ISO21809-1 - Business Review Webinars

Design criteria for PE/PP coatings and a novel PE field joint coating solution Business Review Webinar 12th May2011 Dipl. Ing. Norbert Jansen

© 2008 Borealis AG

Borealis Polymere GmbH

Borealis at a Glance • Leading provider of innovative, value creating plastic solutions

• Developing a Base Chemicals business • More than 40 years of experience • Unique Borstar® technology to develop polyolefin solutions that are tailored to customers’ needs

• 5,400 employees in 20 countries • Joint venture in Middle East and Asia: Borouge (Abu Dhabi)

© 2008 Borealis AG

• Ownership 64% IPIC / 36% OMV

Strong ownership structure

19,2%

© 2008 Borealis AG

36%

64%

Borealis puts high focus on our customers in the major pipe segments Oil & Gas Infrastructure Borcoat PE (onshore & offshore) Borcoat PP (onshore & offshore)

Hot & Cold Drinking water BorSafe PE

Gas

Sewage

BorSafe PE

BorECO PP

© 2008 Borealis AG

Innovative pipe solutions 4

BorPEX

Beta-PPR

Content 1. Challenges during transport, storage, handling and installation of pipes 2.

Reflection to the 3 layer external coating standard FDIS ISO21809-1

3. Wehocoat/Borcoat PE field joint coating technology for onshore PE coated pipes

© 2008 Borealis AG

Discussion, question & answers

5 16 May 2011 Presentation title

Criteria for the selection of coatings • Coating materials are often selected acc. to the Operating temperature given in the specification BUT:

• ISO21809-1 definition of Design temperature includes more: “ Temperature range including maximum and minimum temperature likely to be reached during transport, handling, installation and operation “ Operating temperature 0° to +60°C Pipe storage temperature -10°C to +70°C Transportation temperature -20°C to +60°C Installation temperature -5°C to +70°C

© 2008 Borealis AG

Design temperature for coating 6 16 May 2011 Presentation title

Transportation criteria to be considered for the selection of coatings • Temperature conditions • Weather conditions (intensive sun radiation)  Surface of black coating can get to 65°C-70°C in the sun • Distance to destination • Expected quality of transportation Road conditions • Type of pipe supports used soft/hard Point loads/ surface loads •Number of re-loadings •Specific meter weight of pipe © 2008 Borealis AG

Pictures courtesy of Nord Stream and Borusan

7 16 May 2011 Presentation title

Transport

© 2008 Borealis AG

Point load, surface load combined with friction, vibration, temperature 8 16 May 2011 Presentation title

Storage criteria of coated pipes Often pipes are stored for longer periods at

• the coaters yard • Intermediate storage, like harbour etc • Project installation site

Conditions be considered: • Duration of storage under high UV radiation, maybe protection needed

• High and low temperature

• Limitations to handle at certain temperatures

• Dry/wet conditions and time >> i.e. cut back protection needed?

• Type of pipe supports © 2008 Borealis AG

• Support wood , gravel or sand

Pictures courtesy of Nord Stream and Borusan 9 16 May 2011 Presentation title

Installation & Handling criteria for coatings

Potential damages are caused by: • Pipe lifting on and off from truck

• Welded pipe positioned via rollers • Access to trench • Available quality of lifting devices • Pipe bending operation

© 2008 Borealis AG

• Quality of sand bedding around the pipe • Availability of fine sand • Quality of sieved backfill

Pictures courtesy of Europipe MPC 10 16 May 2011 Presentation title

Specific weight of the pipe • All pipes without additional concrete outer coating require a high level of sand-bedding quality around the pipe • Proper compaction of the backfill • Stone free zone around the pipe

• Water • Oil • Chemicals Risk of Stone

© 2008 Borealis AG

Thickwalled, heavy high pressure pipes

Large diameter high pressure gas pipes

Large diameter liquid filled pipes

Operating temperature versus mechanical protection for PE coatings Tailored Bimodal HDPEhot climates

Operating Temp 90

Bimodal HDPE HD - System

80

MD - System

70 LD - System

© 2008 Borealis AG

60 Average

High

Very high

Mechanical Requirements for PE Topcoat

Hot climate pipe coating needs • Pipelines being installed in hot climates • More construction activities in remote and difficult terrain: •

Long transportation distances and harsh pipe handling

• •

Access for crews and big equipment Big pipe stocks and long storage under sun light

• Higher outside and operating temperatures • Installation techniques are limited:

© 2008 Borealis AG

• • •

Access to enough material for sand-bedding Sieving of soil achieves only coarse backfill Limited access to open trench from one side means pulling the pipe via rollers into final position

Tailored Bimodal HDPE - for hot climates recommended (Borealis & Borouge sourced)

Project experiences Bimodal HDPE BTC Pipeline

Nord Stream Phase 1: 25% of pipes transported from Russia also during strong winter times, first spec. draft was PP.....! Chad Cameroon Exxon oil pipeline: From Germany by ship, then by truck from Cameroon to Chad in hot climate and 2000km road Different phases of IGAT and South Pars, Iran in extremely hot environment >40°C, rough handling, long distances © 2008 Borealis AG

......and all done with one good Bimodal HDPE from...........guess! 14

Pictures courtesy of M.Felt Universal

16 May 2011 Presentation title

Some remarks from a resin manufacturer • Operating temperature is not the only design criteria! • Engineering and pipeline designers should involve us earlier • We can at least give some recommendation and share views • Reference projects might help to decide for the right system • Draft specifications could be exchanged prior to publication • There are PE and PP systems for all applications, just the right choice decides!

© 2008 Borealis AG

• When specifying the coating, think about the field joint solution!

15 16 May 2011 Presentation title

Content 1. Challenges during transport, storage, handling and installation of pipes

© 2008 Borealis AG

2.

16 16 May 2011 Presentation title

Reflection to the 3 layer external coating standard FDIS ISO21809-1

3 layer polyolefin coating process

© 2008 Borealis AG

Side extrusion-wrapping process 17 16 May 2011 Presentation title

Crosshead –hose coating process

© 2008 Borealis AG

Quality in all steps of the coating process

18 16 May 2011 Presentation title

ISO21809 External coatings for buried or submerged pipelines used in pipeline transportation systems • Part 1: Polyolefin coatings (3-layer PE and 3-layer PP) • Part 2: Fusion bonded Epoxy Coatings

April 2008

• Part 3: Field joint coatings

December 2008

• Part 4: Polyethylene coatings (2layer PE)

November 2009

• Part 5: External concrete coatings

© 2008 Borealis AG

FDIS 2011

19 16 May 2011 Presentation title

April 2010

ISO21809-1: Polyolefin coatings (3-layer PE and 3-layer PP)

• First real international coating standard is in Final Draft stage • The standard is the achievable compromise in reflection of all countries input and requests • The standard can only be seen as the MINIMUM level • GOOD: Nomenclature, definitions and test methods are regulated

© 2008 Borealis AG

• Pipeline owners / engineering companies have to continue and specify their project related additional requirements clearly 20 16 May 2011 Presentation title

© 2008 Borealis AG

Table 5 of FDIS 218091 Min. requirements for top layer

Typical values taken for material data 21 16 May 2011 Presentation title

Coating thickness of coatings-ISO21809-1 Class A

Three remarks:

© 2008 Borealis AG

• Offshore does not directly mean PP coating....! • Directional drilling can also be performed with bimodal HDPE, class B3 with higher coating thickness 22 16 May 2011 Presentation title

Class B MDPE/HD LDPE PE ≥920kg/m ≥930kg/m Density ³ ³ Tensile strength ≥10N/mm² ≥15N/mm² 23° Vicat soft ≥95°C ≥110°C Shore D ≥45 ≥55 Hardness ESCR 300h 1000h F50 @50°C Indentati on at ≤0,4mm ≤0,4mm max. at 60°C at 80°C operating temp.

The slight increase in coating thickness for LDPE does not compensate!

Content 1. Challenges during transport, storage, handling and installation of pipes 2.

Reflection to the 3 layer external coating standard FDIS ISO21809-1

© 2008 Borealis AG

3. Wehocoat/Borcoat PE filed joint coating technology for onshore PE coated pipes

23 16 May 2011 Presentation title

Field joints are potential weak points in the corrosion protection systems

“There is a need for compatible, reproducible and cost effective solutions”

© 2008 Borealis AG

Shrink sleeve after soil stress

Corrosion on a pipe joint below the FJC

Continuous improvements of mill applied coatings, but what about field joints? •Photos courtesy David Norman Associates

© 2008 Borealis AG

Wehocoat first prototype machine

Reference Project in Finland at Gasum pipe line project 25 Kari Punnonen – 31.1.2010

Wehocoat – Borcoat™ System

• KWH LTD Finland and Borealis developed a new field joint coating method • Field Joint (FJ) Coating method based on Hot applied melt film technique based on PATENTED SOLUTION, WO 2008/ 132279 A1

© 2008 Borealis AG

• Wehocoat-Borcoat FJ coating system targets to fulfill most of the minimum requirements stated in the ISO – FDIS 21809-1 for factory coated steel pipes and to cover the requirements of ISO21809-3 part 5E • Applicable for PE On-Shore and in future also for Off-Shore applications 26 Kari Punnonen – 31.1.2010

Wehocoat – Borcoat™ Application

© 2008 Borealis AG

blast cleaning of the field joint area after welding

27 Kari Punnonen – 31.1.2010

Wehocoat / Borcoat FJ application steps

Induction heating+epoxy spray application

© 2008 Borealis AG

Wehocoat machine is lifted off

Wehocoat machine applies Borcoat material

Melt cylinder refilled during way to next field joint

Wehocoat – Borcoat™ Application • Application stages • Filling of WehoCoat cylinder ( also direct extrusion possible ) • Mounting of Wehocoat machine onto the pipe • First pre-heating, 120 – 140°C, followed by epoxy powder spray application • Second pipe-heating to 160 - 180 °C during Borcoat application • Dismounting and move to next FJ • Refilling of WehoCoat cylinder ( also direct extrusion possible ) • Cooling of the joint is not necessary • operating speed:0,5-1,2 m/min

© 2008 Borealis AG

• Around 20 minutes per joint for 508mm

29 Kari Punnonen – 31.1.2010

Borcoat materials for Wehocoat process • System only consists of 2 layers: • Fusion bonded epoxy, powder, spray applied

• Modified PE/PP material (like Borcoat ME3000FC)

• Modified PE or PP is a so called “reactive top coat”, i.e. a top coat with ability to  React with the epoxy due to functional groups

 Perfectly weld to the factory applied coating Acts as a top coat related to mechanical protection Borcoat ME3000FC could be described as “MDPE” classB acc

© 2008 Borealis AG

ISO21809-1 related to mechanical strength and protection ability

30 16 May 2011 Presentation title

Wehocoat – Borcoat™ Joint Design PE welding bonds A Top Coat (PO) Adhesive Epoxy Steel Pipe

5

© 2008 Borealis AG

1. 2. 3. 4. 5. 6.

6

Welded Pipe Joint Steel Pipe Factory Epoxy Coating Factory Adhesive and Top Coat Teknos Infralit EP8064 Powder Epoxy BorcoatME3000FC Top Coat

31 Kari Punnonen – 31.1.2010

1

2

3

4

•

A = Overlap Distance Min. 10 mm beyond beveled area

•

Teknos Infralit EP8064 (epoxy thickness) minimum 60 µm

•

BorcoatME3000FC (top coat thickness) minimum 3 mm

Good control of the coating thickness in the FJ area

Left: Mill applied coating 3,47mm

Right: Mill applied coating 2,95mm

Good flow out characteristics of BorcoatME3000FC © 2008 Borealis AG

Easy welding to the mill applied coating 32 16 May 2011 Presentation title

© 2008 Borealis AG

ISO21809-3 for Field Joint coatings shows a long list of solutions...

33 16 May 2011 Presentation title

© 2008 Borealis AG

Borcoat ME3000FC requirement ∆ MFR after thermal ageing

34 16 May 2011 Presentation title

Borcoat ME3000FC Tensile tests after thermal ageing

© 2008 Borealis AG

Full plastic - elastic behaviour maintained after 4800h 35 16 May 2011 Presentation title

Borcoat ME3000FC Tensile tests after thermal ageing

© 2008 Borealis AG

Conclusion: - There is no mechanical degradation after 4800h - ∆MFR criteria not suitable for reactive top coat materials 36 16 May 2011 Presentation title

Project details for Gasum pipeline Mänsälä to Siuntio in Finland Project details -Pipeline operator Gasum :(31%Fortum / 24%Finnish state / 20%/EON / 25%Gazprom) - natural gas pipe DN500, pressure class 80bar - three layer PE coated -Project time: September 2010 to April 2011 -Pipeline length~90km

© 2008 Borealis AG

-Sections with horizontal drilling

37 Kari Punnonen – 31.1.2010

Scratch test performance of Borcoat ME3000FC versus shrink sleeves

© 2008 Borealis AG

Scratch test performed with different loads on shrink sleeve (left side), Borcoat HE3450 and Borcoat ME3000FC (right side) 38 16 May 2011 Presentation title

Wehocoat – Borcoat™ Conclusions

© 2008 Borealis AG

• Meets tough requirements for coated pipes, >200N/cm at 23°C and >40 N/cm at max operating temp., normally 80°C ( PE ) • ISO21809-1 minimum “Properties of applied coating” are fulfilled as for factory coated steel pipe • Excellent mechanical protection vs. shrinkable sleeves • Fast over all application cycle • Assembling of shrink-sleeves manual work – gas flame application....! • Wehocoat with new Borcoat™ products gives excellent repeatability from joint to joint – no weak links anymore • Life Time Cost savings for pipe line: •Competitive Field Joint Installation cost for projects •Longer life time for the whole pipeline

A chain is as strong as it’s weakest link! 39 Kari Punnonen – 31.1.2010

End of presentation Norbert Jansen Date:12.05.11 [email protected] More data at www.borealisgroup.com Mobile: +491722677565

© 2008 Borealis AG

The information contained herein is to our knowledge accurate and reliable as of the date of publication. Borealis extends no warranties and makes no representations as to the accuracy or completeness of the information contained herein, and assumes no responsibility regarding the consequences of its use or for any printing errors.

40 16 May 2011 Presentation title

© 2008 Borealis AG

Back up slides

41 16 May 2011 Presentation title

© 2008 Borealis AG

Some test results acc to ISO21809-1 & -3 and Russian standards

Test

Standard

prEN ISO 21809 -3 (14, type 5 E) prEN ISO 21809 -3 (14, type 5 E) prEN ISO 21809 -3 (14, type 5 E)

Conditions No break down at electrical voltage 5kV per 1mm coating 23 °C / 28 days Max T/ 80°C/28 d 210/ deg

Requirements Testresults No break down at electrical voltage 5kV per >25KV 1mm coating ≤7 mm 30min

Dielectric continuity

OTT 04.00-45.21.30-KTN-002-1-03

Cathodic Disbondment Cathodic Disbondment OIT Indentation Hardness

OTT 04.00-45.21.30-KTN-002-1-03

20°C

≤0,15(depends on type)

Indentation Hardness

DRAFT Russian

60°C

≤0,3(depends on type)

Indentation Hardness

DRAFT Russian

80°C

≤0,4(depends on type)

Indentation Hardness Impact Impact Impact

prEN ISO 21809 -3 (14, type 5 E) DRAFT Russian DRAFT Russian DRAFT Russian

Max T/80°C , 24h, 2,5kg -40 deg 20 deg 40 deg

≤1,0 >8 J/mm >6 J/mm > 4 J/mm >150 N/cm (depends pn type)

Adhesion to factory coating DRAFT Russian

20 deg

Adhesion to factory coating DRAFT Russian

40 deg

Adhesion to factory coating DRAFT Russian

60 deg

Adhesion to factory coating DRAFT Russian

80 deg

Bendability

CAN/CSA modified, 0°C, No cracking 10% per piep diameter

no requirement >100 N/cm(depends pn type) >75 N/cm(depends pn type)

0.09-0,12 average 0,12 average 0,10 0,273 >26,8 13,1/13,6 12,8/14 ave 297 ave 172 ave 151 ave 102 Pass

Elongation at break

OTT 04.00-45.21.30-KTN-005-1-03

20 deg

>350%

>600%

Elongation at break

OTT 04.00-45.21.30-KTN-005-1-03

-40/45 deg

>100%

>200%

42 16 May 2011 Presentation title

White 3-layer PP system

Black 3-layer Polyethylen systems LDPE

Storage UV resistance

© 2008 Borealis AG

Tailored High temp. Bimodal HDPE

PP

up to 85

up to 85

up to 90

up to 110 without UV!

-40

-20

-45

-40

-20 without handling!

fairly good

careful due to induced stress

no problems detected

no problems detected

careful at low temp.

higher risk for damages at high temp.

fairly good at high and low temp.

Pipe bending

temperature sensitive, material pushed away

fairly good

Sand-bedding fine sand required around the pipe Installation temp. too little protection High Installation temp. fairly good Low

Presentation title

Bimodal HDPE

up to 80

Pipe handling general Transport

16 May 2011

Unimodal HDPE

1-2 years 5-10 years 5-10 years 5-10 years 5-10 years outdoor 5-10 years outdoor depending on outdoor due to outdoor due outdoor due to due to 2-2,5% due to 2-2,5% GJ/m² of 2-2,5% carbon to 2-2,5% 2-2,5% carbon carbon black carbon black radiation (global black carbon black black map)

Storage up to 60 - strong temperature High softening! (°C) Storage -20 temperature Low (°C) material gets softer, Pipe supports and white film cover at high temperature stacking due to UV radiation

43

MDPE

fairly good fairly good fairly good

fairly good at no problems ´very good at high high, not detected and fairly good at good at low -45 up to 85°C low temp. temp.

careful at low temperature