Pipeline Coatings Evaluation Begins at New GTI Facility

To control steel-pipe corrosion, today’s pipeline operators have a wider range of pipeline-coating options than ever before. However, the diverse world of coating materials and techniques can complicate the decision-making process—a situation compounded by the equally varied field conditions under which coatings are applied.

Recognizing the need for a thorough evaluation of field-applied pipe coatings, GTI and a consortium of pipeline companies, coating manufacturers, and utilities are conducting a multi-year pipeline coatings study at GTI’s new Pipeline Coatings Facility at GTI headquarters in Des Plaines, Illinois (near Chicago).

The Pipeline Coatings Facility was built in 2001 to address critical pipeline company concerns. The coatings study project began in May 2002 and is being conducted on various types and sizes of pipes in a variety of field conditions. More than 25 companies are contributing funds, pipe samples, and expertise to the program.

“Every company wants to be sure that they are using the most effective materials and the most efficient methods possible when applying pipeline coatings,” explains GTI Materials Scientist Dan Ersoy. “However, with all the options available and limited in-house testing abilities, it is difficult for operators to make their choices based on sound, scientific evidence. Through this program, we will be providing that evidence.”

Ersoy notes that many of the potential methods for controlling costs, improving safety, and meeting regulatory requirements are based on the development and use of new and improved pipeline coatings. However, limiting the use of advanced coatings technology is a lack of unbiased, third-party information available on how the various coating systems perform under different environmental, soil, and service conditions.

“We congratulate GTI for this initiative,” remarks Joe Dzatko, Technical Service Manager for participating company Specialty Polymer Coatings, Inc. “The results of this study will provide the energy industry with a comprehensive comparison of the application characteristics and performance qualities of the most advanced corrosion protection coatings available today.”

GTI’s Pipeline Coatings Facility can mimic an extensive array of real-world operating conditions, including the common problem areas associated with high temperatures, stresses, varied soil types, moisture, and cathodic protection extremes. Surface preparation and coating applications are strictly controlled, monitored, and independently inspected. By using standardized, comprehensive specifications and procedures—and following manufacturers’ recommendations—researchers ensure that variances are minimal.

Testing is being conducted in three extreme soil types; on both small and large pipe; at ambient and elevated temperatures; and under short- and long-term burial.

Results will be contained in a data base with “categorized” performance data for the coating selection process. When complete, operators will be able to match known pipe size, soil type/conditions, and service temperature with the most appropriate and cost-effective coating.

All test conditions and results will be documented in a user-friendly format, allowing for the application to real-life situations that coating and corrosion engineers encounter daily.

Specific information will be developed on costs per joint, time to apply a system, equipment needs and special requirements, and quantitative test data on areas such as:

Adhesion (ASTM D-4541)
Peel (DIN 30 672): For shrink sleeves and tapes
Hardness (ASTM D-2240, 2583)
Impact resistance (ASTM G-14)
Penetration resistance (ASTM G-17)
Abrasion resistance (Tabor)
Cathodic disbondment (ASTM G-8, 42, 95)
Hot water soak (ASTM D-870)
Holiday detection (ASTM and NACE various)
Film thickness (ASTM various).

Says Ersoy: “With the data from this evaluation, one can make informed decisions to select the most cost-effective systems to adequately protect the pipeline.”


	> From GTI Journal Summer 2002 Pipeline Coatings Evaluation Begins at New GTI Facility To control steel-pipe corrosion, today’s pipeline operators have a wider range of pipeline-coating options than ever before. However, the diverse world of coating materials and techniques can complicate the decision-making process—a situation compounded by the equally varied field conditions under which coatings are applied. Recognizing the need for a thorough evaluation of field-applied pipe coatings, GTI and a consortium of pipeline companies, coating manufacturers, and utilities are conducting a multi-year pipeline coatings study at GTI’s new Pipeline Coatings Facility at GTI headquarters in Des Plaines, Illinois (near Chicago). The Pipeline Coatings Facility was built in 2001 to address critical pipeline company concerns. The coatings study project began in May 2002 and is being conducted on various types and sizes of pipes in a variety of field conditions. More than 25 companies are contributing funds, pipe samples, and expertise to the program. “Every company wants to be sure that they are using the most effective materials and the most efficient methods possible when applying pipeline coatings,” explains GTI Materials Scientist Dan Ersoy. “However, with all the options available and limited in-house testing abilities, it is difficult for operators to make their choices based on sound, scientific evidence. Through this program, we will be providing that evidence.” Ersoy notes that many of the potential methods for controlling costs, improving safety, and meeting regulatory requirements are based on the development and use of new and improved pipeline coatings. However, limiting the use of advanced coatings technology is a lack of unbiased, third-party information available on how the various coating systems perform under different environmental, soil, and service conditions. “We congratulate GTI for this initiative,” remarks Joe Dzatko, Technical Service Manager for participating company Specialty Polymer Coatings, Inc. “The results of this study will provide the energy industry with a comprehensive comparison of the application characteristics and performance qualities of the most advanced corrosion protection coatings available today.” GTI’s Pipeline Coatings Facility can mimic an extensive array of real-world operating conditions, including the common problem areas associated with high temperatures, stresses, varied soil types, moisture, and cathodic protection extremes. Surface preparation and coating applications are strictly controlled, monitored, and independently inspected. By using standardized, comprehensive specifications and procedures—and following manufacturers’ recommendations—researchers ensure that variances are minimal. Testing is being conducted in three extreme soil types; on both small and large pipe; at ambient and elevated temperatures; and under short- and long-term burial. Results will be contained in a data base with “categorized” performance data for the coating selection process. When complete, operators will be able to match known pipe size, soil type/conditions, and service temperature with the most appropriate and cost-effective coating. All test conditions and results will be documented in a user-friendly format, allowing for the application to real-life situations that coating and corrosion engineers encounter daily. Specific information will be developed on costs per joint, time to apply a system, equipment needs and special requirements, and quantitative test data on areas such as: Adhesion (ASTM D-4541) Peel (DIN 30 672): For shrink sleeves and tapes Hardness (ASTM D-2240, 2583) Impact resistance (ASTM G-14) Penetration resistance (ASTM G-17) Abrasion resistance (Tabor) Cathodic disbondment (ASTM G-8, 42, 95) Hot water soak (ASTM D-870) Holiday detection (ASTM and NACE various) Film thickness (ASTM various). Says Ersoy: “With the data from this evaluation, one can make informed decisions to select the most cost-effective systems to adequately protect the pipeline.”
	For more information, contact gasoperationsinfo@gastechnology.org