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Coating and Repair Techniques for Pipeline Construction, Exams of Engineering

Liberty University (LU)Engineering

Detailed information on various coating and repair techniques used in pipeline construction. Topics covered include hot applied coating tape, coating survey steps, faying surfaces, fbe field joint quality control, repair patches, maintenance coating selection process, melt sticks, life cycle of a coating system, two-layer pe, three-layer pe, fusion bonded epoxy, tape as a coating on pipeline, fbe process, quality control for tape, advantages and disadvantages of coal tar enamel, typical plant applied coatings, inspection of coal tar enamel, safe operating procedure for low voltage holiday detector, standards used for dry film measurement of coatings over concrete, surface prep for insulated pipeline, application process of insulated pipeline, insulated pipeline quality control, concrete coatings on pipeline, advantages of plural component airless, and inspection procedures of concrete.

Typology: Exams

2023/2024

Available from 05/01/2024

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NACE CIP 2 Master Study Guide solution
What is the cause of chalking in epoxy coating
UV or radiation exposure
Hot applied tape application?
Must be 50% overlap for both Hot and Cold
Minimum overlap of 50 mm (2")
Anchor the end or the tape
Ensure the tape is completely shrunk
Do NOT trap a,nr uder the tape!
What is polymerization cured coating?
Two parts mixed together just prior to use
:Three main products that are transported by pipelines?
• Oil
• Gas
• Water
Examples of non-convertible coatings
1. Chlorinated rubber 2. Vinyl 3. Acrylic 4. Bituminous
There are two ways to tell If the hot applied coating tape Is fully shrunk:
• The tape will shrink down tightly to the pipe surface
• The adhesive flows out from the edges of the hot tape
Non-convertible curing def.
No chemical change during cure cycle
Convertible curing def.
Some chemical change during cure cycle
After fully shrinking tape, do the following checks:
• Look for adhesive bleed-out
• Feel for air pockets
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NACE CIP 2 Master Study Guide solution

What is the cause of chalking in epoxy coating UV or radiation exposure Hot applied tape application? Must be 50% overlap for both Hot and Cold Minimum overlap of 50 mm (2") Anchor the end or the tape Ensure the tape is completely shrunk Do NOT trap a,nr uder the tape! What is polymerization cured coating? Two parts mixed together just prior to use :Three main products that are transported by pipelines?

  • Oil
  • Gas
  • Water Examples of non-convertible coatings
  1. Chlorinated rubber 2. Vinyl 3. Acrylic 4. Bituminous There are two ways to tell If the hot applied coating tape Is fully shrunk:
  • The tape will shrink down tightly to the pipe surface
  • The adhesive flows out from the edges of the hot tape Non-convertible curing def. No chemical change during cure cycle Convertible curing def. Some chemical change during cure cycle After fully shrinking tape, do the following checks:
  • Look for adhesive bleed-out
  • Feel for air pockets
  • Look for holidays
  • Repair holidays per the owner's specification What info should be included when sending samples to a lab?
  1. Identity of materials 2. Properly packed/labeled samples 3. Chain of custody form 4. Type of analysis that is expected and the concentrations of interest *Gathering pipelines Collect raw gas from wells and ships to plants for Processing. Specialized tests or equipment coating inspectors may encounter
  2. AA/AE Atomic Absorption/Emission 2. ISP Induction coupled plasma Spectrometer 3. GLC Gas liquid chromatographs 4. IR, FTIR, FTIR-ATR INfrared spectrophotometers 5. DSC Differential scanning calorimeters What Color are FBE Joints
  • Typically green or red
  • Dual powder is a two-layer fusion bond coating What is a cathodic dis-bondment test? Procedure to determine how easily a coating loosens from a substrate or develops holidays as a result of normal soil potentials Individuals who perform surveys
  1. O-Cat or S-cat tech 2. NACE coating specialist 3. NACE Level III 4. Coating Inspector w/field experience
  2. Coating manufacturer representative 6. Maintenence engineer with specific plant knowledge. FBE Field Joint Surface Preparation
  • Pre-clean the area using the specified method
  • Abrade the surface according to the specification
  • Pre-heat the surface according to the specification
  • Apply the required repair method according to the specification Coating survey steps

abrasion resistance Good resistance to acids, alkalis, salts, and bacteria

  • Uses Include:
  • Pipeline joints and bends
  • Flanges
  • Valves Temperature range for galvanizing kettle 820-850 F Purpose of pickling Hydrochloric or sulfuric acid bath to remove oxides and mill scale Petrolatum Tape Surface Prep
  • SSPC SPl solvent cleaning
  • Usually requires SSPC SP 3
  • There is no requirement for preheating Purpose of caustic cleaning Acid bath or caustic to remove dirt, oil and grease Stages of hot dip process
  1. Surface prep. 2. Galvanizing 3. Post treatment 4. Inspection Petrolatum Tape Application Applied by hand, spirally wrapping with a continuous overlap Sometimes use a paste primer Mastic filler/putty can be used to fill Irregularities May require an outer wrap to help prevent mechanical or UV damage Hot dip galvanizing safety
  2. Can stay for some time 2. Molten metal splash 3. Nascent hydrogen above kettle Pipeline construction materials depend on:
  • Product being transported
  • Services use
  • Environment
  • Economics
  • Safety requirements These products may include, but not be limited to. steel, aluminum, stainless. and plastic Usual layers of galvanized coating consists of:
  1. ETA=100% Zn 2. ZETA= 94% Zn 6%Fe 3. DELTA= 90% Zn 10 Fe 4. GAMMA= 75% Zn 25% Fe Petrolatum Tape Quality Control Testing typically utilizes non-destructive methods including:
  • Visual inspection
  • Physical inspection
  • Holiday detection What is hot dip galvanizing? Coating iron or steel with zinc at temperatures of 820-860 F What are the materials of Pipeline Construction?
  • Steel
  • Aluminum
  • Stainless
  • Plastic If a maintenance coating to be applied is incompatible with the existing coating system__________may occur Curling Mastic fillers should be used prior to applying the repair coating system: ______________ is performed at the work area by working the edges of the repaired area back to achieve a fairly smooth transition from the repair area to sound coating. Feathering You need to know three things to stop a pipeline from rusting too much?
  • Corrosion/Environment
  • Coatings
  • Cathodic protection With regards to maint. coating all parties should agree on___________?
  • Most popular coating used for nominal pipe sizes 1s 5 cm (2 in.) to 40.6 cm (16 in.)
  • Base layer is usually a black mastic (asphalt and rubber) adhesive applied directly to steel substrate Some service situations where permeation may occur include:
  1. Sour crude storage tanks 2. Cooling towers 3. Fertilizer plants What is the surface prep for Two-Layer PE?
  • Pre-blast inspection to remove mill defects
  • Pre-cleaning to remove contaminates
  • Ambient conditions
  • Blast cleanliness in accordance with the specification
  • Anchor profile
  • Documen and Report Special substrated that have tightly adherent oxide films include:
  1. Stainless steel 2. Tin 3. Nickel 4. Cadmium How is the base layer/Primer and top coat applied on Two-Layer PE? •Base Layer Rubber-modified asphalt and sealant that environmental meets the DOT requirements Rated operating for a pipeline temperature to 60°c (140°F) Top Layer: High Density Ployeurethane Jacket (HDPE Jacket) May be either crosshead or side extruded Non-Ferrous substrates include:
  2. Stainless steel 2. Nickel 3. Copper/Nickel alloys 4. Aluminum 5. Aluminum bronzes 6. Copper 7. Bronzes 8. Brass 9. Tin 10. Cadmium 11. Lead 12. Magnesium Two Layer PE Quality Control?
  • Ambient conditions
  • Pre-cleaning
  • Pre-blasting inspection for defects
  • Anchor profile
  • Mixing of primer and application
  • Side extrusion (check the overlap)
  • Holiday testing
  • Handling
  • Document/Report Common reasons wood is coated
  1. Decoration 2. Protection 3. Sealing 4. Stabilization 5. Preservation 6. Flame retardence What is three layer PE?
  • Looks like 2LPE , Includes a layer of FBE directly on the steel '
  • Intermediate layer is an adhesive: usually not visible FBE as Prime is the only difference. The following materials can be used to repair fusion bonded epoxy:
  1. Epoxy FBE melt sticks 2. LIquid epoxy 3. Repair patches Three-Layer PE surface Preparation?
  • Pre-blast inspection to remove mill defects
  • Pre-cleaning to remove contaminates
  • Ambient conditions
  • Blast cleanliness in accordance with the specification
  • Anchor profile
  • DocumenVReport Destructive tests for heat shrink sleeves include_____________ Peel test Three-Layer PE Application?
  • Preheat pipe (if required)
  • Epoxy/FBE application
  • Application of co-polymer adhesive layer
  • Application of PE (side or cross-head extrusion) What is Fusion Bonded Epoxy used to coat?
  • Girth weld area as a field joint
  • Heat induction bends
  • Flanges
  • Valves
  • Tees
  • Other fittings Non destructive tests for heat shrink sleeves include

Can be used as a standalone coating on water lines or as part of an insulation system. Note: Overlap is important - generally should be 50% overlap Disadvantages of CTE coatings include:

  1. Environmental concerns 2. Subject to corrosion and damage from soil stress What is the surface prep for tape on pipelines?
  • Pressure wash the surface
  • Wipe the tape surface with solvent
  • Lightly abrade the tape
  • Completely remove all loose and disbanded coatings
  • Abrasive blast exposed steel Advantages of CTE pipeline coatings
  1. Ease of application 2. Long life What is the application process for tape on pipelines?
  • Preheating pipe to specification
  • Abrasive blast clean to NACE3/SSPC-SP
  • Heat the pipe after blast to the required temperature
  • Apply the primer to the substrate
  • Begin application of the spiral wrap tape
  • Stencil (size, length, storage, pre-positioning)
  • Cut back the coating FBE process includes:
  1. Preheat 2. Grit/shot blast to NACE #2 SSPC-SP10 3. Heat pipe 4. Apply coating 5. Cure coating 6. Quench 7. Stencil What quality control should be followed with Tape? Check the surface pre-cleaning according to specification Check the surface preparation and follow the specification Check the primer application to ensure it is compatible with the required tape Check the over lap for the proper distance Check for holidays Document + Report Common characteristics of FBE include:
  1. Typically green or red 2. Single or two layer 3. DFT from 10-20 mils What are the advantages and disadvantages of Coal Tar Enamel?
  • Ease of application
  • Long life in some environments
  • Subject to corrosion and damage from soil stress
  • Environmental and exposure concerns
  • Use of coal tar Is regulated in some locations Typical plant applied coatings include
  1. Two layer poly 2. 3 layer poly 3. FBE 4. Coal tar enamel 4. Asphalt 5. Concrete 6. Asphalt What is the surface prep for coal tar on pipelines?
  • Pressure wash and solvent wipe the coating surface
  • Shot/Grit blast the external surface of the steel pipe What is the application process for Coal Tar Enamel on pipelines?
  • Prime Pipe
  • Apply coal tar enamel
  • Wrap the application with glass fiber mat
  • Apply a second layer or CTE
  • Wrap the application with a second layer or glass fiber mat
  • Apply an outer wrap or coal tar impregnated glass fiber felt
  • Cool the application The majority of the pipes coated at a facilty or plant and shipped to site are called: Plant applied Construction materials may include:
  1. Steel 2. Aluminum 3. Stainless steel 4. Plastic Inspection of Coal Tar Enamel include?
  • Check for contaminates on the substrate
  • Check the blast cleanliness and profile
  • Check the mixing and application
  • Inspect for holidays and thickness

When would you use concrete coatings on Pipeline + why? Easy to recognize; pipe covered with concrete Used in conjunction with all types of pipeline coatings Used to reduce buoyancy so pipe w1II sink can be applied m many thicknesses Can be applied to any diameter of pipe Advantages of plural component airless over single piston:

  1. Automatic, accurate material mixing 2. Ability to spray thick materials w/o thinning 3. Ability to spray materials 2/short pot lives. Concrete Surface Preparation?
  • Ensure all contamination is removed from the coatings
  • Water wash at low pressure
  • Wrap wire around the pipe 4 stages powder goes thru when heat is applied?
  1. Flow 2. Wetting 3. Gel 4. Curing How is Concrete Coating Applied on Pipeline?
  • Can be applied 1n a plant or in a field repair
  • After the place wire is placed. with spacers between the pipe and the mesh wire
  • Concrete will flow to the substrate and strengthen the joint
  • Pipe placed on a spiral roller system (in plants) and concrete is blown onto the surface. much like a gunite operation What are the inspection procedures of concrete?
  • Ensure the pipe is clean before application
  • Check the mesh wire for size and distance from pipe
  • Check the thickness of the concrete after the application
  • Check the cure time meets the specification
  • Check the handling not to damage concrete Two curing categories of powder coating
  1. Thermoplastic: Softens when heated 2. Thermo-setting: Hardens when heated