Essentials of Coating, Painting, and Lining for the Oil, Gas and Petrochemical Industries

763 Pages·2015·17.294 MB·English

by  Alireza Bahadori

Essentials of Coating,
Painting, and Lining
for the Oil, Gas, and
Petrochemical Industries
Alireza Bahadori, Ph.D.
School of Environment, Science, and Engineering
Southern Cross University, Lismore, NSW, Australia
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ISBN: 978-0-12-801407-3
DEDICATION
Dedicated to the loving memory of my parents, grandparents,
and everyone who contributed so much to my work over the years
About the Author
Alireza Bahadori, Ph.D., is a member of the research staff of the School of Environment, Science,
and Engineering at Southern Cross University in Lismore, NSW, Australia. He received his Ph.D. from
Curtin University in Perth, Western Australia. During the past 20 years, Dr. Bahadori has held many
process and petroleum engineering positions and was involved in several large-scale projects at the
National Iranian Oil Co. (NIOC), Petroleum Development Oman (PDO), and Clough AMEC.
He is the author of about 250 articles and 12 books. His books have been published by many major
publishers, including Elsevier.
Dr. Bahadori is the recipient of the highly competitive and prestigious Australian government’s en-
deavour international postgraduate research award for his research in the oil and gas areas. He also re-
ceived a Top-up Award from the State Government of Western Australia through the Western Australia
Energy Research Alliance (WA:ERA) in 2009. Dr. Bahadori serves as an editorial board member and
reviewer for a large number of journals.
xlv
Preface
The surface preparation process not only cleans steel, but also introduces a suitable profile for apply-
ing protective coating. The main task of such coating is to prevent or control the external corrosion
of buried or submerged steel structures. The coating isolates metal from contact with the surrounding
environment.
Since a perfect coating cannot be assured, cathodic protection is used in conjunction with the coat-
ing system to provide the first line of defense against corrosion. And since a properly selected and
applied coating should provide 99% of the needed protection, it is of utmost importance to know the
advantages and disadvantages of available coatings. The right coating material, properly used, will
make all other aspects of corrosion control relatively easy. The number of coating systems available
requires careful analysis of the many desired properties for an effective pipe coating.
Therefore, the optimum selection and proper application of protective coatings are vital to success-
ful engineering. During extended periods of time, protective coatings deteriorate as a result of contact
with moisture, oxygen, chemicals, fluctuating temperatures, abrasion, pressure, and many other factors.
Therefore, proper and timely maintenance is required to get the optimum performance from a protec-
tive coating.
Meanwhile, selection and application of maintenance coating is more complicated than for initial
construction. Climatic conditions, chemical exposure, available time, budget, health and safety, and
grade of surface preparation have a significant influence on the planning of optimum design coating.
To select the best coating system to fit the environment or oil condition, knowledge of operating and
installation conditions is essential. The steel source and job location may limit the coatings available
for each project. The choice of a high-quality applicator is the most important (but alas, also most ne-
glected) consideration. Following coating and applicator selection, inspection at the coating, especially
on the job site during construction, will go far in ensuring that a high-quality pipe coating system has
been installed.
This engineering book covers the minimum requirements for the design and selection of coating
systems for the external protection of pipes, storage tanks, and piling systems that will be buried or
submerged in water. The contents define the essential elements of surface preparation, selection of coat-
ing systems, and repair of coating defects. It is intended to focus on corrosion protection of steel struc-
tures of the oil and gas and petrochemical industries, including refineries, chemical and petrochemical
plants, gas plants, and oil exploration and production units.
This book covers the minimum requirements for the linings that will be used in various types of
equipment (e.g., vessels, storage tanks, and pipelines). It is intended for use in refineries, petrochemical
plants, oil and gas plants, and, where applicable, in exploration, production, and new ventures.
Several nonmetallic lining systems are discussed. They are classified into the following main groups:
Thermoplastic materials
Thermosetting materials
Rubbers
Mineral and bitumen materials
xlvii
xlviii Preface
This book gives the essential details about the initial construction and maintenance painting of
metal surfaces. It also describes the minimum requirements for the surface preparation and painting of
piping, plant, equipment, storage tank, building, and other elements that will be exposed to different
corrosive environments. Painting schedules, paint systems, and paint color schedules are included in
this respect.
Alireza Bahadori
School of Environment, Science, and Engineering
Southern Cross University, Lismore, NSW, Australia
1 November 2014
Acknowledgments
I would like to thank the Elsevier editorial and production teams, Katie Hammon and Kattie Washington
of Gulf Professional Publishing for their editorial assistance.
xlix
CHAPTER
1
SURFACE PREPARATION
FOR COATING, PAINTING,
AND LINING
1.1 INTRODUCTION
The term surface preparation means the methods of treating the surface of substrate prior to application
of coating (painting, coating and lining, etc.). Surface preparation is the essential first-stage treatment
of a steel substrate before the application of any coating. It is generally accepted as being the most
important factor in the complete success of a corrosion protection system.
The performance of a coating is significantly influenced by its ability to adhere properly to the
substrate material. For steel surfaces, residual mill scale is an unsatisfactory base to apply modern,
high-performance protective coatings; therefore, it needs to be removed by abrasive blast cleaning.
Other surface contaminants on the rolled steel surface, such as oil and grease, are also undesir-
able and must be removed before the blast cleaning process. Typical contaminants that should be
removed during surface preparation include moisture, oil, grease, corrosion products, dirt, and mill
scale.
The surface being prepared must achieve a level of cleanliness and roughness suitable for the pro-
posed coating and permit good adhesion of the coating. The money and effort spent on the preparation
should be in a reasonable proportion to the purpose and nature of the coating. The contractor perform-
ing surface preparation must have the personnel and technical know-how to operate in a technically
satisfactory and operationally reliable manner.
The surfaces must be accessible and adequately illuminated. The relevant accident prevention regu-
lations and safety provisions must be observed. All surface preparation work must be properly quality-
controlled and inspected. Each subsequent coating may be applied only when the surface to be coated
has been prepared in accordance with widely accepted standards.
This chapter gives the minimum requirements for surface preparation of substrates prior to pro-
tecting against corrosion, both for initial construction and for maintenance. It includes the minimum
requirements for surface preparation of ferrous metals, nonferrous metals and nonmetallic surfaces
(e.g., masonry materials and wood). Applicable methods of surface preparation, including degreasing,
pickling, manual cleaning, flame cleaning, and blasting, are discussed in this chapter. Recommenda-
tions are made regarding the selection of appropriate methods of surface preparation and the coating
(including metallic coating and electroplating) to be applied.
The handling of parts or assemblies after cleaning should be kept to a minimum. When handling
is necessary, clean gloves or similar protection should be used. Canvas, polyvinyl chloride (PVC), and
leather are suitable materials for gloves. Cleaned surfaces should be coated as soon after cleaning as is
practical, and before detrimental corrosion or recontamination occurs.
Essentials of Coating, Painting, and Lining. http://dx.doi.org/10.1016/B978-0-12-801407-3.00001-8 1
Copyright © 2015 Elsevier Inc. All rights reserved.
2 CHAPTER 1 SURFACE PREPARATION FOR COATING, PAINTING, AND LINING
There is no single, universal method of cleaning by which all surfaces can be prepared for the ap-
plication of protective coatings. The cleaning method for any given type of article must be carefully
selected and properly carried out.
All materials furnished should be of the specified quality. The entire operation of surface prepara-
tion should be performed by experienced workers skilled in the cleaning of surfaces and overseen by
qualified supervisors.
1.2 SELECTION OF CLEANING METHOD
The cleaning method should be selected with the following considerations in mind. The choice between
blast-cleaning, acid-pickling, flame-cleaning, and manual cleaning is partly determined by the nature
of the coating to be applied. It should be understood, however, that coating applied to a properly pre-
pared (e.g., blast-cleaned) surface will always last longer than similar coating applied to flame-cleaned
or manually cleaned surfaces.
1.2.1 INITIAL CONDITION OF SURFACE (RUST GRADE)
The initial condition of surfaces for preparation, which, among other factors, determines the choice and
mode of execution of the preparation measures and the relevant reference sample to be used, must be
determined.
1.2.2 NEW CONSTRUCTION (UNCOATED SURFACES)
Grade of steel, special treatments or methods have an effect on the preparation (e.g., use of cold rolling
or deep drawing methods).
Figure 1.1 shows samples of the rust grades of uncoated surfaces.
1.2.3 MAINTENANCE (COATED SURFACE)
Rust level of coated surfaces according to standards such as DIN 53210 and ASTM D 610 (see Figure 1.2);
1. Type of coating (e.g., type of binder and pigment, metal coating), approximate coat thickness, and
date when carried out
2. Extent of blistering according to DIN 53209 and ASTM D 714
3. Additional information—e.g., on adhesion, cracking, chemical and other contaminants, and other
significant phenomena
1.3 CLEANLINESS OF THE SURFACES
1.3.1 REMOVAL OF CONTAMINANTS/COATS OF MATERIALS OTHER THAN METAL
This stage of the cleaning process includes removal of dirt, dust, soot, ash, concrete, coal slag, sand,
moisture, water, acids, alkalis, soap, salts, encrustations, growths, fluxes, oily and greasy contaminants,
1.3 CLEANLINESS OF ThE SURFACES 3
FIGURE 1.1
Examples of rust grades of uncoated surfaces. Rust levels: (A) Steel surface covered with firmly adhesive scale and
largely free of rust; (B) steel surface with the beginning of rust attack; (C) steel surface from which scale has been
rusted away or can be scraped off, but which exhibits only a few rust pits visible to the eye; (D) steel surface from
which the scale has been rusted away and exhibits numerous visible rust pits.
and coatings and cementations that are loose, rusted, or unusable as an adhesion surface and corrosion
products of metallic coatings. You should use either the cleaning method specified by the standards or
one of the methods described in this book.
1.3.2 REMOVAL OF COATED MATERIAL RELATED TO THE METAL (SCALE AND RUST)
Removal of firming adherent scale is only possible with the following methods:
1. Blasting
2. Flame-cleaning
3. Pickling
4. Manual cleaning
With each of these methods, only specific surface conditions can be produced and particular levels
of cleanliness achieved. Correspondingly, the appearance of the prepared surface depends not only on
the level of cleanliness, but also on the rust removal method used.