Technical Presentation

Presented by: Mr. Mohammad Al-Hammad Saudi Aramco ID/VID/QCU

CONTENTS
1. 2. 3. 4. INTRODUCTION CORROSION AND COATINGS DEFINITION METHODS OF CORROSION PROTECTION COATINGS

5.
6. 7.

CASE STUDY MEASURES

CONCLUSION DISCUSSIONS

1. INTRODUCTION

Understanding the corrosion on steel and the methods of preventing it by applying anti - corrosive coatings.

2. CORROSION
Definition of Corrosion :

A deterioration of the material and its properties by the chemical or electrochemical reaction between a material, usually a metal, and its environment . Its a natural phenomenon or process.
Almost all materials are expected to corrode with time when exposed to environment elements.

Corrosion cell
Four elements to form the cell of corrosion:

Anode Cathode Metallic Pathway Electrolyte Since steel is not perfectly uniform or homogeneous metal , a single steel plate can have many tiny anodic & catholic areas on its surface

If anode and cathode remain in the same place for period of time , the corrosion is localized forming pitting.

85% of world wide metals are steel that prone to corrosion attack.

3.Methods of Corrosion Protection

Natural Method: The material forming by itself a thin layer protective oxide barrier. Eg: Brass, copper, stainless steel. Artificial Method: Applying anti-corrosive coatings to the surface of metal.

4. COATINGS
Definition of Coating :
Coating is a process whereby a coating is applied to a substrate to isolate the steel surfaces, which are prone to corrosion attack if exposed to moisture & Oxygen, from border environment. The coating could be liquid coating, solid powder, a molten polyolefin, polymeric sheet materials, ceramics (glass), metallic.

Fusion Bonded Epoxy Coating :

One of the most efficient/ popular method of anti corrosive coating is by using Fusion Bonded Epoxy powder ( FBE), mainly used in pipelines and fittings.
FBE coatings are in the form of dry powder at normal atmospheric temperatures. The resin and hardner parts in the dry powder remain unreacted at normal storage conditions. At typical coating application temperatures, usually in the range of 180 to 250 C, the contents of the powder melt and transform to a liquid form. The liquid FBE film "wets and flows on to" the steel surface on which it is applied and soon becomes a solid coating by chemical cross - linking assisted by heat. This process is known as fusion bonding.

5. CASE STUDY OF COATING FAILURE

CAUSES AND PREVENTIVE MEASURES

Causes :
PWHT due to field welding. Improper Planning & poor design Utilizing improper coating material for field application. Lack of inspection

Preventive Measures :
Good Plan & Well design of fabricated spools to be coated at Vendor facilities at Maximum to avoid any chance of coating disturbance by either welding or PWHT at field.
Get all spools fabricated, PWHT, and all tests completed then internally coated as one shot. Get coating applicators Vendors limitations of spools to the maximum. to amend the

Preventive Measures (contd):

Avoid field welding for partially coated spools, If no chance to avoid welding that will be followed by PWHT as first option a flange to be used or otherwise keep it as straight as possible and reachable and have RSA involved & consulted.
CSD to look and work for approval of field coating material that suitable & compatible for existing coating and cover big areas in case of parent coating damage due to PWHT. Enforcing monitoring and inspection at all stages

6. CONCLUSION

It is essential to coat a metal not only for the appearance and extending the life, but also for safe environment.

DISCUSSIONS