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Coating Overview
Audrey BERGERON
Bangkok – January 23rd 2014
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About the instructor
Title Coating specialist
Region / Entity Asia Pacific / TPS
Business segment Subsea – Onshore Offshore
Education Meng./ Chemical Engineering
Contact abergeron@technip.com

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About Technip Singapore
• Shallow to deep water
(3000 m)
• S-laying
• Rigidd pipes (4” to 60 “)
• Piggy-backed pipeline
installation
• Pipe-in-pipe, CRA
OFFSHORE
PIPELINE
INSTALLATION
• Lifting up to 1200 tons
• Installation of
platform, subsea
structures, skids,
modules, etc.
OFFSHORE
STRUCTURE
INSTALLATION,
HEAVY LIFTING
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About Technip Singapore
• Spools
• Risers
• Buckle Initiator Structures
• PLEM
• Manifolds
• Skids
• Crossing Structures
• Installation Aids
FABRICATION
SERVICES
• Full-time divers
• Saturation to 300m
• Pipelines, platform, SCM
de-commissioning /
removal
DIVING, IMR,
DECOMMIS-SIONING

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About Technip Singapore
G1201 - 3rd Generation DP Pipelay Vessel incl. 1200MT Pedestal Crane
Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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Abbreviations
3LPP/PE:
CS:
CUI:
CWC:
FBE:
FJC:
GSPU:
HP/HT:
HSS:
MLPP/PE:
PE:
PFP:
PP:
PU:
SPU:
SS:
TSA:
Three Layer PolyPropylene / PolyEthylene
Carbon Steel
Corrosion Under Insulation
Concrete Weight Coating
Fusion-Bonded Epoxy
Field Joint Coating
Glass Syntactic PolyUrethane
High Pressure/ High Temperature
Heat Shrinkable Sleeves
Multi-Layer PolyPropylene / PolyEthylene
PolyEthylene
Passive Fire Protection
PolyPropylene
PolyUrethane
Syntactic PolyUrethane
Stainless Steel
Thermal Spray Aluminum
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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1. HSE moment
Find the difference:
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1. HSE moment
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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2. Reason for coating
Why do we need coating? What kind of coating?
Corrosion protection
 Anti corrosion paint
Passive Fire Protection (PFP)
 Intumescent Epoxy
 Cementitious coating
Fouling release
 Anti fouling paint
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2. Reason for coating
Mechanical protection
 Polyolefin coatings
Negative buoyancy
 Concrete weight coating
Prevent CUI
(corrosion under insulation)
 Metallizing
(Thermal spray aluminum)
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2. Reason for coating
Anti slip
 Paint + natural aggregate
Insulation
 PU foam
Aesthetic aspect
 Polyurethane, Acrylic
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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3. Introduction to corrosion
According to NACE: “ Corrosion is a deterioration of a material because
of reaction with its environment.”
Liquid water is in contact with metal
AND
corrosive agent is present in the water
CORROSION =

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3. Introduction to corrosion
 Corrosion impact:
o Safety: unsafe corroded structures / equipment
o Cost: For the US, the annual cost of corrosion worldwide is
around 3% of GDP (US$ 250 Billion)
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3. Introduction to corrosion
 Different types of corrosion
 Uniform corrosion
o Uniform loss of mass for external surfaces. Concerns
mainly carbon steel and cast iron.
o Solution: corrosion allowance (3 to 6 mm), painting,
cathodic protection.
 Galvanic corrosion
o Creation of an electric current between 2 materials with
different potential.
o Common cases: aluminum/stainless steel, carbon
steel/stainless steel.
o Solution: isolation joints, cathodic protection, coating
 Erosion corrosion
o Erosion (abrasion): removal of metal by mechanical
action of liquids (or solids). Erosion-corrosion :removal of
corrosion products by mechanical action of liquids ( or
solids).
o Solution: improve flow by design of the piece, change for
better material, corrosion allowance

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3. Introduction to corrosion
Different types of corrosion
 Pitting corrosion
o High chloride concentration leads to passivation layer
breakdown.
o Affects stainless steel, aluminum, titanium
o Solution: increase molybdenum content in SS (CRA),
coating
 Chloride stress corrosion cracking
o Combined action of seawater and mechanical stress
o 316 Austenitic stainless steels subject to CSCC if
chloride concentration > 50 ppm and temperature >
50Ԩ
o Solution: coating, change material grade (316 SS to
22Cr or 25Cr)
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3. Introduction to corrosion
Design
Corrosion
prevention
Coating
Chemical
treatment
Material
selection
Cathodic
protection

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3. Introduction to corrosion
How to prevent corrosion?
 Design: avoid water retention, moisture / salts entrapment
 Inhibitors: chemical added into a fluid to decrease corrosion rate
 Material selection. Examples:
o SS 304L very sensitive to CSCC in offshore environment. SS 316L, 22Cr
duplex or Inconel 625 are preferred.
o Carbon Steel can be selected for offshore structures, provided it is protected
by coating and cathodic protection.
 Cathodic protection: protection of the surface by another “sacrificial”
metal (Zn, Al, Mg, …) who has a more electronegative potential.
 Protective coating
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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4. Surface preparation
Surface preparation: The key step to the coating success
Clean the surface from contaminant
Create roughness for coating adhesion.
objectives
grease dust
mill scale
oil
Soluble
salts
Former
coating
contaminants
Long term stability
to the coating
Did you know? 75% of premature coating failures are caused by
inadequate or improper surface preparation
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4. Surface preparation
Selection of the method depends on:
Substrate: carbon steel, stainless steel, Aluminum, galvanized
steel …
Degree of cleanliness required (paint system type and thickness)
Geometry of the piece (area difficult to access with machines)
Place where surface is prepared (on site, applicator’s plant)
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4. Surface preparation
1. Prior to commencement
• check for fabrication or welding defaults: rough
edges, cuts and welds shall be rounded to a
2mm radius to improve coating coverage and
adhesion on the surface.
• remove weld spatters.
2. Solvent cleaning.
Degrease and remove oil, grease, soluble contaminants with solvent
cleaning (fresh water, emulsion cleaners, detergents, organic solvents,
petroleum based solvents, alkaline cleaners). Does not remove
Chlorides, mill scale or other inorganic materials.
3. Abrasive blasting or other method
Remove chlorides and sulfates, create desired surface profile for
primer adhesion, create a uniform aspect.
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4. Surface preparation
steel shot or grit (carbon steel
surfaces),
aluminum oxide or garnet
sand (stainless steel or carbon
steel surfaces).
Projection of abrasive
particles to remove rust
and other contaminant and
create a rough surface
Abrasive blast cleaning
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4. Surface preparation
Abrasive blasting
equipment
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Surface preparation: other methods
Power tool cleaning (hand or
mechanical). Example: rotary wire brush.
Water jetting. Only to remove previous
coating, does not create roughness.
Pickling. Dipping of steel in an
acid bath
4. Surface preparation
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4. Surface preparation
Substrate Type of system Cleanliness (ISO 8501-1 or
SSPC)
Profile
surface
(ISO 8503)
Carbon steel – external
surfaces
Typical paint system
with DFT > 200μm
Sa 2 ½ eq. to SSPC SP10 50-75 μm
Carbon steel – internal
surfaces
Internal coating
(“lining”)
Sa 3 eq. to SSPC SP5 or Sa 2 ½
eq. to SSPC SP10
50-75 μm
Stainless steel,
Galvanized steel
Typical paint system Sweep blasting eq. to SSPC SP7 20-40 μm
- Carbon steel
- Stainless steel
TSA - Sa 3 eq. to SSPC SP5
- Sweep blasting eq. to SSPC SP7
70-120 μm
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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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5.1 Corrosion protection
coatings
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 Definition
 Application
 Selection
 Protection mode
 Specification
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5.1. Corrosion protection coatings - Definition
PAINT
= A+B
Pigments
+ fillers
Binder
(polymer)
Solvent
Additives
Reactive
+ solvent
Component A
Component B

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5.1. Corrosion protection coatings - Definition
Major paint used for corrosion protection purpose
• 2 component- thermoset coatings
• Excellent adhesion, chemical and water resistance
• Shall be top-coated by UV-resistant topcoat
EPOXY
• 2 component
• POLYURETHANE Resistant to UV, good gloss and color retention
• 2 component – min. zinc content 85%
• Very high substrate adhesion – good chemical resistance
• Max thickness 80 μm, subject to mud-cracking -careful with
repairs
INORGANIC ZINC
• Cure at ambient temp. or with help of heat
SILICONES • For heat resistance up to 600 Ԩ, or foul release
• 2 component coatings
• Very good for immersion service
• Suitable up to 230 Ԩ
PHENOLIC
EPOXIES
• 2 component – used as linings – very resistant to chemicals and
temp.
• High thickness (2 x 1000 μm) VINYL ESTER
•2 component – short pot life (45 min at 20 Ԩ) - Glass flake reinforced
•Excellent resistance to abrasion, water and moisture – good for salt
and fresh water environment and walkways
POLYESTER
5.1. Corrosion protection coatings – Application
Spray application : Air spray vs Airless spray
Air spray
- Spray pattern
easily adjusted
- High quality of
finishes
(automotive)
- Overspray
causes high loss of
coating
- Add solvent to
improve
atomization but
leads to low
thickness
Airless spray
- Less overspray
- Heavier film built
- Better production
rates
-Little control of
coating quantity
- Speed makes it
difficult for small
pieces
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5.1. Corrosion protection coatings – Application
Brush application
 Brush is only for
o Small areas not easily
accessible by spray
o Repairs and touch-up
o Stripe coats, corner, edges,
welds, bolting, flanges
o When environmental conditions
prohibit the use of spray
- Helps coating to have
a good adhesion on
substrate (for primers
and underwater
coatings)
- Good penetration into
surfaces that cannot be
properly cleaned
Roller application
 Do not use roller unless specific client approval
- Slow application (can
be an advantage in
some cases)
- Low DFT achieved
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5.1. Corrosion protection coatings – Protection
mode
Finish coat (polyurethane)
Intermediate coat (Epoxy based)
Zinc rich primer (inorganic zinc, zinc
rich epoxy)
Primer with inibitors (zinc phosphate)
1 – Barrier
2 – Galvanic
3 – Inhibition
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• Impermeability to water vapor, oxygen and salts
(Chloride), thick film, electric resistance 
pigmented epoxies (high solid content, mica
flakes)
1. Barrier
effect
• Primer contains a metallic pigment with a more
electronegative potential  inorganic zinc
silicates and zinc rich organic primers (epoxies)
2. Galvanic
effect
• Isolation of the substrate surface by addition of a
metallic compound chemically bonded to the
surface  zinc phosphate pigment
3. Inhibition

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5.1. Corrosion protection coatings - Selection
Selection of coating depends on:
Atmospheric corrosivity of environment (marine C5M,
industrial C5I, high C4, …)
Substrate (carbon steel, stainless steel, galvanized
steel, aluminum, CRA, …)
Equipment operating temperature
Durability of the coating / installation
1
2
3
4
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5.1. Corrosion protection coatings – Specification
Frequently encountered coating systems – Onshore offshore systems
Substrate System DFT (μm)
CS operating below 120 Ԩ
(Uninsulated)
Zinc rich primer (epoxy or inorganic zinc)
Epoxy high build
Polyurethane topcoat
50-75
150-200
50
CS operating between 120Ԩ and 450 Ԩ
(Uninsulated)
Inorganic zinc primer
Al pigmented silicone
Al pigmented silicone
50-75
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25
SS operating below 120 Ԩ
(Uninsulated)
Epoxy primer, zinc free
Epoxy high build
Polyurethane topcoat
50
150-200
50
SS operating between 120Ԩ and 600 Ԩ
(Uninsulated)
Al pigmented silicone
Al pigmented silicone
25
25
Insulated CS and SS operating below 200
Ԩ
Epoxy phenolic
Epoxy phenolic
100
100
Insulated CS and SS operating between
200 Ԩ and 600 Ԩ
TSA
Sealer (silicone)
250
40
Bulk items (any substrate, any
temperature, valves, piping, …)
Universal coating, inorganic copolymer
(compatible with PU topcoat for color
marking)
As per
manufacturer
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5.1. Corrosion protection coatings – Specification
Frequently encountered coating systems – Onshore offshore systems
Internal coatings (Carbon steel surfaces)
Application System DFT (μm)
Potable water below 60 Ԩ Solvent free epoxy
Solvent free epoxy
300
300
Crude oil, diesel, condensate, below 60 Ԩ:
bottom up to 1m + roof and upper 1m of wall
Abrasion resistant epoxy
Abrasion resistant epoxy
150-180
150-180
methanol, MEG below 80 Ԩ Inorganic zinc primer 60
Process vessel below 120 Ԩ Solvent free epoxy Novolac 300-600
Galvanized surfaces
Substrate System DFT (μm)
Galvanized steel operating below 120 Ԩ Epoxy primer, zinc free
High build epoxy
Polyurethane
50
100
50
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5.1. Corrosion protection coatings – Specification
Antiskid surfaces
Substrate System DFT (μm)
Carbon steel Epoxy primer
Frequently encountered coating systems – Subsea systems
Substrate System DFT (μm)
CS and SS in splash zone
Abrasion resistant epoxy (glass flakes)
300
operating below 100 Ԩ
Abrasion resistant epoxy (glass flakes)
300
CS and SS immersed
operating below 100 Ԩ
Abrasion resistant epoxy or high build epoxy
Abrasion resistant epoxy or high build epoxy
175
175
Ultra high build epoxy + non-skid aggregates
Polyurethane
50
600-3000
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Note: 1. Surface friction coefficient may need to be indicated.
2. Use of Aluminum oxide (and other non-ferrous irregular surfaces) is preferred
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5.1. Corrosion protection coatings – Specification
Checks and Quality Controls
Before painting application
o Operator and inspector Qualification certificates
o Instrumentation device calibration certificates
 Surface preparation
o Environmental conditions (Dew Point, surface T°C and Ambient T°C measurement),
o Abrasive contamination,
o Grade of cleanliness + surface roughness,
o Chloride content + dust level
 Painting application
o Wet and dry film thickness,
o Visual inspection
 After painting application
o Curing of inorganic zinc,
o Adhesion test
o Pinhole detection (only for immersed, underground and internal coatings)
5.2 Specific coatings
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 Metallizing
 Passive Fire Protection
 Fouling-release coatings

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5.2 Specific coatings: Metallizing (TSA)
Thermal Spray Aluminum
 Spraying of molten Aluminum wire by flame spray or arc spray
 Good for immersion and CUI prevention.
 Applied on Carbon steel or Stainless steel operating up to 600 Ԩ
- Excellent corrosion
protection properties
- Excellent resistance to
mechanical damages
- Very high durability (up
to 50 years)
- Zero VOC.
- Porous: need to apply a
sealer on top (epoxy or
silicone).
- Cost effective process
- HSE rules must be strictly
followed.
- Critical surface
preparation: high degree
of cleanliness required
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5.2 Specific coatings: Metallizing (TSA)
TSA coating systems
Substrate System DFT (μm)
CS and SS operating below
TSA
250
120 Ԩ
Epoxy sealer compatible with TSA
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CS and SS operating above
120Ԩ
TSA
Silicone sealer compatible with TSA
250
40
Application examples
 Bulk valves (all temperatures, CS and SS)
 Offshore or immersed structures
 Flare top
TSA applicators
 Norimax
 WASCO
 MTM Metalization
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5.2 Specific coatings: Metallizing (TSA)
Splitter column Turret component
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5.2 Specific coatings: Metallizing
Other Thermal Spray Coatings:
 Zinc
 Al-Zn
 Stainless steel
 Inconel
 Copper Nickel
 Monel
 Hastelloy
Harder material  Higher operating temperature gun
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5.2 Specific coatings: PFP
 Steel begins to lose strength as its temperature rises in a fire  structural collapse.
 PFP is designed to protect structures supporting high risk and valuable equipment.
 Objective: prevent the substrate to rise in temperature during a fire to avoid steel to collapse:
o Jet fire
o Hydrocarbon fire
o Cellulosic fire
1400
1200
1000
800
600
400
200
0
Fire Curves
0 30 60 90 120 150 180
Temperature °C
Time (minutes)
Cellulosic
Hydrocarbon
Jet Fire
Jet fire: Release of hydrocarbon fuel
under pressure through a relatively
small opening such as a crack or hole
 high levels of turbulence, “erosion”
of the PFP coating.
Pool fire: Hydrocarbon fuel burning
under atmospheric pressure.
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5.2 Specific coatings: PFP
Organic coatings: Intumescent epoxy
They are inert at ambient temperature but react when exposed to
temperatures above about 200ºC. The reacted coating forms a thick carbon
based char. Applied with reinforcement mesh
- Provides corrosion
protection
- Low DFT for 2h
protection (2-10
mm)
- Low density
- Requires the use
of skilled applicators
- Cost effective

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Spray application equipment
Source: PPG
Typical Plural Component
Pump
Typical plural component
mixing block and spray gun
5.2 Specific coatings: PFP
 Thickness of PFP is determined by:
o Size, shape of steel section to protect (beams, hollow section)
o Critical failure temperature
o Duration of protection needed
 Calculation of DFT with Hp/A value.
The higher Hp/A value, the higher PFP thickness will be required.
High Hp
Low A
Fast Heating
Low Hp
High A
Slow Heating
Source: PPG
Hp = heated perimeter
exposed to fire
A = cross-section area of steel
element
5.2 Specific coatings: PFP
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5.2 Specific coatings: PFP
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5.2 Specific coatings: PFP
Inorganic coatings: Cementitious
Lightweight with nominal density around 500 kg/m3.
Must be topcoated with a high water vapor permeability
coating. Must also be applied with mesh reinforcement.
- Cheap, easy to install
and repair
- Hard and durable
- Heavy
- Thickness around 25 mm
for a 2h fire protection
- Poor flexibility
- Risk of hidden corrosion in
reinforcement by water
ingress

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5.2 Specific coatings: PFP
PFP systems
Substrate System DFT (μm)
Fireproofed carbon steel
surfaces
Zinc rich epoxy or inorganic zinc silicate
Intumescent PFP epoxy
Polyurethane
50
As calculated
50
Fireproofed stainless steel
surfaces
Zinc free epoxy primer
Intumescent PFP epoxy
Polyurethane
50
As calculated
50
Fireproofed carbon steel
surfaces
Zinc rich epoxy or inorganic zinc silicate
High build epoxy
Cementitious PFP
50
150
As calculated
Fireproofed stainless steel
surfaces
Zinc free epoxy primer
High build epoxy
Cementitious PFP
50
150
As calculated
5.2 Specific coatings: Fouling release coatings
Objective: prevent formation of biofouling on vessels and
structures (mussels, barnacles, algae, etc.).
2 mechanisms: fouling release coatings and antifouling
coatings (biocide release).
Fouling release coatings:
- Silicones
- Fluoro-polymer
Prevent attachment of micro-organisms on the structure
by creating a smooth finish with low surface tension.
Source: PPG
TBT-based coatings are prohibited
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5.2 Specific coatings: Fouling release coatings
Fouling release system
Substrate System DFT (μm)
Any (riser, structure, hull, etc.) Epoxy primer
Foul release coat (1 or 2 coats)
Finish coat
50-100
200-600
100-150
Note: Fouling release systems depend on each coating manufacturer; all products of the system should
be compatible with each other. The proposed system is for example only.
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5.2 Specific coatings: Shop primers
 Thin film inorganic zinc primer applied on applicator’s plant
for more accurate control of application process.
 Typical application: steel plates for tank storage.
 Purpose: Protect against corrosion and environment during
transport and before erection.
 Primer is applied automatically or not at 15-30 μm.
Source: TOTAL – GTS presentation

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5.2 Specific coatings: Shop primers
Source: TOTAL – GTS presentation
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5.2 Specific coatings: Shop primers
Source: TOTAL – GTS presentation

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Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
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6.1 Pipe coating
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 Selection
 Properties
 Standards
 Systems
 Subcontractors
 Futures challlenges

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6.1. Pipe coating - Selection
Pipeline protection = Combination of
 Adequate protective coating,
 Supplementary cathodic protection
Selection of the coating system depends on:
o Pipe material characteristics
o Service / design temperature
o Pipeline design thermal profile
o Maximum water depth
o Specific properties requirement (cathodic disbondment, elongation, strength, …)
o Laying method
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6.1. Pipe coating - Properties
Properties for Corrosion protection coating
Main properties
o Strong adhesion to the pipe
o Corrosion properties
o Strong resistance to cathodic
disbondment
o Durability for design life of the
pipe
o Good mechanical strength
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6.1. Pipe coating - Properties
Properties for Thermal insulation coating
 Pipes are insulated to prevent hydrate formation, waxing and to satisfy separator
arrival temperature.
Main properties
o Thermal conductivity
o Density
o Adhesion to base material
Properties for Weight coating
Main properties
o Density
o Compressive strength
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 Types of pipe coatings
o Fusion Bonded Epoxy (FBE), Liquid epoxy
o 3-layer Polyethylene (3LPE) / Polypropylene (3LPP)
o MLPP Foam / syntactic
o GSPU, SPU
o Concrete Weight Coating (CWC)
Corrosion
protection
Flow
assurance
Negative
buoyancy
6.1. Pipe coating - Properties
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6.1. Pipe coating - Standards
International standards in pipe coating: ISO 21809
 3LPE/PP: ISO 21809 - 1
 FBE: ISO 21809 - 2
 CWC: ISO 21809 - 5
ISO 21809 replaces DIN (German), NF (French), CSA (Canadian)
Other standards or specifications
 AWWA (American Water Works Association): AWWA C213-07 (FBE)
 DNV-RP-F106 (FBE, 3LPP, 3LPE)
 NACE RP0394-2002 (FBE)
 DNV-OS-F101 (CWC)
 NO STANDARD FOR INSULATION COATING
6.1. Pipe coating - Systems
 Liquid coating
- Mainly used for buried pipe operating at elevated temperature, where 3LPE and 3LPP cannot be
considered.
- Generally a high built coating applied by airless spray with DFT up to 3000 μm.
- Maximum service temperature can go up to 200Ԩ , depending on the type of resin (epoxy, epoxy
novolac, phenolic epoxy, vinyl ester).
- Can be reinforced with glass flakes to improve moisture and mechanical resistance.
- Can be applied as an internal lining to protect against corrosive fluid. In this case, thickness up to
300 μm.
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6.1. Pipe coating - Systems
 Fusion Bonded Epoxy (FBE)
Coating system description Single layer fusion bonded epoxy
Type of protection Corrosion protection
Typical coating thickness 350-500 μm
Design temperature 90Ԩ
Water depth limit Unlimited
Major characteristics - Excellent long term corrosion resistance to steel,
- Cathodic disbondment resistance (reduce cost of
cathodic protection)
- Good chemical resistance.
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6.1. Pipe coating - Systems
 FBE coating process
Source: Bredero Shaw

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6.1. Pipe coating - Systems
 Three Layer Polypropylene (3LPP)
Coating system description FBE + PP Adhesive + Solid PP
Type of protection Corrosion protection
Mechanical protection
Typical coating thickness 2- 4.5 mm
Design temperature 110Ԩ (up to 130 Ԩ with high temperature FBE)
Water depth limit Unlimited
Major characteristics - High film thickness
- Good PP flexibility  mechanical protection to the
pipe.
- Good impact strength
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6.1. Pipe coating - Systems
 3LPP coating process
Source: Bredero Shaw

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6.1. Pipe coating - Systems
 Three Layer Polyethylene (3LPE)
Coating system
description
FBE + PE Adhesive + Solid PE
Type of protection Corrosion protection
Mechanical protection
Typical coating
thickness
2- 4.5 mm
Design temperature 80Ԩ
Water depth limit Unlimited
Major characteristics - Cheaper than 3LPP, but does not have as good mechanical
characteristics as 3LPP.
3LPE process is the same as 3LPP
72
6.1. Pipe coating - Systems
 Multilayer PP (MLPP) – Foam MLPP
Coating system
description
FBE + PP Adhesive + (Solid PP) + PP Foam + Solid PP
Type of protection Corrosion protection + Mechanical protection + Thermal
insulation
Typical coating
thickness
Depends on thermal requirements
Design temperature 120Ԩ
Water depth limit 600 m
Major characteristics K-value around 0.17 W/m.K, density 600-800 kg/m3
1. FBE
2. 2. PP adhesive
3. Solid PP
4. PP foam
5. Outer PP shield
Source: Bredero Shaw

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73
6.1. Pipe coating - Systems
 Multilayer (MLPP) – Glass syntactic MLPP
Coating system
description
FBE + PP Adhesive + (Solid PP) + GSPP + Solid PP
Type of protection Corrosion protection + Mechanical protection + Thermal
insulation
Typical coating
thickness
Depends on thermal requirements
Design temperature 130Ԩ
Water depth limit 3000 m
Major characteristics K-value around 0.16 W/m.K, density 650-700 kg/m3
Hydrostatic pressure resistance is reinforced by glass
microspheres added into the PP matrix.
74
6.1. Pipe coating - Systems
 Syntactic PU - polymer syntactic (sPU)
Coating system
FBE + sPU
description
Type of protection Corrosion protection + Thermal insulation
Typical coating
Depends on thermal requirements
thickness
Design temperature 115Ԩ
Water depth limit 300 m
Major characteristics - K-value around 0.12 W/m.K, density 600-700 kg/m3
- Thin wall + low polymer mechanical properties decrease
compression resistance of the foam.

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75
6.1. Pipe coating - Systems
 Syntactic PU - Glass syntactic (GSPU)
Coating system
FBE + GSPU
description
Type of protection Corrosion protection + Thermal insulation
Typical coating
Depends on thermal requirements
thickness
Design temperature 130Ԩ
Water depth limit 3000 m
Major characteristics - K-value around 0.16 W/m.K, density 800 kg/m3
- Hydrostatic pressure resistance reinforced by glass
microspheres added into the PU matrix.
- Grade of glass influences the collapse pressure and
theoretical maximum water depth.
76
6.1. Pipe coating - Systems
 Injection moulding PU process
Source: Bredero Shaw

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 Concrete Weight Coating (CWC)
 Purpose: provide negative buoyancy
and mechanical protection to the pipe.
 Mixture of cement, iron ore and wire wrap
 Main properties:
o Density (1900-3700 kg/m3): varies iron ore
quantity.
o Compressive strength: depends on cement
and water content.
o Thickness: depends on pipe diameter.
o Water absorption: ISO standard recommend
a maximum of 5% vol.
 Reinforcement
o Rigid preformed cages
o Wire mesh fabric
Source: Bredero Shaw
6.1. Pipe coating - Systems
77
78
6.1. Pipe coating - Systems
 Concrete Weight coating
Type of protection Negative buoyancy + Mechanical protection
Typical coating thickness Depends on pipe diameter
Design temperature N/A
Water depth limit Unlimited
Major characteristics Density (1900-3700 kg/m3): varies with iron ore quantity.

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79
6.1. Pipe coating - Systems
Concrete Weight Coating (CWC)
 Impingement method
Source: Bredero Shaw
80
6.1. Pipe coating - Systems
Concrete Weight Coating (CWC)
 Wrap-on method
Source: Bredero Shaw

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81
6.1. Pipe coating - Systems
 Elastomer coatings (Neoprene, EPDM, butyl rubber, etc.)
Mainly used for splash
zone protection
Be careful of chamfering
 can cause failure of
the bond
Source: Yadana riser – F. Duesso
82
6.1. Pipe coating - Subcontractors
APAC
 Bredero Shaw
 WASCO Energy
Americas
 Bredero Shaw
 CRC Evans
EMEA
 Bredero Shaw
 Eupec
 Socotherm
 Tenaris

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83
Operators - Gap analysis with ISO 21809-1: Microsoft Excel
Worksheet
6.1. Pipe coating - Operators
84
6.1. Pipe coating - Operators
Microsoft Excel
Worksheet Operators - Gap analysis with ISO 21809-1:
 ENI = based on ISO
 TOTAL SHELL and PETRONAS: more stringent on different tests

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85
6.1. Pipe coating – Future challenges
 HT/HP
- R&D programm in different pipe coating applicators and manufacturers
to test different materials like glass syntactic silicones
 Arctic
- Bredero Shaw involved in JIP for new material in arctic conditions
 Flexible weight coating
 Ultra deep waters – thermal insulation
6.2 Field joint coating
86
 Definition
 Selection
 Standards
 Systems
 S-Lay installation
 Subcontractors

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6.2. Field joint coatings - Definition
Field joint definition: Part of pipe left bare for welding prior to installation
 Purpose of FJC: anticorrosion or thermal insulation.
 Field joint is the weak point in a pipe coating system.
 Welded joints are highly sensitive to corrosion.
3LPP
coating
pipe
 Cut back length shall be predetermined and mainly
depends on type of FJC.
 Properties shall be the same as the parent coating
(pipe coating).
 FJC are mostly applied in field  application shall
be easy, fast and reliable.
FJC
 FJC = FBE, HSS, Polyolefin tapes, IMPP, IMPU, PE, PP, liquid resins
87
6.2. Field joint coatings - Selection
Line pipe working conditions
• density, thermal conductivity (if thermal
insulation), coating breakdown factor
Pipe laying environment
• mechanical protection expected
(impact strength, abrasion,
compressive strength, flexibility, water
absorption, curing time)
Parent coating
Parent coating FJC possibilities
FBE FBE
Heat Shrinkable Sleeves
Liquid coating
Polyethylene HSS
Liquid coating
PE flame spray
Polypropylene PP flame spray / tapes
IMPU
IMPP
Liquid coating
Concrete coating HSS + HDPUF
88

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6.2. Field joint coatings - Standards
International standards in field joint coating: ISO 21809
 ISO 21809 - 3
Other standards or specifications
 DNV-RP-F102
 NACE RP0303 - HSS
 EN 12068 – tapes and HSS
 NO STANDARD FOR INSULATION COATING
89
6.2. Field joint coatings - Systems
 FBE
Coating system
description
FBE
Type of protection Corrosion protection
Typical coating
350-500 μm
thickness
Design temperature 90Ԩ, modified epoxies can withstand higher temperatures
Water depth limit Unlimited
Major characteristics - The most widely used coating
- Good chemical resistance
- Very good corrosion protection
- Very common and easy to find subcontractors
- Low impact resistance
Overlap on parent
coating
50 mm
90

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6.2. Field joint coatings - Systems
 Heat Shrink Sleeves: 2-layers (mastic HSS)
Coating system
description
Mastic adhesive + Polyolefin backing on St3 steel
Type of protection Corrosion protection
Typical coating
2 mm
thickness
Design temperature Up to 100Ԩ (depending on product: PE or PP)
Water depth limit 3000 m
Major characteristics Manual application with gas torch
Example of HSS system PE:
- KLNN Canusa
- WPC 100M (Berry Plastic)
PP:
- GTS PP 100
Overlap on parent
coating
100 mm
91
6.2. Field joint coatings - Systems
 Heat Shrink Sleeves: 3-layers (hot-melt HSS)
Coating system
description
Liquid epoxy + hot-melt adhesive + Polyolefin backing on Sa
21/2 steel
Type of protection Corrosion protection
Typical coating thickness 2 mm
Design temperature > 100Ԩ (depending on product: PE or PP)
Water depth limit 3000 m
Major characteristics Manual application with gas torch
Example of HSS system PE:
- GTS 80 (Canusa)
- HTLP80 (Berry Plastic)
PP:
- GTS PP (Canusa)
Overlap on parent
coating
100 mm
92

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6.2. Field joint coatings - Systems
 PP tape wrap
Coating system
description
FBE + Adhesive PP + PP tape
Type of protection Corrosion protection
Typical coating
3 mm
thickness
Design temperature 110Ԩ
Water depth limit 3000 m
Major characteristics - Applied in spiral or wrapped by hand or by wrapster
with the determined overlap (50% recommended).
- Only compatible with 3LPP pipeline coating
Example of tape wrap
system
FBE: Scotchkote 226N (3M)
Adhesive: Hifax EP 510/60m (Basell)
PP tape: Hifax EP 510/60 (Basell)
Overlap on parent
coating
70 mm
93
6.2. Field joint coatings - Systems
 Flame spray PP
Coating system
description
FBE + Adhesive PP + PP powder
Type of protection Corrosion protection
Typical coating
3 mm
thickness
Design temperature 110Ԩ
Water depth limit 3000 m
Major characteristics Similar to tape wrap
Overlap on parent
70 mm
coating
94

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6.2. Field joint coatings - Systems
 Injection moulded polyurethane (IMPU)
Coating system
description
FBE + Solid PU or PU primer + Solid PU
Type of protection Corrosion protection + thermal insulation
Typical coating
+4 mm
thickness
Design temperature Up to 130Ԩ
Water depth limit 3000 m
Example of system FBE: Scotchkote 226N (3M)
Solid PU: Hyperlast FJ302 (DOW)
Overlap on parent
coating
70 mm
95
6.2. Field joint coatings - Systems
 Injection moulded polypropylene (IMPP)
Coating system
description
FBE + PP adhesive + Moulded PP
Type of protection Corrosion protection + thermal insulation
Typical coating
4-10 mm
thickness
Design temperature Up to 110Ԩ (130Ԩ with high temp. FBE)
Water depth limit 3000 m
Example of system FBE: Scotchkote 226N (3M)
Adhesive: BB 127E (Borealis) or Hifax EP5 10/60 (Basell)
Solid PP: EA 165E (Borealis) or CA 197 (Basell)
Overlap on parent
coating
70 mm
96

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6.2. Field joint coatings – S-lay installation
S-lay:
 Firing line is horizontal
 Pipeline is support by a stinger to avoid high bending stress.
97
6.2. Field joint coatings – S-lay installation
98

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6.2. Field joint coatings – Subcontractors
Bredero
Shaw
Canusa CPS
PIH
OJS
FBE, IMPU, IMPP
HSS, liquid epoxy, tape wrap
FBE, flame spray PP & PE, HSS, IMPU, IMPP, PU
foam infill
HDPUF, HSS
99
10
0
Summary
1. HSE moment
2. Reason for coating
3. Corrosion prevention - Generality
4. Surface preparation
5. Painting & coating
6. Pipe & field joint coating
7. Coating qualification – process and requirement
100

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7. Coating qualification
101
 Painting
 Pipe and field joint coatings
7. Coating qualification - Painting
Norsok M501 rev.6
CS surfaces operating < 120 Ԩ
Ballast water tanks/ seawater filled
vessels
Anti-slip for walkways, escape
routes, lay down areas
Intumescent epoxy + cementitious
PFP
Splash zone and immersed surfaces
1
3B
4
5
7
102

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7. Coating qualification - Painting
Norsok M501 rev.6
Test (acc. to ISO 20340) Assessment method Acceptance criteria
Seawater immersion
ISO 4624- pull-off test
5MPa
- 4200h
ISO 4628-3,4,5,6
No defect
- For system 3B, 7A, 7B, 7C and 1
when used in tidal or splash zone
Ageing
- 4200h
- For system 1, 3B, 4, 5A, 5B, 7A
ISO 4624- pull-off test
ISO 4628
5MPa
No defect
Cathodic disbonding
- 4 weeks
- For system 3B, 7A, 7B, 7C, 1 when
used in splash or tidal zone
ISO 15711 Max. 20 mm
103
7. Coating qualification
Shell systems that need to be qualified as per DEP
TSA (DEP 30.48.40.31)
DFT checking
Ballast water tanks/ seawater filled
vessels
Anti-slip for walkways, escape
routes, lay down areas
Intumescent epoxy + cementitious
PFP
Splash zone and immersed surfaces
104

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7. Coating qualification
Shell systems that need to be qualified as per DEP - TSA
Test Assessment
method
Measurement Acceptance criteria
Visual examination ISO 14918 100% surface Uniform appearance, no defect
or blisters
Coating thickness ISO 2808 Min. 5 Min. 250 μm
Coating adhesion ISO 4624 Min. 3 > 7 MPa
Overall quality Bend test (DEP) Min. 3 Minor cracks
Sealer Visual inspection 100% surface No open pores at the surface
 Check every step of the ITP.
 The process leads to qualification of:
o operators (blasters, sprayers),
o equipment,
o subcontractor coating procedure.
 Example of PQT done for Prelude FLNG
Microsoft Word
7 - 2003 Documen
Adobe Acrobat
Document
105
7. Coating qualification – Pipe & FJC
Qualification of 3LPE and 3LPP as per ISO 21809-1: Adobe Acrobat
Document
Properties 3LPE 3LPP
Continuity Zero defect Zero defect
Impact strength > 7 J/mm > 10 J/mm
Indentation at 23 Ԩ
< 0.2 mm
< 0.1 mm
Indentation at max temp.
< 0.4 mm
< 0.4 mm
Elongation at break > 400 % > 400 %
Peel strength at 23 Ԩ
> 15 N/mm
Peel strength at max. Temp.
> 3 N/mm
> 25 N/mm
> 4 N/mm
Cathodic disbondment 23 Ԩ, 28 d
Cathodic disbondment 65 Ԩ, 24 h
Cathodic disbondment max. temp., 28 d
< 7 mm
< 7 mm
< 15 mm
< 7 mm
< 7 mm
< 15 mm
Hot water immersion test (80 Ԩ, 48h) Average < 2 mm and
max. < 3 mm
Average < 2 mm and
max. < 3 mm
Flexibilitty No cracking at 2° angle No cracking at 2° angle
Curing of epoxy As per manufacturer As per manufacturer
106

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Sources
Bibliography:
[1] NACE CIP 1 Manual
[2] Encyclopedie de la peinture: formuler, fabriquer, appliquer, tome 1
[3] ISO 8501-1
[4] ISO 21809-1 to 5
[5] PPG – PFP and Fouling release coating presentation
Websites:
[6] www.nace.com
[7] http://www.corrosion-doctors.org/Seawater/Fouling.htm
[8] www.brederoshaw.com
107
Thank you
108