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The ShawCor Difference

Performance and Technical Requirements ofAnti-Corrosion Coatings for X90/X100 Line Pipes

X90/X100 管线钢管防腐涂层性能及技术要求

Dr. Shiwei William Guan 管世伟博士

X90/X100 Pipeline Steel Engineering Application Technology Seminar

Beijing, China September 13, 2012

Dr. Shiwei William Guan 管世伟博士

Vice President – Strategic Markets & Technology, Bredero Shaw加拿大劭氏集团Bredero Shaw百劭公司技术与战略市场副总裁

加拿大McMaster大学材料科学与工程（腐蚀学）博士

Chair of NACE International TG265 for two layer polyolefin pipe coatings, Chair of NACE TG353 for multi-layer polyolefin pipe coatings, and Chair of NACE TG281 for field applied polyurethane coatings 美国NACE国际腐蚀工程师协会TG265 双层聚烯烃管道防腐涂层技术委员会主席、NACE TG353 多层聚烯烃管道防腐涂层技术委员会主席、NACE TG281 聚氨脂防腐涂层现场施工、补口和修复技术委员会主席

国际 ISO TC67/SC2/WG14管道内防腐涂层技术标准委员会成员

美国AWWA水工协会涂层技术标准委员会成员

国际Anti-Corrosion Materials and Methods (《防腐材料与方法》)杂志编辑顾问

NACE CIP 注册涂层检验师(＃9484)和CIP教员

Content 内容

1. Strain ageing of high strength steels 高钢级管线钢的应变时效– Strain ageing 应变时效

– Influences of pipe preheat temperature of a pipeline coating process on strain ageing of high strength steels 涂覆钢管预热温度对高强钢应变时效的影响

2. Requirements for a high performance pipeline coating对高性能管道防腐涂层的要求– The pyramid of pipeline coating standards and specifications标准规范金字塔

– Comparison on the requirements between the Chinese and international standards and specifications 比较中国与国际标准规范要求之间的差异

– Why is a proper pipe preheat temperature so critical to pipeline coating performance? 为什么钢管预热温度对管道防腐涂层性能如此关键？

– Why do we need to set up the level of the requirements high rather than just fit for purpose?为什么要如此高要求而不是去量身定做？

3. New developments of high performance coating technology for high strength steels 用于高钢级管线钢的高性能管道涂层最新技术

4. Conclusion remarks 结语

1. Strain ageing of high strength steels高钢级管线钢的应变时效


Strain ageing: A behaviour usually associated with the yield point phenomenon in which the strength is increased and the ductility is decreased, when a low carbon steel has been subjected to a certain amount of cold deformation and is then allowed to age at a relatively low temperature for a period.

Cottrell atmosphere

应变时效:低碳钢经过一定量冷塑性变形之后，在相对较低的温度下放置一段时间而导致其力学性能发生变化（通常是屈服强度增高并伴有展延性降低）的现象。


Mechanism: During ageing, solute interstitial carbon and nitrogen atoms diffuse to broken dislocations and pin them.

Nitrogen has a greater influence than carbon at pipeline operation and low preheat temperatures:– Higher diffusivity in ferrite than carbon– Greater solubility

Temperature related:– Below 100oC: nitrogen atoms (diffusivity of C too low)– Above 220oC: Carbon atoms really influence– ≥ 250oC: Significant diffusivity of both N and C atoms

机理：存在于钢中的间隙溶质C 、N 原子通过扩散在塑性变形中裂开之后位错的周围重新偏聚，形成柯氏（Cottrell）气团，造成位错钉扎。

因为扩散率和溶度更高，在管线运行温度与较低预热温度下N原子的影响比C原子更大。温度相关：低于100摄氏度为N原子；220度以上C原子开始影响；250度以上两者扩散率很大。

Induction preheating and coating process 中频预热与涂覆工序

A conventional FBE coating process requires the preheat application temperature between 230oC – 250oC

常规FBE涂覆工艺需要施工温度在230－250oC之间

Effects due to preheating for FBE/3LPE:1) An increase in the yield strength (4-16%) 2) A negligible or very small increase in the tensile strength3) An increase in the Y/T ratio as a result of combining 1) and 2) 4) Inconsistent results in ductility5) Dependent on pipe grade and microstructure

– The higher strength steel, the more effects– Dual phase (bainite+martensite) is more sensitive than single phase

(bainite)

The higher the pre- strain/temperature/time, the more severe the effects

Common limitations of related research1) Small samples subjected to furnace heat treatments (vs. actual pipes going

through actual coating process)2) Focused more on large diameter/thick wall UOE/JCOE/SSAW than thinner

wall ERW3) Focused more on Y/T strength. Least conclusive on ductility and toughness

(which is the most important for strain based designed pipelines)4) Less on the effect of field hydrotest on the mechanical property changes

General observations of the impact of pipe preheating on X80 – X120

涂覆管子预热对X80－X120钢的影响

屈服强度增加4-16%，抗拉强度增加甚微，屈强比增加，对延展性影响结果不一致，与钢级和显微组织有关，钢级越高影响越大。双相

比单相更敏感。预变形越大、温度越高、加热时间越长，影响越显著。

More preheat temperature effects on higher grades 预热温度的影响随钢级升高而更为显著

– At 150oC: little or no effect 无或甚小影响

– At 200oC: some effect 稍有影响

– At 250oC: great effect, unacceptable results 很大影响，结果不能被接受

– Strain ageing might not be even completed after the coating process 应变时效也许在涂覆工艺完成之后亦尚未结束

General observations of the impact of pipe preheating on X80 – X120

A. Liessem et al., “Production and Development Update of X100 for Strain-Based Design Application”, 2009

涂覆管子预热对X80－X120钢的影响

Even so, it generally requires that the preheat pipe surface temperature for pipe coating application should be <200oC for strain-based designed pipelines and/or high strain applications

HOP technology can minimize the strain aging effect

N. Ishikawa et al., “Mechanical and Metallurgical Properties of High Strength Linepipes for High Strain Application”, International Pipeline Forum, Beijing, March 20-21, 2008

尽管在线热处理技术降低了应变时效影响，但应变设计或者大应变区还是要求管道涂层的施工温度低于200oC

2. Requirements for a high performance pipeline coating 对高性能管道防腐涂层的要求

The Pyramid of Pipeline Coating Standards and Specifications

International & IndustryStandards and Codes (ISO, DNV, NACE, API…)

Country Standards(CSA, DIN, BS, AS…)

Company Specifications(TOTAL, SHELL, TCPL…)

Project Specification

(Alaska Pipeline…)

Minimum requirements

Highest requirements for high performance and design life 标准规范之金字塔效应

最低要求

国际标准

国家标准

企业规范标准

工程项目规范

确保高性能和设计寿命的最高要求

Requirements on multi-layered MDPE/HDPE coating structure

Standards Specifications GB23257‐2009 ISO21809‐1 CSA

Z245.20/21 PetroChina (WEGP II)

Int’l Company 1

Int’l Company 2

FBE (µm) ≥120 ≥125 ≥120 ≥120 150‐250 ≥200Adhesive (µm) ≥170 ≥150 ≥100 ≥170 ≥200 ≥127

Polyethylene Various Various Various Various Various Various Allowed coating thickness reduction

30% on weld seam

Max. 10% on weld seam

Minimum thickness has to be met

30% on weld seam

Max. 10% on weld seam

Minimum thickness has to be met

对中高密度聚乙烯多层涂层结构的要求

Standards Specifications GB/T23257‐

2009 ISO21809‐1 CSA Z245.20/21

PetroChina (WEGP II)

Int’l Company 1

Int’l Company 2

Density (g/l) 1.3‐1.5 g/cm3 ±0.05 manuf. spec

±0.05 manuf. spec

1.3‐1.5 g/cm3

manuf. spec.

±0.05 manuf. spec

Moisture (% wt) ‐ ≤0.6

(mass loss)

≤0.5 (titration)

≤0.6 (mass loss)

‐ ≤0.5

(mass loss)

≤0.5 (titration)

≤0.6 (mass loss)

Volatile ≤0.6 ‐ ‐ ≤0.6 ‐ ‐

Tg2 (oC) ≥95oC

≥95oC & manuf. spec

manuf. spec ≥95oC ≥100oC manuf. Spec

Gel time (s) ≥12 & ±20% manuf. Spec

±20% manuf. Spec

±20% manuf. Spec

≥12 & ±20% manuf. Spec

manuf. Spec manuf. Spec

Cathodic disbondment (mm, 65oC)

≤8 (‐1.5V, 48h)

≤15 (‐1.5V, 30d)

‐

≤6.5 (‐3.5V, 24 h)

≤8.5 (‐1.5V, 28d, 20oC) ≤20 (‐1.5V,

28d)

≤8 (‐1.5V, 48h)

≤15 or ≤20 (LAT) (‐1.5V, 30d)

‐

≤4.5 (‐3.5V, 24 h)

≤4.5 (‐1.5V, 48h)

≤11.5 (‐1.5V, 14d)

≤13.5 (‐1.5V, 28d)

HWS ≤ Rating 2 (75oC, 48h) ‐

Rating 1‐3 (75oC, 24h,

28d)

≤ Rating 2 (75oC, 48h or 95oC, 24h)

‐ Rating 1‐3 (75oC&95oC, 24h, 48h, 28d)

Water absorption ‐ ‐ ‐ ‐

<15% uptake 28d

80oC ‐

Bend test 2.5o @‐20oC ‐ 2.5o @‐30, ‐18, or 0oC

2.5o @ ‐30oC

2.5o at min. temp

2.5o @‐30oC 1.5o @‐30oC

Other ‐ ‐ Met all CSA Z245.20 ‐

IR, particles size

Exceeded CSA Z245.20

Requirements on qualification of FBE primer/coating 对FBE的鉴定

Requirements on qualification of applied 3LPE 对涂覆好的3层PE的鉴定

Standards Specifications GB/T23257‐

2009 ISO21809‐

1 CSA

Z245.20/21 PetroChina(WEGP II)

Int’l Company 1 Int’l Company 3

Continuity Free of defects

Free of defects

≤2 holidays (B1)

<10 cm2 (B2)

Free of defects

Free of defects Free of defects

Impact (J/mm) ≥7 @20oC ≥7 @23oC ≥3J @‐30oC ≥8 @20oC ≥7 @23oC ≥26J @23oC (for

DN>800)

Indentation (mm) ‐

≤0.2 @23oC

≤0.4 (max design temp)

‐ ‐ ≤0.2 @23oC ≤0.5 (80oC)

≤0.2 @23oC ≤0.3 @50, 60,

80oC ≤0.4 >80oC

Elongation at break (%) ‐ ≥400

@23oC ‐ ‐ ≥500 @23oC ≥400 @23oC

Peel strength (N/mm)

≥10@20oC ≥5@≥70oC

≥10@23oC ≥2@≥60oC ≥150 N (B1) ≥10@20oC

≥7@≥50oC ≥20@23oC ≥4@≥80oC

>15@23oC >8@50oC

>3@60,80oC

∆Tg (1st layer of epoxy, oC)

≤5oC & ≥95% cure

≤5oC & manuf. spec

‐ ≤5oC & ≥95% cure ≤3oC Between

‐2oC & +3oC

∆MFR (%) production ‐ ≤20 ‐ ‐ ≤20 ≤20

Cathodic disbondment

(mm)

≤6 (‐1.5V, 48h, 65oC)

≤15 (‐1.5V, 30d, max oper. temp)

≤7 (‐1.5V, 28d, 23oC) ≤7 (‐3.5V, 24h, 65oC)

≤15 (‐1.5V,

28d, max oper. temp)

≤12 (‐1.5V, 28d, 20oC) Purchaser’s

spec (‐1.5V, 28d, max oper. temp)

≤8 (‐1.5V, 48h, 65oC)

≤15 (‐1.5V,

30d, 65oC)

≤5 (‐1.5V, 28d, 23oC) ≤3 (‐1.5V, 48h, 65oC)

≤15 (‐1.5V, 28d,

80 oC)

≤7 (‐1.5V, 28d, 23oC)

≤10 (‐1.5V, 28d, @50, 60oC)

≤15 (‐1.5V, 28d, 80 oC)

Flexibility 2.5o@‐30oC 2o @‐2 ‐ 0oC 2.5o@‐30oC 2.5o@

‐30oC ‐ 2o @‐2 ‐ 0oC

HSW ‐ Average ≤2Max. ≤3 Rating 1‐3 ‐ ‐

<5 mm edge & peel >15 N/mm (28d, max temp)

Other ‐ ‐ ‐ ‐

Porosity(10KV/mm) Homogeneity Shore D≥50

≤35% ∆MFR and remain

elongation >50% after thermal and

UV ageing

Requirements on production inspection and test of 3LPE 生产检验

Standards SpecificationsGB/T23257‐

2009 ISO21809‐1 CSA Z245.20/21 PetroChina(WEGP II)

Int’l Company 1

Int’l Company 3

Min. FBE thickness 1/shift 1/shift 1st, 4, 10, 35, 50

pipes 1/shift 1/shift 1/shift

Min. adhes. thickness ‐ 1/shift 1st, 4, 10, 35, 50

pipes ‐ 1/shift 1/shift

Degree of cure 1/shift 1st &

1/shift ‐ 1/shift 1st & 1/shift 1st & 1/shift

Continuity Each pipe Each pipe Each pipe Each pipe Each pipe Each pipe

Total DFT 1,5,10 & each 10 pipes

Every 10 pipes

1st, 4, 10, 35, 50 pipes

1,5,10 & each 10 pipes

Every 10 pipes Each pipe

Impact resistance ‐ 1/PE batch ‐ ‐ 1/shift 1/shift

Peel strength 2 temp/shift Every 4h One pipe

size/WT/shift (B1)

2 temp/shift Every 1h Every 4h

Indentation ‐ Each PE batch ‐ ‐ Each PE

batch 1/shift

Tensile Strength & Elongation

50 kms Each PE batch

One pipe size/WT/week

(B1) 50 kms Each PE

batch Each PE batch


10,20,30 & each 50 kms

(≤6, ‐1.5V, 48h, 65oC)

1/day (≤7, ‐3.5V, 24h, 65oC)

One pipe size/WT/shift (≤7, ‐3.5V, 24h,

65oC)

10,20,30 & each 50 kms (≤6, ‐1.5V, 48h, 65oC)

1/every 2 shifts

(≤3, ‐1.5V, 48h, 65oC)

1/shift (≤3, ‐1.5V, 48h, 65oC)

HSW ‐ 1/day One pipe

size/WT/shift (B2)

‐ 1/day 1/day

Flexibility ‐ ‐ One pipe

size/WT/shift (B2)

‐ ‐ ‐

∆MFR (%) In process ‐ 1st /shift ‐ ‐ 1st /shift 1st /shift

Cutback Each pipe Each pipe Each pipe Each pipe Each pipe Each pipe

Coating repair Each pipe Each defect. Each pipe Each pipe Each

defect. Each defect.

Residual mangnetism ‐ ‐ Each pipe ‐ Each pipe ‐

Shore D ‐ ‐ ‐ ‐ 1/shift ‐

Standards

GB/T23257‐2009

5.2 在开始生产时，先用试验管段在生产线上分别依次调节预热温度及防腐层各层厚度，各项参

数达到要求后方可开始生产。 5.3 应用无污染的热源对钢管加热至合适的涂敷温度，最高加热温

度应不影响钢管的性能。6.2 应对涂敷过程中的钢管加热温度等工艺参数进行连续监测，钢管的

加热温度应符合确定的涂敷生产工艺参数。

ISO21809‐1

The coating shall be applied in accordance with the APS. During the application of the coating components, the preheating temperature of the pipe shall be monitored and recorded using optical pyrometers or contact thermometers. Temperature measuring crayons may be used to measure temperature only if agreed upon prior to coating, and shall be validated for temperature control during qualification and production of the coating system. Once the coating temperature is established, the coating temperature shall be continuously monitored and recorded for each pipe unless agreed with the end user/ purchaser.

CSA Z245.20/21

Application and curing temperatures of the external pipe surface shall be as selected by Applicator and shall not exceed 275oC. Such temperatures shall be accordance with the powder manufacturer’s recommendations. The surface temperature of the pipe immediately prior to coating application shall be monitored and controlled within the limits recommended by the material manufacturer. The temperature shall be recorded at start‐up and at least once every hour of production thereafter.

Specifications

PetroChina (WEGP II)

5.2 在开始生产时，先用试验管段在生产线上分别依次调节预热温度及防腐层各层厚度，各项参

数达到要求后方可开始生产。 5.3 应用无污染的热源对钢管加热至环氧粉末生产厂家推荐的且经

适用性试验确定的涂敷温度，涂敷 X80 钢级管道有低温涂敷要求的最高加热温度应低于 200oC。6.2 应对涂敷过程中的钢管加热温度等工艺参数进行连续监测，钢管的加热温度应符合确定的涂

敷生产工艺参数。

Int’l Company 1

ISO21809‐1 and add: The pipes shall be preferably heated by induction. The temperature of the pipe and the intercoat time (between primer and adhesive) shall be set according to the gel time of the epoxy primer and following the epoxy MANUFACTURER recommendation, in order to obtain, as a minimum, adhesion values required (and within 5% of recorded value during PQT).

Int’l Company 3 ISO21809‐1 and add: The maximum pipe temperature shall be 280oC

Requirements on pipe preheating temperature prior to coating 预热温度

Comparison between the Chinese and International Requirements 中外比较

The level of requirements for normal applied coatings 对常规涂层的要求

– International: A pyramid from the minimum requirements in standards to high performance in company and project specifications 国际：从标准最低要求到企业与项目规范高性能要求的金字塔结构

– Chinese: 中国：标准与规范要求基本无差异，均为最低的和不完全的技术要求

– Little or no difference in standard and specifications: All uncompleted minimum requirements(3LPE ≤8 mm CDT 48h 65oC for WEGP II lower than ≤6 mm as per GB/T23257-2009) 西二线阴极剥离指标要求比国标更低

– Lower and less requirements than international in all the key areas 在所有关键处均低于国际要求

– FBE primer and weld seam coating thickness 比如FBE底漆和在焊缝上的总涂层厚度

– Qualification of raw materials such as FBE: CD ≤8 mm vs. ≤4.5 mm (Int’l 2) 短期原材料鉴定

– Qualification of applied 3LPE 防腐产品的鉴定指标

– Production inspection and test of 3LPE production, for example: 涂覆生产质量检验与测试

– CD (48h, -1.5V, 65oC): ≤6 mm (Chinese) vs. ≤3 mm (Int’l 1 & 3)– Surface preparation such as pipe preheating temperature prior to coating 涂覆前表面处理例

如钢管预热温度

Requirements for LAT coating application on X80/X100/X120 steels– International: the same requirements as for a coating of normal application– Chinese: Even lower requirements specified: 国际上对高强钢防腐产品性能的技术要求与常规涂层并无差异，

– FBE qualification CD (28/30d, -1.5V, 65oC): 而中国在原本已执行着防腐涂层质量最低要求的基础上对关键的30天阴极剥离性能指标做了大幅度的降低，因此进一步扩大了与国际上高性能防腐涂层生产质量技术要求指标之间的差距

≤20 mm (Chinese WEGP II) vs. ≤15 mm (normal) vs. ≤13.5 mm (Int’l 2)

Coating application at <200oC preheat temperature is good for maintaining the mechanical property of high strength steels but creates challenges on a coating adhesion to the substrate and thus long term performance

Three major components of FBE adhesion to the substrate* 粉末熔融环氧与基体附着力3要素:

1) Mechanical 机械附着力2) Polar-polar 极性与极性间附着力3) Chemical 化学附着力

* Kuruvila Varughese, “Improving Adhesion Properties of Three Layer Polyethylene Systems for Underground Pipeline Protection". DuPont Powder Coatings, U.S.A. Houston, TX

Can a conventional FBE be coated at below 200oC for high strength steels?

Why is a proper pipe pre-heat temperature so critical to the pipeline coating performance? 为什么钢管预热温度对管道防腐涂层性能如此关键？

The griping force of the coating to the substrate. It is dictated by shapes and densities of the surface profile created during the blast cleaning operation and the coating flowing and wetting ability to the profile

High temperature will decrease the viscosity of the melted FBE allowing it to flow into the profile avoiding air pockets and increase its wetting

Mechanical adhesion机械附着力Preheat temperature 预热温度之影响

Sprayed FBE layer Flow and WetFBE Melt and Fuse

Polar-polar adhesion is the sum of the attractive forces between the positive poles (H+) of the hydroxyl (OH-) radicals and the negative (O2-) poles of the hydroxyls of the coating and the pipe surface

Even though Polar-Polar adhesion is a major contributor, it will be reduced or eliminated by the presence of water at the metal interface. Since all organic coatings are permeable to oxygen and water, it is possible to have the total adhesive force considerably reduced on pipes operating in wet environments due to the permeation water

Polar-Polar Adhesion极性与极性间附着力

Chemical adhesive strength is true chemical reaction between the pipe and the coating, measured as the force needed to remove the chemically bonded epoxy group from the pipe substrate.

– One chemical bond is 10,000X stronger than the mechanical bond and 20-1000X stronger than the polar-polar bond

– Chemical bonds are not easily destroyed– The higher temperature increases the chances for increasing

the number of chemical bonds.

The thermally cross-linked FBE needs sufficient activation energy for cross linkage with the hydroxyls on the pipe surface. More energy provided through higher initial steel temperature increases the chance for this chemical reaction. Having maximum number of chemical bonds increases the chance for the coating system to stay bonded to the pipe even when water molecules reaches the pipe interface

Chemical adhesion 化学附着力Preheat temperature 预热温度之影响

FBE has to achieve at least 97% cross-linking (cure) in order to have the optimum properties. The curing process is a heat related phenomenon. It depends on the initial steel temperature and the duration that the pipe retains the heat

It is important that FBE achieves full cure, since the unreacted epoxies and curing agents in the FBE system can absorb water leading to a loss of adhesion. Lack of full cure can also affect the cohesive strength of the coating

Chemical adhesion 化学附着力Preheat temperature 预热温度之影响

Can conventional FBE be applied at temperatures lower than 230-250oC?

A Case Study– An International Brand Name Fusion Bonded Epoxy Coating– Application temperature range:

– 230oC-250oC normal application (One of the widely used powders with good international project track records)

– 180oC-230oC can be used as per manufacturer’s recommendation and the product data sheet

– Curing rate >98%

难道常规FBE就不能在温度低于230oC-250oC之下涂覆？某一国际品牌产品的实例

Can conventional FBE be applied at temperatures lower than 230-250oC?

Test CSA Criteria 24 hrs

7 days

14 days

28 days

Hot water soak at 75oC

24 hrs and 28 days adhesion, Rating 1-3

R#1 R# 1,2 R# 2 R# 2


28 days, -1.5V @ 65oCr≤20 mm (≤13.5mm TPCL)

6 mm 14 mm 24 mm

Qualification tests as per CSA Z245.20-10 and TPCL Specification for the international brand

name FBE powder coating applied at 190-200oC从通常的24h、48h生产检验标准要求而言，这一常规粉末产品也许可混为“合格”

Why do we need to set up the level of the requirements high rather than just fit for purpose?为什么要如此高要求而不是去量身定做？

RECENT PIPELINE INCIDENTS IN US美国近来的管线事故

San Bruno, CA in Sept 2010

Fatalities: 8 Injuries: 51 Property Damage: $375,400,000

RECENT PIPELINE INCIDENTS IN US美国近来的管线事故

RECENT PIPELINE INCIDENTS in US美国近来的管线事故

Rural Texas in June 2010

Fatalities: 1 Injuries: 7

RECENT PIPELINE INCIDENTS in US美国近来的管线事故

Allentown, PA in Feb 2011Fatalities: 5; Injuries: 7 Property Damage: $1,666,100

ALL NATIONAL PIPELINE SYSTEMS: SERIOUS INCIDENTS in US (1992-2011)美国国家管线网严重事故一览表

8 51 $375,400,000

Year Number Fatalities Injuries Property Damage1992 69 15 118 $7,646,0531993 67 17 111 $3,999,5151994 76 22 120 $38,927,7971995 59 21 64 $5,108,9021996 63 53 127 $13,657,4991997 49 10 77 $4,379,2501998 70 21 81 $41,641,0861999 66 22 108 $54,555,1842000 62 38 81 $6,594,7912001 40 7 61 $4,623,0942002 36 12 49 $4,729,9282003 61 12 71 $9,688,9002004 44 23 56 $9,172,3172005 39 13 47 $17,962,1662006 32 19 34 $8,058,8292007 43 15 47 $18,546,8622008 38 9 57 $47,877,8712009 46 13 62 $18,890,3442010 34 19 104 $381,117,5572011 34 12 55 $5,590,412Totals 1,028 373 1,530 $702,768,357

2012 YTD 16 8 23 $6,607,741

PHMSA 美国政府运输部下设的管道和危险材料安全管理局的最新要求

Pipeline and Hazardous Material Safety Administration Existing Pipelines 现有管线

– More stringent pipeline safety regulations such as new rules on record-keeping and pressure testing更严格的管线安全规定

– More frequent inspection and monitoring更频繁的检验与监控

– Re-qualification of pipeline, risk assessment, etc.重新鉴定与风险评定

New Pipelines 新管线

– More stringent requirements on pipe coatings更严格的管道涂层要求

– More stringent testing in the field (e.g. Testing voltage for holiday had increased by 25%) 更严格的现场检验（漏电电火花电压提高25%）

3. New developments of high performance coating technology used for high strength steels用于高钢级管线钢的高性能管道涂层最新技术

North Central Corridor pipeline project42” pipe, X80 and X100 Steel300 kms including 1,1 km Peace River HDDCoated by Bredero ShawThe world class coating process control process

LAT-FBE and LAT-2LFBE单双层低温施工粉末熔融环氧涂层技术

Test Test Parameters Acceptance Criterion Standard FBE LAT-FBE

Adhesion –Hot Water Immersion

24 hours at 75°CRating 1-3

Avg. 1 Avg. 12 days at 75°C Avg. 1 Avg. 128 days at 75°C Avg. 2 Avg. 124 hours at 95°C

Rating 1-3Avg. 1 Avg. 1

28 days at 95°C Avg. 2 Avg. 1

Cathodic Disbondment (Disbondment

Radius)

28 days at 23°C 8.0 mm max[6.5 mm TCPL] Avg. 5.0 mm Avg. 5.2 mm

28 days at 50°C 11.5 mm max Avg. 7.9 mm Avg. 6.9 mm1 day at 65°C 4.5 mm max Avg. 3.4 mm Avg. 2.3 mm

2 days at 65°C 5 mm max[4.5 mm TCPL] Avg. 3.3 mm Avg. 3.9 mm



Test results – standard vs. LAT-FBE常规与低温施工粉末环氧性能比较

Test Test Parameters Acceptance Criterion

Standard FBE LAT-FBE

Flexibility-30°C

2.5°/pd with no cracking

Pass Pass0°C Pass Pass20°C Pass Pass

Impact

-40°C

1.5J with no holiday

Pass Pass-30°C Pass Pass-10°C Pass Pass0°C Pass Pass20°C Pass Pass50°C Pass Pass

PorosityCross-section

Rating 1-42 1

Interface 2 1

Test results – standard vs. LAT-FBE常规与低温施工粉末环氧性能比较

HPPC (CSA Z245.21 All powders B2 System) – formerly known as HPCC

1. Steel 2. Fusion Bonded Epoxy3. FBE/Adhesive Interface4. Polyethylene

High Performance Powder Coating高性能全粉末多层聚乙烯管道涂层（CSA Z245.21之B2涂层系统）

HPPC – ADVANTAGES OVER FBEHPCC相对于FBE的优势

Better mechanical protection because of the PE outer layer 由于聚乙烯外层带来的机械性能的提高

Less moisture absorption 吸水性的降低

Eliminate interlayer adhesion failure 涂层层与层之间附着力失效的隐患不复存在

Provide excellent uniform coverage of the raised weld焊管高焊缝优秀的涂层覆盖率

Peerless/Godin Lake36” pipe, X100 and X120 SteelCoated at Bredero Shaw CamroseBending at -45oC

LAT – HPPC低温施工的HPPC涂层技术

LAT - SW HPPC for Mackenzie Gas Project低温施工侧缠绕加厚SW-HPPC技术

LAT-YJ2K (3LPE) for Mackenzie Gas Project 低温施工3LPE涂层技术

Tested as per CSA Z245.21 and MGP specification

At a total coating thickness of 2 mm or less, RPE is 2.5 to 3 times more impact resistant than a 3.5 mm thick 3LPE at 23oC and remains its good impact resistance and flexibility even at -60oC

RPE – Reinforced Polyethylene无胶粘剂层增强型聚乙烯RPE涂层技术

Rock Jacket for pipe up to 48” (Φ1219)大口径防腐管石夹克机械保护涂层技术

A bendable, compression wrapping applied reinforced concrete pipe coating system to provide a unique mechanical protection to coated pipes

Has the lowest total installed cost (material supply cost + direct and indirect installation costs) in the industry No thick/heavy duty ACC required No bedding/padding required No jeeping and ACC repairs needed prior to lower-in No ROW over-excavation for bedding No separators or pads needed during transportation

and handling No costs with sand truck or other specialized

equipment No surplus trench spoil material disposal costs No slow down pipeline installation process

End-to-end pipe coating solution:End plasma treatment for liquid FJC

No loss of adhesion (>2500 psi or 17.23 MPa) before and after 50

thermal cycles (-40°C for 16h and RT for 8h)

Hot Water Immersion at 75°C for 120d: Rating 1 adhesion

CDT (28d, -1.5V, 23°C) : 4 mmCDT (48h, -1.5V, 65°C) : 1 mmCDT (28d, -1.5V, 65°C) : 5 mmCDT (28d, -1.5V, 95°C) : 8 mm

焊管端与端之间涂层全面解决方案：防腐厂管端等离子处理液体补口涂层技术

4. Conclusion remarks结语

Conclusion remarks 结语

1) Strain ageing of high strength steels due to the conventional pipe coating process and strain based design of pipeline construction have provided a challenge to the industry to develop coating solutions with high performance which can be achieved while being applied at <200oC.由于常规管道防腐涂层施工工艺而导致的高钢级管线钢的应变时效现象以及基于应变设计的管线建设给管道工业带来了一个挑战：需要开发出可以在<200oC下施工的各种防腐涂层技术，并要求这些涂层技术在此工艺条件下亦达到具备有高性能的标准。


2) Comparison on the requirements between the Chinese and international standards and specifications reveals significant gaps in all key areas of pipeline coating technology in China: coating design, raw material qualification, finished coating qualification, process control, and production inspection. The Chinese pipeline industry will need to raise the bar from the current uncompleted minimum requirements to high performance, in order to ensure the integrity and protection of oil and gas pipelines in China with the use of high strength steels and strain based design. 通过对中国与国际有关管道防腐涂层标准规范要求之间的比较，可以看出中国在管道防腐涂层几乎所有的技术要求关键处都存在着明显的差距。这些技术要求的关键处包括：涂层结构设计、涂料原材料鉴定、防腐产品鉴定、涂覆工艺控制和生产检验，等等。随着高钢级管线钢和大应变管道设计的应用，中国管道工业需要把技术要求的横杆从目前的最低的不完全的要求提高到高性能要求，方能确定中国油气管线的完整性和失效安全性得到保护。


3) New developments of high performance coating technology for high strength steels are not only possible but also a reality.用于高钢级管线钢的各种高性能管道涂层技术的开发不但是可能的，而且也是一个现实。

Acknowledgment 致谢

The presenter would like to thank ShawCor CR&D in Toronto, and in particular, Dr. Dennis Wong and Ms. Catherine Lam, for their excellent work on the product development and contributions to this presentation.发言者在此感谢劭氏公司加拿大多伦多集团研发中心的同仁特别是Dennis Wong 博士与Catherine Lam女士在产品研发上卓越的工作和对本发言的贡献。

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