Innovations in internal pipeline

cleaning and coating

by Steve Lalumandier
Union Carbide Industrial Services Co, USA

Contents of this Paper:

Introduction

Overview of cleaning and coating process

Case studies

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Pipeline Pigging and Integrity Monitoring Conference: Houston, 1992

Introduction
As more and more emphasis is being placed on preventive maintenance, methods of suppressing internal
corrosion in pipelines are receiving increasing amounts of attention. Internal corrosion may cause leaks, with
possible disastrous environmental effects, or may cause the product carried by the line to become discolored or
otherwise contaminated. The costs associated with internal corrosion can be staggering, but can usually be
prevented by one of several methods. This paper describes one such method, the 'double-plug extrusion' process
for applying coating to the inside of in-place pipelines. It will also address surface preparation.

Overview of cleaning and coating process

Three critical factors influence the success of any coating project: surface preparation, coating selection and
coating application. The wrong choice in any area may cause premature failure of the coating. This, of course, is
true for any coating project. However, these factors are more difficult to control and inspect on internally-coated
pipelines. For this reason, methods must be used which offer the highest potential for success.

Surface preparation
The first step of any coating job is to thoroughly clean the inside of the pipe to properly prepare its surface. The
preferred cleaning standard is a white-metal blasted finish (NACE #1 or SSPC SP5). The primary reason for
having good surface preparation is to remove all deposits from the line, including rust, scale, and salts that could
interfere with the coating bond. It is also important to create a deep angular anchor pattern for the coating to
adhere to. After cleaning, the line should be completely dry and under a purge of an inert gas to prevent flash
rusting. All of these requirements are met using Sandjet, which is the abrasive blasting procedure used in the
InnerCure pipeline renewal service developed by UCISCO (Union Carbide Industrial Services Co). The Sandjet
process involves scouring the inside of the pipeline with an abrasive material, such as flint, which is propelled in a
low-pressure, high-velocity stream of nitrogen. The cleaning particles impact the wall of the pipe at a low angle of
incidence, gouging and/or chipping away the deposit. Removed material is then carried through the line with the
nitrogen, and collected at the outlet. To ensure that anomalies such as welds are cleaned uniformly, cleaning is
typically performed in both directions. After abrasive cleaning, pigs and/or solvents are used to remove any
remaining dust. Erosion, where changes in pipeline direction exist, is minimized by tightly controlling nitrogen
velocity and cleaning material density through the pipeline.
The equipment required for the cleaning process consists of:
1. a mobile nitrogen pumping unit, usually a pumper truck (which vaporizes liquid nitrogen) or a tube trailer
(which contains high-pressure gaseous nitrogen);
2. a trailer-mounted cleaning unit consisting of a feed pot and all equipment to accurately control the
nitrogen flow rate and the feed rate of the cleaning material;
3. an injection device which is connected to the pipe's inlet by a standard flange;
4. a dust-suppression/waste-collection system, usually a vacuum truck or covered dumpster.
Occasionally, Sandjet cleaning may uncover very thin, hard deposits, such as magnetite, which are more
economically cleaned with chemicals. If this is the case, chemical cleaning is used in addition, and the line is
abrasively cleaned after chemical cleaning to re-establish the desired anchor pattern and remove chemical residue.
Also, by removing rust or scale, cleaning may expose leaks that must be repaired before coating.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Innovations in internal pipeline cleaning and coating

Clear advantages of this system over traditional cleaning methods, such as pigging or chemical washing, are
numerous. Most important is its ability to reach a NACE #1 or SSPC SP5 white-metal blasted finish, which
eliminates any contamination that may prevent bonding between the pipe and coating. The cleaning particles
produce a deep, angular anchor pattern that enhances the coating bond. The nitrogen used to propel the cleaning
particles also dries the line and establishes an inert environment to prevent flash corrosion. Most lines can be
cleaned in about eight hours, because long sections of pipelines can be cleaned with each setup, reducing
excavation costs and time. In general, the maximum length that can be cleaned per setup is a function of the inside
diameter of the pipe; a good rule of thumb says that taking the ID of the line (in inches) divided by three will give
the length (in miles) that can be cleaned in one setup. For example, this method can clean up to four miles of 12in pipeline for each setup.

Coating selection
A wide variety of coatings have been used to internally coat in-place pipelines. The 'double-plug extrusion'
process requires the coating to have specific thixotropic properties. These enable the coating to be spread onto the
pipe wall with pig pressure and then immediately 'gel' to prevent the coating from running or sagging.
The most commonly-used coating is a two-part polyamide-cured epoxy. It is moderately chemical and abrasion
resistant, and will withstand temperatures of up to 150F under immersion service (220F, atmospheric service)
and pressures up to 500psig. The polyamide coating is recommended for lines carrying potable, fresh, and salt
water, as well as crude oils, transportation fuels, natural gas, and some solvents. It is not recommended for lines
containing strong aromatics, strong organic acids, or high levels of sulfur dioxide or hydrogen sulfide. The normal
cure time for this coating is seven days at 70F, although it may be cured in less time if the line can be heated.
Many other coatings such as polyamines and polyurethanes have been used, depending on the operating
conditions of the line. At this time, there is no clear choice of coatings for 'hostile' environments (high pressure
and/or high temperature). Much testing is currently being done in this area and some options are available. In
most cases it is good practice to install a test spool cleaned and coated under field conditions to assure
compatibility with the intended service.
The life of a coating system is an important topic. In all cases the life varies, based upon the coating material and
the service to which it is exposed. However, UCISCO has been coating lines since 1977, and some of these lines
are still in service.

Coating application
Coating is applied to in-place pipelines by placing the coating material between two pigs and propelling the pig
train through the line. Several types of pigs, including multiple-cup-and-disc, bi-directional disc, and spherical,
are commonly used. UCISCO often uses inflatable spheres because they are reversible, non-collapsible, will
negotiate tight bends without leaving gaps, and will conform to internal pipe irregularities. Spherical pigs also
produce thicker coating layers, usually 4-6mils (dry film thickness), as opposed to 1-3mils for other types of pig.
The coating thickness is affected primarily by the size of the spheres (shear pressure on the coating) and the
coating train speed (shear rate of the coating). By controlling the differential pressure across the coating train and
hence the train's speed, the required coating thickness can be achieved. Nitrogen is used as both the driving force
and back pressure because its flow rate and velocity can be easily controlled by the same pumping equipment
used to clean the line, and because the inert environment prevents any possibility of igniting the VOCs (usually
MEK) contained in the coating. Typically, in non-hostile environments, two coats are applied, one in each
direction, to ensure thorough coating of welds, and joints.
The 'double-plug extrusion' process has limitations. Even though coating serves as a barrier for future corrosion or
product contamination, it will not repair leaks, or add structural strength to the line, and all leaks must be repaired
prior to coating. While this method can clean and coat much longer lengths than most alternative methods, it
cannot coat through diameter changes, and lines must be separated at these points.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Pipeline Pigging and Integrity Monitoring Conference: Houston, 1992

Case studies
Many types of line have been successfully coated by the 'double-plug extrusion' process. They include: potable
water, raw water, brine, crude oil, refinery off gas, jet fuel, isopropyl alcohol, ethylene glycol, and others. Below
are a few case studies.

Chemical solvent lines at shipping terminal

A large chemical producer coated 2000ft of new, buried 6-in carbon steel pipe to prevent iron and corrosion from
contaminating several water-white chemicals. The alternative, stainless steel pipe, would have cost up to ten times
that of coating carbon steel.

Jet-fuel lines at military base

Several military installations have coated jet-fuel lines, both new and old, in order to prevent contamination from
internal corrosion. The alternative, cleaning and de-watering the fuel with filters and separators, was more costly
and less reliable.

Water feed to steam generator used in crude-oil production

An oil producer that uses steam for down-hole injection coated 5.5miles of 10-in new water lines to the steam
generators to prevent corrosion from contaminating the generators. The alternative, pre-coated, or yard-coated,
pipe was about 40% more expensive, and would leave coating gaps at the joints.

Boiler feed-water line in refinery

A major refinery coated 1600ft of 4-in boiler feed-water line which had severe flow restriction due to
tuberculation. The alternative, replacement of the pipe, was twice as expensive and would take much longer than
coating.

Wet natural gas-gathering lines

A major utility company coated 4.3miles of 6-in and 4miles of 4-in new natural gas-gathering lines. The lines
were being chemically treated with corrosion inhibitors, but the customer wanted additional protection in an
environmentally-sensitive area.

Brine feedwater lines

A major producer of brine coated several sections of 12-in new, buried and floating line ranging from 5000ft to
15,000ft in length, in order to prevent corrosion in an environmentally-sensitive area. The alternatives, slip-lining
and yard-coating, were approximately three to four times the cost of coating the carbon steel pipe.

Natural gas service - river crossing

A major utility company coated 3000ft of 8-in to 12-in natural-gas supply lines. The lines were coated to prevent
corrosion in an enviromentally-sensitive area, and to extend the life of the pipeline and reduce maintenance costs.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.