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    Construction & Pipeline Coatings

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    Di
    The document discusses issues related to pipeline coating quality and construction practices. It provides details on: 1) Common coating defects found such as improper surface preparation, application method, thickness, and holiday detection; 2) The importance of operators having written coating procedures and providing training to ensure requirements are followed; 3) Examples of problems identified by PHMSA including failing to inspect coatings properly, using incorrect voltages for holiday detection, and damage caused during construction.

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    Construction & Pipeline Coatings

    Uploaded by

    Di
    80 views67 pages
    The document discusses issues related to pipeline coating quality and construction practices. It provides details on: 1) Common coating defects found such as improper surface preparation, application method, thickness, and holiday detection; 2) The importance of operators having written coating procedures and providing training to ensure requirements are followed; 3) Examples of problems identified by PHMSA including failing to inspect coatings properly, using incorrect voltages for holiday detection, and damage caused during construction.

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    The document discusses issues related to pipeline coating quality and construction practices. It provides details on: 1) Common coating defects found such as improper surface preparation, application method, thickness, and holiday detection; 2) The importance of operators having written coating procedures and providing training to ensure requirements are followed; 3) Examples of problems identified by PHMSA including failing to inspect coatings properly, using incorrect voltages for holiday detection, and damage caused during construction.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    80 views67 pages

    Construction & Pipeline Coatings

    Uploaded by

    Di
    The document discusses issues related to pipeline coating quality and construction practices. It provides details on: 1) Common coating defects found such as improper surface preparation, application method, thickness, and holiday detection; 2) The importance of operators having written coating procedures and providing training to ensure requirements are followed; 3) Examples of problems identified by PHMSA including failing to inspect coatings properly, using incorrect voltages for holiday detection, and damage caused during construction.

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    of 67

    Construction & Pipeline

    Coatings
    Corrosion Found
    Less than One Year of Service
    Coating reflects Quality

    • Inspection and repair of coating on a new


    pipeline reflects the Quality of the
    contractors workforces and training.
    • The job is not difficult, nor glamorous, but
    requires knowledge, skill, and will to pay
    attention mile after mile, looking for large
    and many small defects.
    Preface

    • Operators are responsible for construction


    to be in compliance with Code of Federal
    Regulations Part 192 or 195 and to follow
    the operator’s procedures.
    • Not the contractor
    • Not the inspection service
    Written Construction Procedures
    Gas & Liquid
    Gas Liquid
    • § 192.605(a) Each operator • §195.402(a) Each operator shall
    shall prepare and follow …a prepare and follow …a manual of
    manual of written procedures written procedures for;
    for; (c)(3) Operating, maintaining,
    (2) Controlling corrosion in and repairing the pipeline system
    accordance with in accordance with each of the
    the…requirements of subpart I requirements of this subpart and
    • Coating Procedures need to subpart H of this part
    List Approved Coating • Coating Procedures need to List
    Materials (Manufacturer & Approved Coating Materials
    Product #) (Manufacturer & Product #)
    • Operator should be able to • Operator should be able to justify
    justify requirements of § requirements of § 195.559 (a) –
    192.461(a)(1-5) and (b) (f)
    Written Construction Procedures
    Gas & Liquid

    • The operator’s procedures are to be made


    known to all the personnel responsible for
    those various tasks.
    • Beneficial: Conduct a training session for
    those individuals on these specific procedures.
    • Operator Qualifications required for O&M
    construction and new 80% SMYS permit
    construction.
    Gas Regulations Even
    Specify What Is Intuitive

    • § 192.461 External corrosion control: Protective


    coating
    (a) Each external protective coating, whether
    conductive or insulating, applied for the
    purpose of external corrosion control must—

    (1) Be applied on a properly prepared surface;


    Surface Preparation

    • Purpose of Surface Preparation


    • Clean Metal Surface
    • Abrade Metal Surface
    • Surface/Anchor Profile
    Surface Preparation

    Coating Manufacturer will specify the


    type of surface preparation required

    Industry Standards
    • Steel Structures Painting Council (SSPC)
    • NACE International
    Surface Preparation
    • SSPC-SP 1 Solvent Cleaning
    • Removes Grease/Oil and Debris
    • SSPC-SP 2 Hand Tool Cleaning
    • Removes loose mill scale, rust, paint, and other
    detrimental foreign material with hand tools
    • SSPC-SP 3 Power Tool Cleaning
    • Removes loose mill scale, rust, paint, and other
    detrimental foreign material with power tools,
    • Examples: white metal blast, near white metal and
    commercial blast cleaning
    • Near white - Typical Surface Prep. for Epoxies
    Coating Procedures
    • Surface Preparation Requirements
    • Specify by Industry Standards (SSPC & NACE)
    • Application Method
    • Spray, Brush or Roller?
    • Application Conditions
    • Air & Surface Temperature
    Caution use Infrared Temperature Guns that are
    calibrated to surface
    • Relative Humidity & Dew Point (Epoxies &
    Urethanes)
    Coating Procedures
    • Thickness Requirements
    • Dry Fill Thickness (mils) per Coat for
    Liquid/Powder Coatings
    • Overlap Requirements
    • Tape Coating & Shrink Sleeves
    • Minimum Overlap of Consecutive Wraps
    • Minimum Overlap of Existing Coatings
    • Cure Time prior to Recoating or Burying
    Poor Patch Stick Application
    Lack of Adhesion
    Excessively Large Patch Stick Application
    Use for Pinholes Only on 42” Pipe
    Inappropriate Bundling of Patch Sticks
    Use One Only-Small Areas
    Coating Inspection

    • Visual
    • Runs, Drips, Blisters, Foreign Inclusions
    • Wrinkles and Insufficient Overlap in Tape &
    Shrink Sleeves
    • Thickness Measurement
    • Critical for Liquid Applied Coatings
    • Holiday Testing (jeeping)
    • Electrical Test for Small Defects
    Holiday Detection (Jeeping)

    • Holiday: A discontinuity in a protective


    coating that exposes unprotected surface
    to the environment.*
    • Holiday detector: A device for locating
    discontinuities in a coating.*

    (*NACE SP0490-2007)
    Voltage Settings for
    Holiday Detectors
    • Operators O&M Manual: §192.605 (a)(2)
    §195.402(a)
    • Requirements should be in Operators Written
    Procedures or Project Specifications
    • NACE RP0274-2004: High-Voltage Electrical Inspection
    of Pipeline Coatings
    • NACE SP0490-2007: Holiday Detection of Fusion-
    Bonded Epoxy External Pipeline Coatings Coating
    • Manufacturer’s Published Instructions
    Recommended Testing Voltages (non-FBE)
    (*NACE RP0274-2004)
    Recommended Testing Voltages for FBE
    (*NACE SP0490-2007)
    Thin Field Joint Coating
    Joint Coating Applied over Dirt/Debris
    Coating Damage Cause by Welding Band
    (Jeep did not indicate holiday)
    Tape on Pipe Preventing proper
    Holiday Detection
    Lowering
    Sidebooms Spaced Per API 1104, Appendix A,
    ECA Stress Analysis
    Bored Crossing – Failed Hydro Test
    Rocks against pipe
    (No screening for over 1 mile)
    Pipe laid directly on solid rock
    PHMSA New Construction
    Coating Issues

    • Failing to visually inspect pipe


    • Electronic Holiday Detection (Jeeps)
    • Failing to follow written instructions
    • Low voltage setting
    • Using bent defective springs
    • High resistance in electrical circuit (grounding)
    • Jeeping over duct tape and fiberboard
    • Jeeping only at skid locations upon lowering-in
    • Traveling too fast and with Holiday Detector not working
    PHMSA New Construction
    Coating Issues

    • Two Part Epoxy


    • Failing to follow Written instructions
    • Failing to properly prepare surface and use solvent
    wipe (some manufacturers require solvent wipe)
    • Applying coating repair after epoxy starts to set (pot
    life)
    • Applying coating below or above manufactures
    recommended temperature or not heating pipe before
    application
    PHMSA New Construction
    Coating Issues

    • Fusion Bond Epoxy issues


    • Failing to follow written instructions
    • Improper application temperature
    • Heating pipe containing water (water prevents
    obtaining proper temperature)
    • Coating over mud or rust
    • Poor preparation during sand blasting (no sweeping
    over factory coating)
    PHMSA New Construction
    Coating Issues

    • FBE Patch Stick Issues:


    • Failing to follow written instructions
    • Not heating pipe during application
    • Using the patch stick on bare metal - for pinhole or
    abrasion repair only
    • Failing to prepare surface by sanding as required by
    manufacturer
    • Repairing two part epoxy with patch stick
    PHMSA New Construction
    Excavation Issues

    • Insufficient burial depth


    • No One Call Notifications
    • Inadequate use of rock shield, padding
    machines, or selective backfill
    • Dents caused by placing pipe on rocks
    • Construction crews damaging pipe and coating
    during installation in ditch and backfill and
    when installing river weights
    Construction Damage
    Section of Pipe was Replaced
    (found by DCVG Survey-Line was in Service)
    Gouge in Pipe
    (found by DCVG Survey-Line was in Service)
    What Not to Do with
    Equipment

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