developments in field coating used in new dutch pipelines · summary and conclusions [1] •...
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Developments in field coating used in new Dutch pipelines
Ir. A.M. Dam,
29th February 2012
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Content
Introduction
Types of pressings and drillings
Coating approach and choices
Tests and experiences
Developments and improvements
Summary and Conclusions
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Introduction [1]
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Introduction [2] North – South project
600 km 48 inch pipeline
2 Compressor stations
Investment >2.000 mln euro
Owner: Gasunie
Construction: 2010-2013
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Introduction [3]
pressing
drilling
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20
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60
80
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120
140
5 15
25
35
45
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65
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length ranges [m 5m]
nu
mb
er
[/
]
Pressings.
Total: 476
≥
±
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2
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32
5
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75
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75
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25
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75
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75
14
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length ranges [m 25 m]
nu
mb
er
[/
]
Drillings.
Total: 63
±
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Types of drillings and pressings [1]
• Open front end pressing
pushing (avegaar)
impact ramming
• Cutter head conventional pressing
Horizontal Directional Drilling (HDD)
pilot drilling + roaming (conventional)
push and pull with “Pipe thruster”
cutter head (“Direct pipe”)
Pressings length most < 100 m
Drillings length > 2750 m and increasing
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Types of drillings and pressings [2]
Pushing and pulling:
• on steel => conventional
• on coating
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Coating approach and choices [1]
Mill coating.
General => multi-layer coatings
– Anti-corrosion layer
– Mechanical protection layer
Mill coating => 3-layer coatings: chosen by Gasunie:
– Line pipe => PE
– Pressings & drillings => PP with additional thickness:
– ≤ 20”: min. 4.5 mm (3.0 mm on weld seams)
– > 20”: min. 6 mm (4.0 mm on weld seams)
Approval:
– According ISO 21809-1 => PQT, PPT, “production”
– NO standard on mill coating for pressings & drillings
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Coating approach and choices [2]
Field coating (1).
General => multi-layer coatings
– Anti-corrosion layer
– Mechanical protection layer
Field coating => options given by Gasunie, choice by contractor
– Line pipe
– Anti-corrosion layer: epoxy or visco-elastic material
– Mechanical protection layer: shrink sleeve
– Fittings
– Visco-elastic material + tape
– Butyl rubber based material + PE-tape
Approval:
– According ISO 21809-3 => PQT, PPT, “production”
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Coating approach and choices [3]
Field coating (2).
– Drillings and pressings => options given by Gasunie:
– PP Flame Spray
– Canusa GTS PP
– PUPPlining
Remark: NO GRE / epicoat / wavistrong
Approval:
– NO standard on field coating for pressings & drillings
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Tests and experiences [1]
Material Resin : Epikote 828 Hardener : Euredur 43 Glass : Woven, 10 cm wide, 280 gr/m2 360 gr/m2 580 gr/m2 Non woven KH1603
Laminate instructions for steel welded joints for pipe diameter: 16" – 40”
Tests with GRE / epicoat / wavistrong :
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Tests and experiences [2]
Experiences with GRE / epicoat / wavistrong:
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Tests and experiences [3]
Experiences with PP Flame Spray:
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Tests and experiences [4]
Experiences with Canusa GTS PP:
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Tests and experiences [5]
Experiences with PUPPlining:
steel
PP mill coating
PP plate
polyurethane
PP “weld”
fibers
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Tests and experiences [6]
Tests with PUPPlining:
Test: • 18 m pipe 36” • filled with water => total weight 17.5 ton • length test track app. 1000 m
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Tests and experiences [7]
Impressed current tests:
Criterion, where A [m2]:
0 – 1000 m2: Imax = A *0.001 [mA] 1000 – 5000 m2: Imax = 1 + (A-1000)*0.00005 [mA]
DCVG (Direct Current Voltage Gradient) • directly after burial • within 1 year (guaranty period)
0,0
1,0
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length [m]
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rren
t d
en
sit
y [
uA
/m
2]
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Tests and experiences [8]
steel
PP mill coating
flush
Experiences with HDD’s & pressings (@ e.g. 48” diameter).
steel
PP mill coating
Experiences with HDD forces.
0
100
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0 200 400 600 800 1000 1200 1400
Pipe diameter [mm]
Fo
rce [
kN
]
Loose clay / peat
Stiff clay
Normal sand
Hard sand
R = 800 – 1000 * diameter [m]
R
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Tests and experiences [9]
Scratch tests on mill and field coatings (1):
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Tests and experiences [10]
Scratch tests on mill and field coatings (2):
y = 0,0003064x
R2 = 0,9943897
y = 0,0002401x
R2 = 0,9845693
0
1
2
3
4
5
6
0 3000 6000 9000 12000 15000
scratch load [N]
red
ucti
on
coati
ng
th
ickn
ess [
mm
]
6 mm PE
6 mm PP
Lineair (6 mm PE)
Lineair (6 mm PP)+ 28 %
0
1
2
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7
0 3000 6000 9000 12000 15000 18000 21000 24000
scratch load [N]
red
ucti
on
coati
ng
th
ickn
ess [
mm
]
PE mill coating
PE field coating
PP mill coating
PP field coating
8 mm thickness4,5 & 6 mm thickness
Results PE versus PP (6 mm mill coating)
Results mill versus field
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Tests and experiences [11]
Scratch tests on mill and field coatings (3): Results PE versus PP (mill & field coating)
0
3000
6000
9000
12000
15000
8:09:36 8:24:00 8:38:24 8:52:48 9:07:12 9:21:36 9:36:00 9:50:24
time [hh:mm:ss]
scratc
h f
orce [
N]
0
3000
6000
9000
12000
15000
8:09:36 8:24:00 8:38:24 8:52:48 9:07:12 9:21:36 9:36:00 9:50:24
time [hh:mm:ss]
pu
ll f
orce [
N]
y = 0,45867x
R2 = 0,37718
y = 0,57257x
R2 = 0,40737
0
3000
6000
9000
12000
15000
0 3000 6000 9000 12000 15000
scratch force [N]
pu
ll f
orce [
N]
PP
PE
Lineair (PP)
Lineair (PE)
diff. 25%
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Developments and improvements [1]
Repair:
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Developments and improvements [2]
Wehocoat:
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Summary and conclusions [1]
• Gasunie is expanding its network with pipelines in 48” size. • the amount and length of drillings and pressings is large and increasing. • there are new methods for drillings: “Pipe thruster” and “Direct Pipe”. • PP is a stronger (± 25%) coating material than PE for use in drillings & pressings. • in the “North-South” project an existing and a new PP field coating system are successfully used. • those field coating systems have the same strength as the PP mill coating. • after some start-up problems the performance of those field coating systems is excellent now. • drillings with increasing pipe diameter give an increase in load on the coating. • the amount of load, a coating can coop, increase with increase in coating thickness. • drillings and pressings with large diameter (eg 48”) pipe require “flush” field coating systems. • the height of weld caps (round, seam or spiral) in steel pipe or pipe connection reduces the effective coating thickness.
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Summary and conclusions [2]
• new repair methods for coatings are successfully introduced in the field and which originate from the “plastic industry”. • a new field coating system is under investigation. • the human factor is important and often decisive for the quality obtained especially in the field. • quality checks like “impressed current test” and “DCVG” work very fine. • contrary to line pipe, the pipe in a HDD can NOT be excavated and repaired. A high level of coating quality is compulsory in a HDD !
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