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Two large scale problems with three layer polyolefin (3LPO) coatings are discussed here and possible reasons for the failures. Lessons learned and recommendations for future usage of such coatings are provided.
In recent years three layer polyolefin (3LPO) coatings, including three layer polypropylene (3LPP) and three layer polyethylene (3LPE) have become the system of choice for pipeline coatings in many companies worldwide. The main reasons for the growth in popularity of these coatings are their resistance to high temperatures (up to 140ºC for 3LPP), good mechanical properties, and increased availability of these coatings and compatible field joint coatings. A series of recent failures, however, have put a question mark over the long term performance and suitability of these coatings, especially for high temperature (>100ºC) gas pipelines. Two large scale problems are discussed here and possible reasons for the failures, together with lessons learnt and recommendations for future usage of such coatings are provided.
Keywords: polyolefin, polyethylene, polypropylene, fusion bonded epoxy, heat shrink sleeve, flame spray, liquid epoxy.
This paper begins with a brief discussion of essential properties of all pipeline coatings, and a listing of multi-layer systems designed to meet specific needs. It then focuses on special considerations regarding application parameters for multi-layer systems that use fusionbonded epoxy as the primer.
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Three layer polypropylene (3LPP) pipeline coatings failed prematurely in the oilfields of Abu Dhabi in the United Arab Emirates (UAE). A failure investigation and analysis into this phenomenon was instigated. The coating disbondment has been found to be due to high residual stress concentration and adhesion loss.
In this paper the approach of an Oil Company is demonstrated from the initial choice between different primers: inorganic zinc and organic (epoxy) zinc., to all the preliminary pre-qualification tests, the subsequently field test performed, and the procedures adopted, costs included.