1.1 Fusion Bonded Epoxy
Fusion Bond Epoxy is a powder epoxy thermosetting coating applied for anticorrosion protection to steel pipelines. The pipe is first blast cleaned and heated. Then epoxy powder is spray applied by electrostatic guns to melt and form a uniform layer that hardens within a minute from application. Utilizing industry accepted materials supplied by manufacturers such as 3M, DuPont, and Nap-Gard,etc.
It is applied in the form of a dry powder at thicknesses of 400-600 microns onto the heated surface of the steel pipe. Once applied and cured, the epoxy film exhibits an extremely hard surface with excellent adhesion to the steel surface. The FBE protective surface is homogeneous and offers an excellent resistance to chemical reaction.
The FBE coating systems provide protection at moderate temperatures (-40ºC to 85ºC) and come in two options:
· FBE Dual: recommended for sub-sea pipelines and flowlines operating in the toughest environments. It offers excellent impact resistance and abrasion properties which, combined with its good flexibility, provide suitable protection against coating damage during pipe transportation and construction
· FBE Non-slip: this coating system provides a rough, non-slip surface for a pipeline that will subsequently be concrete-coated
Fusion Bonded Epoxy with Abrasion Resistance Overcoating (FBE/ARO) – Utilizing two completely separate powder systems, the facility can produce FBE with an ARO at unprecedented processing speeds using industry accepted materials such as 3M 6352, DuPont 7-2610, and Nap Gard.
Abrasion Resistant Overcoating (ARO) is an optional sacrificial second layer in the FBE process that is designed to protect the FBE from impact and/or rock damage while still retaining mild flexibility. Directional bores and road crossings are common examples of installations that require ARO to keep the anti-corrosion coating intact. The ARO is applied immediately following the FBE application using a similar method but normally in a separate coating booth. While the FBE is still in the gel state, the applied ARO powder forms a commingled layer with the FBE and ultimately a strong, durable and resistant outer shell, usually at a final thickness of 20 to 40 mils.
Fusion Bonded Epoxy with High Temperature Resistant Overcoating – Utilizing two completely separate powder systems, the facility can produce FBE with a high operating temperature resistant overcoating such as DuPont’s Nap-Gard Gold and 3M’s 6258.
1.3 Internal Coating
The primed FBE coating is a two-layer structure anti-corrosion system for pipe internal surface consisting one liquid phenolic primer layer and fusion bonded epoxy (FBE) coating as topcoat.
· Liquid epoxy
· Internal Fusion Bonded Epoxy (FBE)
· Special anticorrosive painting
Internal coating features:
· Suitable for fresh and salt water immersion
· Effective for speeding up production
· Suitable for corrosive environments
· Resistant to many solvents and chemicals
· Resistant to cathodic disbondment
1.5 Comparison of Anti-Corrosion Coating Protection Systems
Fusion Bonded Epoxy (FBE)
Single Layer FBE
· Long term corrosion protection
· Good mechanical and chemical protection
· Max operating temp. -30°C to 110°C
Dual Layer Fusion Bonded Epoxy (DFBE)
2 Layers FBE
· Excellent impact and abrasion resistance
· Resistance to cathodic disbondment
· Max operating temp. -30°C to 110°C
2. Coating Specification
2.1External Epoxy Coating
CAN/CSA-Z245.20 Standard for External Fusion Bond Epoxy Coating for Steel Pipe
API RP 5L9 External Fusion-Bonded Epoxy Coating of Line Pipe
AS 3862 Standard Specification for External Fusion-Bonded Epoxy Coating for Steel Pipes
AS 4352-2005 Testing for Coating Resistance to Cathodic Disbonding
AWWA C210 Standard for Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
AWWA C213 Standard for Fusion Bonded Epoxy Coating for the Interior and Exterior of Steel Water Pipelines.
BP GIS 06-402 Guidance on Industry Standard for Fusion Bonded Epoxy Powder External Pipeline Coatings
DEP 18.104.22.168-Gen TECHNICAL SPECIFICATION FOR EXTERNAL FUSION-BONDED EPOXY POWDER COATINGFOR LINE PIPE
NFA 49-710 Standard Specification for External FBE layered Coating
ISO 15741: Paints and Varnishes - Friction-Reduction Coatings for the Interior of On-and Offshore Steel Pipelines for Non-Corrosive Gas.
ISO 21809-2:2007, Petroleum and natural gas industries-External coatings for buried or submerged pipelines used in pipeline transportation systems-Part 2: Fusion-bonded epoxy coatings
NACE RP0394 – National Association of Corrosion Engineers Standard Recommended Practice, Application, Performance, and Quality Control of Plant Applied, Fusion Bonded Epoxy External Pipe Coating.
NACPA 12-78 – National Association of Pipe Coating Applicators External Application Procedure for Plant Applied fusion Bonded Epoxy (FBE) to Steel Pipe.
SAES-H-002 Internal and External Coatings for Steel Pipelines and Piping
09-SAMSS-089 Shop-Applied External FBE Coating
09-SAMSS-091 Shop-Applied Internal FBE Coatings
TransCanada TES-CO-FBE-GL: External Fusion Bond Epoxy for Steel Pipe Specification (CAN-US-MEX) Table 12-1 & Table 12-2 (Fusion-Bonded Epoxy Powder & Coating Qualifications).
2.2. Internal Coating
2.2.1 Epoxy Coating
API RP 5L2 Recommended Practice for Internal Coating of Line Pipe for Non-Corrosive Gas Transmission Service.
DEP 22.214.171.124 1998 Internal coating of line pipe for non-corrosive gas transmission service (amendments/ supplements to API RP 5L2)
AWWA C210: Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines
NFA 49-709 Internal can be epoxy 80 microns
NFA 49-708 Recommended Practice for Internal Coating of Line Pipe
TransCanada TES-COAT-INT: Internal Coating of Line Pipe for Non-Corrosive Gas Transmission Service (Cdn-US).
TransCanada TES-COAT-EPU: External Multi-Component Liquid Coating Systems for Below Ground Facilities (Cdn-US-Mex).
TransCanada TES-EPU-TEST: External Multi-Component Liquid Coating Systems Test Requirements (Cdn-US-Mex).
2.2.2 Bitumen Lining
DIN 30673 Bitumen coatings and linings for steel pipes, fittings and vessels
UNI-ISO 5256/87 STANDARD-BITUMEN COATING
2.2.3 Cement Mortar Lining
AS 1281-2001 Cement mortar lining of steel pipes and fittings
AS/NZS 1516 Cement Mortar Lining of Pipelines In Situ
AWWA C203-02: Coal-Tar Protective Coatings & Linings for Steel Water Pipelines, Enamel & Tape, Hot-pap. (Incl. add. C203a-99)
AWWA C205-00: Cement-Mortar Protective Lining and Coating for Steel Water Pipe- 4 In. (100 mm) and Larger-Shop application
AWWA C602 Standard for Cement-Mortar Lining of Water Pipelines - 4 inch (100 mm) and Larger - In Place
2. Coating Materials
3M: SK 134, SK6233, SK6352 Toughkote, SK 314, SK 323, SK 206N, SK 226N, SK 6251 DualKote SK-6171, SK 206P, SK226P,
3M Internal Coatings: Coupon EP2306HP
DuPont: 7-2500, 7-2501, 7-2502, 7-2508, 7-2514, 7-2803, 7-2504 Nap Gard Gold 7-2504, Nap Rock: 7-2610, 7-2617 FBE Powders
DuPont: Repair Kits; 7-1631, 7-1677, 7-1862, 7-1851
DuPont Internal Coatings: 7-0008, 7-0010, 7-0014, 7-0009SGR, 7-0009LGR, 7-2530, 7-2534, 7-2509
Akzo Nobel: Interzone 485,Interzone 505,Interzone 954,Internline 876 Seal Coat
Denso: 7200, 7900 High Service Temperature Coatings
Internal Liquid Epoxy: Powercrete Superflow