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Fig. 3: EIS on a failed FBE coating
The failures. The entire pipeline system was inspected us-
ing a MFL intelligent pig in January 2004. 13600 features
were reported, the majority of which being in the first 13 km
(hottest side). All the signals were due to external corrosion,
the majority (12494) at less than 20% wt, 1168 between 20
and 40%, 11 greater than 40% wall thickness, and the maxi-
mum being 57%, close to section 1 pipe inlet. Excavations in
this area confirmed the information of intelligent pig survey.
The major part of corrosion is located under field joint
coatings at girth welds, massive disbonding of HSS leading to
corrosion caused by the cathodic protection shielding effect
SPE93600 7
(see Fig.4 and Fig.5). Excavations revealed that adhesive was
molten on the whole surface, but bonding on plant applied PE
coating failed due to brush abrasion limited to bevels of coat-
ing.
Fig. 4: Disbonding of HSS
Fig. 5: Corrosion underneath disbonding of HSS
3LPE plant applied coating generally appears externally
correct but was found fully disbonded (when cut with a tool)
between FBE and steel at the excavation locations near section
1 inlet. Except the presence of an important layer of magnetite
on the steel surface, no significant corrosion of the steel was
noticed (see Fig.6). However, the analysis of inspection pig
data showed that some corrosion was found under PE plant-
applied coating on some pipe lengths (46 tubes, all in the first
13 km, except one). Excavations showed that in this case PE
coating was longitudinally cracked and opened at 3 and 9
oclock (see Fig.7). No correlation between cracking/opening
and bending during laying was found (4 pipes bent over 46).
Measurements on samples taken from disbonded coatings re-
vealed an important thermal aging of PE (loss of elongation at
break, increase of melt index and Shore D hardness and typi-
cal peaks of aged PE on surface IR spectrum).
As further excavations carried out at all the other inlets and
outlets of the 3 pipeline sections and on spare pipes did not
reveal any disbonding of coatings or aging of PE, it can be
concluded that the major parameter for disbonding and corro-
sion is temperature. No significant influence of cathodic over-
protection (alone) has been noticed: Section 1 was highly
overprotected (-6.4 V/sat.Cu-CuSO
4
) in 1991 during 2 months
due to dysfunctioning of an automatic solar cells powered CP
station caused by lightning damage.
Fig. 6: Disbonding of 3LPE
Fig. 7: Cracking of disbonded 3LPE
Analysis of problem. Possible explanation for disbonding
of 3LPE is:
water and oxygen diffusion through PE (accelerated by
thermal aging and temperature);
water saturation of FBE layer;
superficial corrosion of steel surface forming magnetite;
all steps being accelerated by temperature.
Corrosion under disbonded 3LPE only occurs when it is also
cracked due to thermal aging, which leads to an important gap
between disbonded coating and steel allowing renewal of ag-
gressive species.
Disbonding of HSS may be due to:
temperature effect;
surface preparation by brush cleaning;
penetration of water at disbonded overlaps over 3LPE
plant coating.
Corrosion under disbonded HSS may be due to:
penetration of water through disbonded overlaps;
shielding effect preventing CP;
8 SPE93600
acceleration of corrosion rate by temperature.
From now it has been decided that abrasive blast cleaning of
girth welds is mandatory when HSS is applied over a liquid
epoxy on onshore pipelines.
Investigations in the field will be continued, especially
through excavations in different locations, for a better knowl-
edge of the effect of temperature on coating disbonding and
thermal aging and of the status of 3LPE where corrosion has
been detected. DCVG and CIPS measurements appeared to be
somewhat efficient to detect the problem. Field tests will be
continued.
On another hand, lab programmes are launched to study PE
thermal aging and to investigate the parameters which may be
significant in coating disbonding such as surface preparation
(chloride or grease contamination, rugosity profile or brush
cleaning vs. abrasive cleaning for HSS), epoxy materials,
thickness of FBE, effect of temperature, cathodic overprotec-
tion. Concerning epoxy materials, their precise chemistry (e.g.
the dicyandiamide content
23
) could explain various behaviours
due to their specific interaction with water.
Standardisation: a way for improvement
Important efforts are currently produced in the field of Interna-
tional Standardization (ISO) for specifying the best compro-
mises for pipeline coatings and cathodic protection.
National
24-30
and Regional (EN in Europe
31-35
, Austral-
asia
36-37
) standards exist for specifying pipeline coatings, to-
gether with Recommended Practices, especially written by
NACE International
38-40
. Presently, significant efforts are pro-
duced to write ISO standards in the frame of ISO TC67 SC2
WG14 (Oil & Gas Industry Pipelines Coatings). A series
of parts of the future ISO 21809 on Petroleum and natural gas
industries - External coatings for buried and submerged pipe-
lines used in pipeline transportation systems will be issued
within a few years, the first ones being:
ISO 21809-1, Three layer polyolefin coatings
ISO 21809-2, Fusion-bonded epoxy powder coatings
ISO 21809-3, Field joint coatings
ISO 21809-4, Two layer polyethylene coatings
The standard on field joint coatings will codify the various
families of coatings, specify general requirements and detail
specificities for each of the families.
The new ISO and CEN standards concerning cathodic pro-
tection of pipelines have been mentioned hereabove.
Conclusions
A comprehensive Corrosion Management system should
be implemented for pipelines from the design stage to
abandonment in order to ensure the safest condition for
these strategic assets during the whole operation lifetime;
It is highly recommended that onshore pipelines be buried
or immersed, including flow-lines;
The best guaranty for ensuring external corrosion preven-
tion of buried or immersed pipelines is based on adequate
cathodic protection and qualified and well applied and in-
spected plant and field applied coatings;
For existing flow-lines laying above ground, when sup-
porting is not possible, cathodic protection has to be
adapted to achieve the best protection level (insulating
joints, additional cathodic protection stations,);
As long as coatings remain bonded to steel and cathodic
protection is correctly applied, monitored and maintained,
no corrosion risk exists. Disbonding may prevent access
of cathodic protection current to steel exposed to a corro-
sive electrolyte ("cathodic shielding effect") and cause ex-
ternal corrosion for onshore pipelines but this risk does
not seem to be significant offshore;
In addition to the metal loss corrosion process, disbonded
coatings may lead to various forms of Environmentally
Induced Cracking which should be assessed for onshore
pipelines;
For offshore pipelines, the major risk of corrosion con-
cerns the transition zone between the thick riser coatings
and the atmospheric paint system, where water may dam-
age the bonding;
In-line inspection using intelligent pigs constitutes the
most efficient inspection method for a corrosion risk
management programme applied to pipelines, including
for detection of external corrosion under disbonded coat-
ings;
It is necessary to study the parameters which lead to dis-
bonding of 3LPE coatings;
Sharing experience feed-back is necessary to better un-
derstand these parameters and modify specifications for
improving reliability of coatings and reducing corrosion
risks.
Important efforts are currently produced in the field of
International Standardization (ISO) for specifying the best
compromises for pipeline coatings and cathodic protec-
tion.
Acknowledgements
The author wishes to thank his Company and affiliates for
permitting the publication of this paper. He thanks also very
much his colleagues who supplied information and comments
for the preparation of the paper.
Nomenclature
CBF Coating Breakdown Factor
CIPS Close Interval Potential Survey
CP Cathodic Protection
DCVG Direct Current Voltage Gradient
DSC Differential Scanning Calorimetry
EIS Electrochemical Impedance Spectroscopy
EPDM Ethylene Propylene Diene Monomer
FBE Fusion Bonded Epoxy
FPSO Floating Production, Storage and Offloading
GRP Glassfibre Reinforced Plastic
HISC Hydrogen Induced Stress Cracking
HSS Heat Shrinkable Sleeve
ICCP Impressed Current Cathodic Protection
3LPE 3 Layer Polyethylene
3LPP 3 Layer Polypropylene
MFL Magnetic Flux Leakage
MIC Microbiologically Induced Corrosion
MMO Mixed Metal oxides
OIT Oxidation Induction Time
SPE93600 9
PE Polyethylene
PP Polypropylene
PU Polyurethane
SCC Stress Corrosion Cracking
SCR Steel Catenary Riser
Tg Temperature of glass transition
TLP Tension Leg Platform
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