David McQuilling Panhandle Energy

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1 David McQuilling Panhandle Energy

2 Outline Plant Applied vs. Field Applied Coatings Girth Weld Coatings FBE patch sticks Recent Concerns

3 Plant Applied Vs Field Applied Plant Applied Coatings Controlled environment Centralized inspection Permanent mount equipment Near continuous line operation Routine destructive testing High quality air / power sources Blast media / coating storage / handling / recycling procedures Industry Guidelines (NACE SP 0394) Handing / Transportation Field Applied Coatings Must address environmental conditions Wind / Dust / Heat / Rain / Cold Multiple field inspection points Moving equipment Constant start / stop operation Limited test capability Onsite air and power generation Field blast media / coating storage / handling / recycling procedures Industry Guidelines (NACE SP 0402) Handling / Lowering / Backfill

4 How Do We Quantify Field Coating Quality? What is good enough? Manufacturer s performance data is generally not based on field applied products. Unrealistic to expect field applied coatings to perform as well as those applied in a coating mill or laboratory setting. Need to remove subjective evaluations Doesn t look professional Bubbles in coating Shouldn t smoke when applied to heated pipe Contamination of substrate by heating after cleaning Driving factors should be related to performance

5 PHMSA Construction Issues Girth Weld Coatings Fusion Bonded Epoxy Incorrect Application / Procedures Coating over mud or rust Failure to follow manufacturer s recommendations Incorrect feathering of existing FBE Water in pipe during heating Environmental Issues Inconsistent pipe temperatures Coating in high wind with blowing dirt Mechanical Issues Damage to factory FBE (heat / mechanical) Procedural Issues No specifications on site Two Part Epoxy Incorrect Application / Procedures Failing to follow manufacturer s instructions Inadequate surface preparation Application after epoxy starts to set Inadequate mixing Applying above or below recommended temperature Using unapproved IR temperature sensors

6 Common Liquid Girth Weld Coatings 100% Solids Epoxy Denso 7000 / 7200 SPC 3888 / M Scotchkote 323 Powercrete F 1 Nap Gard % Solids Epoxy / Urethane SPC % Solids Polyamide Epoxy Nap Gard / 1848 Patch Compound Near 100% Solids Epoxy Polyamine Wilko Gator Kure (96% solids)

7 Field Applied Coatings How Do We Ensure / Improve Quality Procedures Should include product specific coating parameters Should address realistic field conditions and variables Should address what if conditions and provide alternatives Should clearly outline stop work conditions Should mesh with capabilities of onsite equipment Should be based on coating performance data Should have provisions for changes during construction

8 Field Applied Coatings How Do We Ensure / Improve Quality Field Personnel Training Difficult to believe anyone on ROW believes coating over mud is acceptable Flash rust Failure to follow procedures Inspector Training / Knowledge Can not inspect quality into a project Can not catch everything More manual steps when using liquid girth weld coatings All Training Must be Product Specific One Size Does Not Fit All

9 Hot Melt Patch Sticks Easy to apply Usable in all weather conditions Quick setting for immediate installation and handling No solvents No mixing, metering, or pot life problems Flexible Color matched to fusion bonded epoxy coatings Easy to use Speeds production time Facilitates quick repair at the ditch

10 Hot Melt Patch Sticks If it s so easy, why do we have such a problem? Failing to follow manufacturer s instructions Not adequately heating pipe before application Inadequate surface preparation Use on defects larger than 0.5 in 2 Application over two part epoxy Improper accelerated drying by patting Use on bare metal

11 Hot Melt Patch Sticks Manufacturer s Instructions Variations in Plant and Field Applied Specifications Thickness of Repairs Surface Preparation Variations between Manufacturers Thickness of Repairs Surface Preparation Maximum Size of Repair Area Small holidays and damaged areas Minor pinholes and abrasions Holidays up to 2 mm in diameter Recommended for pinholes but can be used to repair other defects at discretion of end user

12 Hot Melt Patch Sticks NACE SP0402 Section 8.2 Coating System Repairs Patched areas should overlap the parent coating a minimum of 13 mm (0.50 in.). The surface to be repaired should be suitably prepared to ensure adhesion of the patch material. Minimum thickness of the repaired coating shall be in accordance with Section 7 of this standard.

13 Patch Sticks Repairs to Bare Steel No reference can be found to support position that Hot Melt Patch Sticks can not be used on bare steel. Scotchkote 226P can be used on holidays up to 2 mm in diameter. The following 3M two part epoxies should be used for bare steel areas larger than pinholes, depending on the functional and application properties required: Scotchkote 323 Scotchkote 323i Scotchkote 352 Scotchkote 327

14 Accuracy of IR Guns Widely used in industry in both plant and field applications Variations between FBE Manufacturers Specifications Heat temperatures shall be monitored and controlled with an optical and recording pyrometer. Pyrometers installed to monitor pipe temperature before the coating application shall be checked periodically with a Tempil Stick to assure accurate calibration of the instrument. Infrared sensing devices shall be used to monitor the temperature of the applied coating. Do not use on uncoated / bare steel. Due to varied emissitivity; optical / IR pyrometers should not be used to determine preheat on blasted surfaces. Liquid coating vendors generally support use

15 Contamination of Substrate with Applied Heat Application of heat after cleaning but prior to coating application is a common industry practice Application standards for FBE products require noncontaminating heat source The heat source shall not leave a residue to contaminant on the pipe surface. Preheat the parent coating surface using a noncontaminating heat source, such as portable hand held butane torch. The heat source shall not leave a residue or contaminant on the pipe surface. Oxidation of the steel in the form of blueing or other apparent oxide formation is not acceptable.

16 Steam from Pre Heating Pipe Before Coating Common industry practice to pre heat pipe prior to application of 100% solid liquid coatings to accelerate cure time Product may steam when applied to hot pipe Manufacturer s product testing indicates no degradation of coating performance when applied over heated pipe All products are different Tg VOC Content

17 Air Bubbles in Epoxy Coatings Voids will exist in all epoxy coatings Standards for acceptable levels porosity are widely used in the industry Reference Appendix G of RP0394 Appearance of bubbles at surface is generally not a cause of concern

18 Paths Forward Focus on technical aspect of any quality control issues related to coating systems Focus on performance of industrial coating systems, not aesthetics One size does not fit all can t paint with a broad brush Procedures and training are critical to quality

A. The CONTRACTOR shall provide pipe coating, complete and in place, in accordance with the Contract Documents.

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