation, has been determined. It has been shown that defect formation in the insulation coatings of gas pipelines up to the present time is, as a rule, a low-intensive process, which has been confirmed, among other things, for gas pipelines operated for a long time. The obtained results were included into the justification of abolition of the previously used 40-year normative service life of steel gas pipelines in the new edition of the Rules of Technical Safety in the Field of Gas Supply of the Republic of Belarus.

Environmental considerations around in-situ decommissioning of oil and gas pipeline infrastructure in marine environments

The base case for decommissioning of oil and gas infrastructure under Australian laws and regulations is the full removal. However, alternative options may be considered, provided equal or better environmental, safety and well-integrity outcomes compared to complete removal can be demonstrated. In order to evaluate in-situ retention options, the composition of materials, including any contaminants, must be fully understood, along with degradation timeframes and exposure pathways to the marine environment. In this paper, we articulate measurable parameters for the evaluation of pipeline materials including their composition chemistry, material degradation products and their properties, environmental toxicity, and potential interaction of infrastructure components with seawater and ecological receptors. In the absence of measured data from the degradation of pipeline materials over time, theoretical modelling is an essential tool to evaluate the transportation, distribution, and fate of materials such as plastic particles from pipeline coatings. Most of the components present in oil and gas pipelines, when degraded, are either soluble in water or if insoluble, accumulate locally in the sediment. However, the accumulated components will be rapidly dissipated by the wave currents around the pipeline and physical movements within the sediments, which will prevent the chemicals from accumulating to concentrations that could cause toxicity.

Investigation of the Pipeline Coating Properties Degradation to Increase the Energy Efficiency of the Cathodic Protection Stations

In this paper, it is proposed to investigate the influence of the parameter providing the rate of pipeline coating degradation on the protective length of cathodic protection systems (CPS). Comparison of the calculated values of the pipeline coating resistance with the predicted values is carried out according to the theoretical distribution of the pipeline coating resistance in time. The difference between the practical value of the parameter providing the rate of coating degradation of the considered pipeline section from the predicted one is determined. The dependence of the parameter providing the rate of pipeline coating degradation on the protective length of the CPS has been formed, which makes it possible to reduce the number of cathodic protection stations along the pipeline path at the design stage, and to diminish their energy consumption in the electrochemical protection system from corrosion of oil and gas pipelines.

Service Reliability Test Method for Anticorrosion Coatings on the Compressor Outlet Pipelines of Natural Gas Stations.

Compressor outlets are subject to high temperatures and vibrations; when pipelines are subject to such conditions, degradation of the anticorrosive layer on the pipeline is likely. Fusion-bonded epoxy (FBE) powder coating is the most common type of anticorrosion coatings on compressor outlet pipelines. It is necessary to study the reliability of anticorrosive layers in compressor outlet pipelines. In this paper, a service reliability test method for the corrosion-resistant coatings of compressor outlet pipelines of natural gas stations is proposed. Testing involving the simultaneous exposure of the pipeline to high temperatures and vibrations is conducted to evaluate, on a compressed timescale, the applicability and service reliability of FBE coatings. The failure mechanism of FBE coatings exposed to high temperatures and vibrations is analyzed. It is found that, due to the influence of initial imperfections in the coatings, FBE anticorrosion coatings typically do not meet the standard requirements for use in compressor outlet pipelines. After simultaneous exposure to high temperatures and vibrations, the impact resistance, abrasion resistance, and bending resistance of the coatings are found not to meet the requirements for their intended applications. It is therefore suggested that FBE anticorrosion coatings be used with extreme caution in compressor outlet pipelines.

ASSESSMENT OF THE GENERAL LEVEL OF DAMAGEABILITY TO INSULATION COATINGS OF STEEL UNDERGROUND GAS DISTRIBUTION PIPELINES

The article presents the results of analysis of long-term dynamics of damage of protective coatings of distribution gas pipelines revealed in the process of operation. The applied methodology of complex instrumental inspection and diagnostics of insulation is highlighted. The estimation of the general level of damageability of protective coverings on the basis of the value of specific density of defects was carried out. The received results testify to an insignificant degree of wear and absence of signs of approaching the limit state of gas pipelines' insulating coatings, including those being in operation for more than 40 years. This is an additional argument in favor of revising the normative service life of steel distribution gas pipelines towards increase.

The anti – Temperature-vibration properties of viscoelastic anticorrosive tape

Viscoelastic anticorrosive tape is extensively used for repairing anticorrosive layers on compressor outlet pipelines in the oil and gas industry. However, there is no relevant research on the coupling effect of temperature and vibration on the performance of viscoelastic anticorrosive tape. In this paper, acceleration tests of temperature and vibration coupling conditions were conducted to investigate the performance of viscoelastic anticorrosive tape. After temperature and vibration treatment, the specimens showed wide variance in thickness, and the adhesion and chemical soaking resistance of the tape was reduced. However, the viscoelastic anticorrosive tape still showed high adhesion. According to theoretical calculations, the tested viscoelastic body can repair pipes with a maximum diameter of 903 mm. Therefore, this viscoelastic anticorrosive tape is suitable for the compressor outlets of buried pipelines with diameters smaller than 903 mm. The research in this paper provides a method and basis for the selection of repairing materials for the anticorrosion coatings of compressor outlet pipelines.

Результаты оценки опасности производственной деятельности персонала компрессорных станций магистральных газопроводов

During gas transportation operations in extreme low-temperature natural and climatic conditions of the Far North, one of the urgent issues is the assessment of the probability of personnel death in the event of emergencies and occupational diseases during regular operation when operating the technological equipment of the compressor stations of main gas pipelines. The article discusses the results of an assessment based on the developed methodology for calculating integral indicators of the risk of damage to the life and health of employees of the compressor stations of main gas pipelines in the conditions of the Far North, aimed at ensuring the safety of personnel in the workplaces. When creating the methodological approach, specific features affecting the level of safety of life and health of personnel were considered, such as: microclimate, the mechanism of brittle destruction of equipment metal, temperature inversion, prolonged exposure to aggregates noise, etc. To determine the influence of each of the listed factors, a single criterion for assessing damage to the health of personnel (days of under-living) located directly at the investigated hazardous production facility (compressor stations of main gas pipelines) was selected and justified: machinists, automation and metrological support fitters, repair fitters. Based on the statistical data, the damage of under-living to retirement age is determined, adjusted for the conditions of the Far North in the event of the death of an employee of each profession in the event of an emergency at a compressor station. Further, in the range from the beginning of employment to the estimated age of death calculated above, the damage from occupational diseases is determined. These provisions of the methodological approach for assessing the cumulative damage to health allowed to develop recommendations for calculating insurance payments in the event of the death of an employee, calculating additional payments for harmful and hazardous working conditions and design changes in the form of the use of special coatings for pipelines for reducing the occupational risk of personnel of the compressor stations of main gas pipelines in given conditions.

Internal polymeric coating materials for preventing pipeline hydrogen embrittlement and a theoretical model of hydrogen diffusion through coated steel

This work develops a theoretical analysis of the coating permeability necessary for use as internal coatings of transmission pipelines to prevent hydrogen embrittlement. Internal coating materials suitable to be applied in situ on existing steel pipelines are also evaluated. Twelve different commercially available coatings; crosslinked poly (vinyl alcohol) (PVA), poly (vinyl chloride) and bisphenol A diglycidyl ether (DGEBA)/polyetheramine (D-400) epoxy coatings prepared in-house were tested. Films fabricated from two commercial epoxies had hydrogen permeability of 0.40 Barrer and 0.35 Barrer respectively, which show potential as coating materials. A hydrogen permeability of 0.0084 Barrer was achieved with a crosslinked poly (vinyl alcohol) coating, indicating that this material shows the highest potential of all coatings tested. Unsteady-state hydrogen diffusion through coated steel was then modeled to evaluate the effect of the coating film in reducing hydrogen embrittlement. The result shows that with a 2 mm PVA coating, hydrogen permeation inside the coating will take seven years to reach equilibrium and the final hydrogen concentration on the steel surface will be 44% lower than that without a coating. Greater protection can be provided if coatings can be developed with lower hydrogen permeability.

Water transport through epoxy-based powder pipeline coatings

We examined the water permeation kinetics of two common epoxy-based powder coating systems for pipelines across a range of industrially-relevant temperatures (from room temperature to 80 °C). We exclusively analyzed the nonlinear dependency of water transport on the vapor concentration at 65 °C. The vapor transport analysis of epoxy coatings demonstrated a turning point around this temperature, perhaps due to clustering of water molecules. At higher temperatures, break-up of water clusters and plasticization of the polymer expedited the transport. We also examined microstructural changes of the epoxy network due to water transport and found evidence for irreversible damage to epoxy coatings under hydrothermal exposures. It appears that the combination of thermal exposure and internal stresses in the glassy epoxy leads to a phase separation of filler particles from the epoxy matrix, as well as to a distinctive cavity formation in the coating membrane. Our results indicate that hydrothermal exposure is likely to increase aggregate porosity of the coating and a conservative implementation of standard coating procedures is therefore reasonable to avoid early degradation issues. Analysis of wet-state permeation is not only crucial for protection of transport pipelines, but it also is of high relevance to process equipment and underground storage tanks.

A Critical Review of the Time-Dependent Performance of Polymeric Pipeline Coatings: Focus on Hydration of Epoxy-Based Coatings.

The barrier performance of organic coatings is a direct function of mass transport and long-term stability of the polymeric structure. A predictive assessment of the protective coating cannot be conducted a priori of degradation effects on transport. Epoxy-based powder coatings are an attractive class of coatings for pipelines and other structures because application processing times are low and residual stresses between polymer layers are reduced. However, water ingress into the polymeric network of these coatings is of particular interest due to associated competitive sorption and plasticization effects. This review examines common analytical techniques for identifying parameters involved in transport in wet environments and underscores the gaps in the literature for the evaluation of the long-term performance of such coating systems. Studies have shown that the extent of polymer hydration has a major impact on gas and ion permeability/selectivity. Thus, transport analyses based only on micropore filling (i.e., adsorption) by water molecules are inadequate. Combinatorial entropy of the glassy epoxy and water vapor mixture not only affects the mechanism of membrane plasticization, but also changes the sorption kinetics of gas permeation and causes a partial gas immobility in the system. However, diffusivity, defined as the product of a kinetic mobility parameter and a concentration-dependent thermodynamic parameter, can eventually become favorable for gas transport at elevated temperatures, meaning that increasing gas pressure can decrease selectivity of the membrane for gas permeation. On the other hand, reverse osmosis membranes have shown that salt permeation is sensitive to, among other variables, water content in the polymer and a fundamental attribute in ionic diffusion is the effective size of hydrated ions. In addition, external electron sources—e.g., cathodic protection potentials for pipeline structures—can alter the kinetics of this transport as the tendency of ions to dissociate increases due to electrostatic forces. Focusing primarily on epoxy-based powder coatings, this review demonstrates that service parameters such as humidity, temperature, and concentration of aggressive species can dynamically develop different transport mechanisms, each at the expense of others. Although multilayered coating systems decrease moisture ingress and the consequences of environmental exposure, this survey shows that demands for extreme operating conditions can pose new challenges for coating materials and sparse data on transport properties would limit analysis of the remaining life of the system. This knowledge gap impedes the prediction of the likelihood of coating and, consequently, infrastructure failures.

Polypropylene pipe interface strength on marine sandy soils with varying coarse fraction

The interface shear strength of polypropylene pipeline coatings and marine sandy soils was investigated through direct and surface-over-soil interface shear box testing. Polypropylene specimens were acquired by removal from existing manufactured steel pipes and test soils were fabricated to closely resemble typical compositions and particle size distributions of North Sea marine sediments. The test sands varied according to their coarse particle fractions, with 0, 15 and 35% being retained on a 0·4 mm sieve. Testing was carried out at the very low stresses pertinent to pipeline interfaces, between 2·5 and 37·5 kPa, in both loose and dense states. The experimental results suggest a dependency of the interface shear strength on the stress level and relative density, with the coarse particle fraction playing a modest role. Surface characterisation and lack of volumetric deformation suggests that the shearing kinematic is predominantly grain sliding rather than rolling. Interface efficiency was largely constant despite some scatter due to variability in surface specimens. The distinct seams apparent on some of the polypropylene surfaces as inherent manufacturing artefacts had a negligible influence on interface strength. The relationship between interface strength, normalised roughness and Shore D hardness was assessed, discussed and compared with results from other works.

Technology Focus: Production and Facilities (December 2020)

The notion of reducing our environmental footprint, minimizing leaks and spillages, and identifying operational efficiencies is nothing new. We have been addressing these issues for years. Sustainability, however, has gained a higher profile recently, especially since the 2015 United Nations Framework Convention on Climate Change accord and the evolution of alternative energies. It came, therefore, as a pleasant surprise to review an extraordinary wealth of well-written papers relating not only to this topic, but to all manner of fascinating engineering issues. Let me back up a bit. For 6 years, I have provided commentary concerning matters relating to reservoir simulation. This was often illuminating, but my primary interest has always been in full-field modeling: coupling our models for flow in porous media, wellbore, network, and to facilities. I firmly believe that unified full-field modeling can furnish benefits both operationally and economically. In accepting the challenge to write this, however, I did not expect to encounter the extraordinary breadth of topics covered. Saying that, one clear thread did emerge from the articles reviewed - namely reliability, emissions control, and energy saving and monitoring, all of which relate to sustainability in one way or another. Novel methods for valve- failure prediction, pipeline coatings, floating storage tank roof optimization, and the use of drones (from spray painting to surveillance) along with robots for unmanned installations were all topics represented in the papers provided me. Paper SPE 198165 is an informative overview of alternative fuels and how these may affect Middle East production; however, this should appeal to a wider readership because it reviews alternative energies nicely. Paper IPTC 19775 provides a means to better quantify separator shrinkage, which can result in errors in stock-tank rates up to 20% (essential if one is to quantify unit energy consumption accurately). Paper SPE 197759 proposes methods for energy savings. These papers represent but a small sample of a broader swath of articles from the past year relating to this catch-all term “sustainability.” Recommended additional reading at OnePetro: www.onepetro.org. SPE 197753 Parametric Study on Wind Fatigue Life of Long Span Flare-Boom Based on Directional Input Parameters to Harris Wind Spectra and Selection of Wind Blocks by Sachin Samant, National Petroleum Construction Company, et al. SPE 198133 Internal Corrosion Severity Ranking of Crude Oil Pipelines by Amer Jaragh, Kuwait Oil Company, et al. SPE 197620 Ground Robotics Enabler for Normally Unattended Installations by Jean-Michel Munoz, Total, et al.