NON-SHIELDING CORROSION COATINGS

PRESENTATION FOR CORROSION COATINGS

FOR NEW PIPES, GIRTH WELDS &

REHABILITAITON AND MAINTENANCE

PETROMARYS

NON SHIELDING CORROSION

COATINGS

NEW PIPES, REHABILITAITON / MAINTENANCE

AND GIRTH WELDS

Non-shielding Coating System - RD-6

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Safety Moment

Corrosion Solutions

҉ Corrosion Solutions

End-to-endComplete solutions in

Corrosion prevention Systems

Customers

About PetroMarys

Established in 2002

Head Office in Jebel Ali Free Zone, Dubai

Branch office in Pakistan with trained and certified staff in Pakistan

Contracting and trading companies in Abu Dhabi, Dubai and Sharjah.

Having a mix of engineers, diploma holders, trained and certified staff

Provide corrosion prevention and mitigation solutions – integrity assessment, pipeline structural and coatings rehabilitation services.

About Polyguard Products Inc.

Polyguard is a 100% employee owned company having head office and manufacturing facility in Ennis, Texas, US.

It has been manufacturing speciality coatings for more than 50 years.

The company started manufacturing RD-6® Non Shielding Corrosion Coating in 1988.

Since 1988 it has been extensively used in US and in more than 35 countries in the world.

RD-6 Regional References

DOW – Supply of RD-6 Corrosion Coatings for 6” New Pipeline for Dock Chemicals Pipelines

DUSUP – Supply of RD-6 Corrosion Coatings for Rehabilitation & Maintenance Coatings for 24” Pipeline

DEWA – Rehabilitation of Underground Pipeline Coating with RD-6 for 24” Gas Pipelines and Furnace

Oil Lines

Emarat Petroleum – Supply of RD-6 Corrosion Coatings for Rehabilitation & Maintenance for 24”

Pipeline

GASCO, Abu Dhabi – Trial application of RD-6 coating on 42” pipeline

Dolphin Energy – Supply of RD-6 Coating System for Rehabilitation & Maintenance Coatings for 12” to

48” Diameters Pipelines

SSGC – Supply of RD-6 Corrosion Coatings for New Pipes

POL – Supply of RD-6 Corrosion Coatings for Rehabilitation and Maintenance for 6” Pipeline

Mari Petroleum – Trial Application on 8” Pipeline

Saudi ARAMCO + DOW Refinery – New Pipelines 6-12 Inches

SWC-Saudi – Girth Welds up to 96”

COATINGS WISH LIST vs RD-6 COMPLIANCE

Characteristic RD-6 Compliance

Remarks/Value

For New Distribution Lines Yes Perfect Application – 20Y Material

Warranty

Girth Welds – 3LPE Coating Yes Compatible with 3LPE, FBE, Coal

Tar etc. (except Wax Tapes) –

GASCO 42” and Saudi 96”

Re-coating on Transmission

Lines

Yes ExxonMobil while testing 29 other

coating technologies has rated RD-

6 as No. 1 Rehabilitation &

Maintenance Coating

Cold Application Yes No Heat, Torch – Safe

COATINGS WISH LIST vs RD-6 COMPLIANCE

Characteristic RD-6 Compliance

Remarks/Value

Good Resistance to Dis-

bondment

Yes CD = < 5mm @ 23C for 30 Days & Tmax = <

10mm @ 66C (PE Tapes = 20mm @ 50C)

Non Shielding Yes Since last 26 years in field and lab proven

Non Shielding

Good Electric Insulation Yes Good Resistance to Electrical Interference Di-

electric Strength > 12 kV

Minimal Harm to HSE Yes Environmentally Benign, User Friendly, NO

VOC’s or Toxic Material

Machine Application in Yard

& Field

Yes Hand Applied & with Machines > 6”

COATING’S WISH LIST vs RD-6 COMPLIANCE (Additional)

Characteristic RD-6 Compliance

Remarks/Value

Simple – 1 Layer, 1” Overlap Yes Excellent Soil Stress Resistance

Excellent Adhesion Properties Yes Peel Adhesion Value 3.5 kN/m @ 23C

Simple Machinery Yes Fast, 1-2 persons handling

Self-Healing Yes Can heal punctures, cuts etc

Excellent Soil Stress

Resistance

Yes Non Bonded Outer-wrap acts as a sacrificial

slip layer and saves RD-6

Minimal Surface Preparation Yes ST-3 (Wire Brush)

No Mix or Cure Time Yes Back-fill immediately

Cost Comparison w/o Field Applied Coating Technologies

Coating System Cost Comparison

with RD-6

Life in Years Shielding

Hot Bitumen/Coal Tar

(Carcenogenic, Hot

Application)

15 – 20% Expensive 15 Y Yes

Poly Ethylene (PE) Tapes 10 – 15% Expensive 15 Y Yes

Visco Elastic Coatings 30-40% Cheaper 20 Y Yes

RD-6 N/A 20-25Y No

Understanding Shielding?

A large percent of corrosion failures on cathodically protected structures are associated with dis-bonded coatings that shield cathodicprotection currents.

Please see the video

Shielding – any PE, PVC Backing will Shield CP Current

Cathodic Shielding – Under Girth Welds?

Cathodic Shielding – Under Girth Welds?

NACE defines shielding as;

“Preventing or diverting the cathodic protection current from its intended path”

NACE Standard RP0169-2002, Control of External Corrosion on Underground or Submerged

Metallic Piping Systems,

NACE International, Houston Texas 77084-4906, p3.

www.nace.org/nacestore/dept.asp?Cat%5FID=2905

FBE

•Current reaches water

•pH raised >9

•No significant

Shrink Sleeve

•Current shielded from

water

•pH remains <9

RD-6™

•Current reaches water

•pH raised >9

No significant corrosion

Internal

Surface of

Steel Pipe

Wall

SS or

tape

compoun

d

Solid film backing of

SS or tape does not

allow current to enter

if disbondment

occurs and water is

present.

WHEN WATER IS PRESENT UNDER THE COATING PAST THE OVERLAP

TYPICAL CURRENT FLOW PATH FOR SHRINK SLEEVE OR SOLID FILM

BACKED TAPE COATINGS

When water is present under a shrink sleeve or solid

film tape coating, corrosion and SCC can occur

because CP is shielded! Water pH usually 5 to 7.

Primer if

required

Current protects pipe

where the coating is

missing.

Return path for CP

current through the pipe

steel

CP current from ground bed

Internal Surface of

Steel Pipe Wall

RD-6 compound

RD-6 woven geo-

textile fabric backing

allows current to

enter at overlaps

only if disbondment

occurs and water is

present past the

overlap.

WHEN WATER IS PRESENT UNDER THE COATING PAST THE OVERLAP

TYPICAL CURRENT FLOW PATH FOR RD-6 COATING

Water under the coating because of improper tension,

surface preparation or application, but RD-6 allows CP

to protect the pipe and changes the pH to 9 to 13!

CP current from ground bed

Polyguard

600 Primer

Return path for CP current

through the pipe steel

Internal Surface of

Steel Pipe Wall

RD-6 compound

RD-6

woven

geo-

textile

fabric

backing

WHEN PROPER TENSION IS USED, HELIX AREA IS COMPLETELY

SEALED WITH COMPOUND, THEREFORE NO WATER IS PRESENT AND

CP CURRENT CAN NOT PENETRATE TO THE STEEL.

Helix area of overlap is completely filled with

compound with proper application tension,

therefore no CP or water can penetrate!

CP current from ground bed

Polyguard

600 Primer

TYPICAL CURRENT FLOW PATH FOR RD-6 COATING

Soil Stress Impact

One of the most common reasons coating fail – PE Tapes very much prone to failure because of poor adhesion, high elongation

Most severe forces with soil stress occur in the first 6 months of a coating life-span as soil settles, expands and contracts

Polypropylene Mesh is much less flexible and elongating than PE material

RD-6 stretch to break point is < 20%

PE Tapes expands from 200% to 400% - forming wrinkles – water penetrates creating corrosion

SP-6 (Non Bonded) Outerwrap – strongly recommended and acts as a sacrificial slip layer over the RD-6

SOIL STRESS FORCES

Considerable

weight and

pressure starts

the movement

of the coating.

Significant

downward forces

occur here to start

the wrinkling and

disbondment of

shrink sleeves and

solid film tapes.

The downward

and side ways

pressure in this

area is significant

because the ditch

line restricts the

soil path and

causes more

stress on the

coating as it

compacts around

the pipe.

Very little stress

in this area.

Typical areas of disbondment

and wrinkling of shrink sleeves

and solid film backed tapes

where water penetrates and

corrosion can occur.

Ditch line

Soil effects on stretchy type pipeline coatings

SOIL STRESS FORCES

Considerable

weight and

pressure starts

the downward

movement of

the coating .

Significant

downward forces

occur here to cause

the wrinkling and

disbondment if SP-

6 outer wrap is not

used.

The downward

and side ways

pressure in this

area is significant

because the ditch

line restricts the

soil path and

causes more

stress on the

coating as it

compacts around

the pipe.

Very little stress

in this area.

Ditch line

SP-6 Outer wrap takes the

stress, and slips or

wrinkles, leaving the RD-6

without damage.

SP-6 non-bonded outer-wrap enhances soil

stress resistance of RD-6

RD-6

Soil Stress – Wrinkle on a 10” Pipe

Soil Stress – Visco Elastic Coating Failing

Fails Famous for Failing , DISBONDMENT

Shields/Impedes CP Currents Corrosion, Pitting under dis-bonded portions

2 Layer, 50% O/L Coating System

Poor Adhesion Poor Soil Stress Resistance

Mechanical Resistance Not Good Strikes & Punctures are Easy

Soil Stress – PE Tapes Issues

Corrosion under dis-bonded PE Tapes – Failed & shielded CP Currents Wrinkling Under Solid Back (PE) Tapes

Most Tape Coatings recommend Commercial Blast

Most will also allow for power or hand brush very Poor Adhesion

Soil Stress – PE Tapes Issues

Solid-film backed PE Tapes, failure caused from Soil Stress. Water penetrates, CP is blocked or limited

MESH-BACKED COATINGS SYSTEM

Understanding Polypropylene Mesh-Backed Coating System RD-6

A 25 Years Success Story

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In 1970’s and 80’s companies begin to find wrinkling in the solid film backed tapes from

soil stress, pipe movement, poor surface preparation etc.

This caused to loose adhesion, allowing water to penetrate causing massive corrosion

Cathodic Shielding Coatings suffered from different form of corrosion EC, SCC and

caused many companies to remove ALL Tapes coatings from their list of corrosion

coatings

Polyguard then chose to make a coating system which will support CP

Basket Weave Design Mesh Backing:

Allows for current if → disbondment occurs and water is present

Very strong, with very little stretch → to provide resistance to soil stress

Allows compound to extrude through opening → compound to compound adhesion

at overlaps

Better adhesion than compound to solid film back tape coating system

Why Mesh-Backed Tape

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1 layer – 1” Overlap – 50 mils

50% Overlap for transport to field, high water table/rocky soil conditions

Adhesive dries quickly

Can be used all day or following day, if covered quickly

Simple Machinery

Heating the pipe only to remove moisture or to bring the temperature of the

pipe surface to above dew point

No mix or cure times, back fill after holiday detection

65C tolerance, high temperature 77C

SP-6 Outerwrap accessory always recommended

Self-healing

Why Mesh-Backed Tape – Benefits

Girth Welds Coatings ~ Replacing Heat Shrink Sleeves

Rehabilitation Coatings ~ Replacing PE Tapes, Coal Tar and other Visco Elastic Coatings

New Pipes ~ PE Tapes Replacements

RD -6 Applications (Field Applied)

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RD-6 for Girth Weld Coatings

Characteristic RD – 6 Shrink Sleeves

Cost Competitive Expensive

CP Shielding No – Field & Lab proven Yes, incase of dis-bondment

Torch/Flame needed for Application

(Safety)

No Yes

Primer Yes 2 Part Epoxies

Heating of Pipe Required No (Only when pipe is wet or temp. is < 7°C) Yes (Must pre-heat pipe + sleeves)

Human Error Factor No (Wrapster Machine) Yes, (Over-heating can cause sleeve to continue to

shrink and crack, under-heating does not allow proper

bonding)

Typical Time Required to Apply 3 – 5 Minutes 5 – 10 Minutes

Ease of Application No Special Tools required, brush or roller for

primer and Tape Wrapster for applying

Torches and Rollers required (Must pre-heat pipe to 120 –

195⁰F, but difficult to provide consist heat with torch.).

Overheating causes cracks and under-heating does not

allow proper-bonding

Affected by Soil Stress No (Excellent Bonding & resists Soil Stress Yes (Many examples of soil stress problems even when

properly applied and shielding issues)

Compatibility All (3LPE, FBE etc), except Wax All (Over-heating can damage 3LPE)

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Heat/Flame/Torch Required → Safety Issues → Slow Production Rates

Proper Heating for both the Pipe + Sleeve Required → Improve Heating will either

cause improper bond/air pockets or Sleeve to Shrink More

Two Part Epoxies → Increases Complexity → Shoots Cost

Slow, Complex & Time-Taking Process

Expensive and Long Lead Times

Shielding – Proven in many failed cases

Manual Process and in demanding conditions, excessive heat or fatigue → proper

application depends upon the person working in the ditch → examples of improper

application on the next page

Heat Shrink Sleeves Problems

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Heat Shrink Sleeves Problems – Over & Under Heating & Enclosure Strip

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Heat Shrink Sleeves Problems – Shielding CP Current

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No stripping of weld seams

Applied over dis-bonded coal tar allowing water to

migrate along weld seam under the RD-6

Incomplete primer application

Applied in Severe Soil Stress Area without proper

tension

No SP-6

Wrinkling

Water between RD-6 and Pipe

Study Cases – Shielding & Bad Application

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Study Cases – pH b/w 9-10 under RD-6 and b/w 5-6 under Coal Tar

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No stripping of weld seams

Applied over dis-bonded coal tar allowing water to

migrate along weld seam under the RD-6

Incomplete primer application

Applied in Severe Soil Stress Area without proper

tension

No SP-6

Wrinkling

Water between RD-6 and Pipe

Study Cases – Shielding & Bad Application

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Proven Non Shielding Properties

Excellent soil stress resistance – superior adhesion

No heat required to apply – safe – simple application

Minimal Surface Preperation

1 Layer – 1” Overlap

Application – Faster

Resistance to Cathodic Disbondment

Compatible with all coating systems except wax tapes

With time RD-6 has displayed it Non Shielding property with many pipelines inspected

with ILI, ECDA and other exposures, even when rare disbondments have occurred, no

reports of significant corrosion, SCC or MIC problems have been associated with soild

back coatings.

Conclusion

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RD-6 Pipeline Coating System in North American Market since 1988

Featured in Pipeline & Gas Journal – April 1991

Ranked #1 of 29 Pipeline Maintenance and Rehabilitation Coatings in

a test by Mobil – February 1995

One of the best of eleven evaluated “Field Applied External Pipeline

Coatings” in a test by Charter Coating Service Canada (Joint Industry

Project) in June 1997

Credentials

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Illustrative Pictures

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Illustrative Pictures

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Illustrative Pictures

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Illustrative Pictures

THANK YOU FOR YOUR INTEREST,

ATTENTION AND PATIENCE

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