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A remarkable amount of financial loss is incurred every year because of premature failures of paints and coatings. The budget to repair such failures extremely outweighs the initial cost of coatings, since excessive engineering may be looked-for to access the deteriorating areas of a coating system. Additional accountability may also be anticipated if a facility stops operation for the essential repairs to be made.
Protective coatings are used to protect the metal surfaces to hinder their direct interaction with service fluids. In this case study, a broad investigation was performed to determine the reason behind the failure of the FRE (fiber-reinforced epoxy) lining of a condensate storage tank located in the Arabian Gulf region. Visual inspections revealed various coating defects, including checking and crazing marks. Pull-off testing revealed that two out of six readings were not meeting the specifications for adhesion compliance. DFT (dry film thickness) checks revealed several locations, which were either undercoated or over coated beyond the specified limits. SEM (scanning electron microscope) analysis alongside the cross-sectionsrevealed inter-layers delamination. In addition, the primer layer was visible from the surface, which implies the degradation of intermediate and topcoats. Finally, rust stains were visible at certain locations. FTIR (Fourier transform infrared) spectrum of the applied lining system indicated that it bears resemblance with phenoxy resin, which was in fact, incompatible with the condensate service. The failure mechanism leading to the failure of the applied lining is analyzed and discussed in this paper.
In oil and gas industries the material surface of pipelines, tools, and equipment is exposed to many harsh operational conditions- one of which is the repetitive impingement of contaminated solid particles when encountering a mixture of gas and sand or liquid solids-laden slurries. In addition to maintenance and material expenses, mass loss of materials due to erosion results in unstable production rates. Hence, predicting the erosion provides the ability to optimize the design and qualify it for operation in an erosive environment for the required operational life.
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For years, people have relied upon a variety of industry accelerated testing methods in order to predict how long a coating / lining system may be useful in service. This type of testing would include heat aging, Atlas Cell immersion testing for lining products and accelerated weatherometer testing for coating systems, just to name a few. Polyurea spray applied elastomeric materials have been no exception to this type of testing. One of the most important testing evaluations has been accelerated weatherometer exposure for products used in outdoor application areas.
Changing conditions in the Oil and Gas industry are yielding greater corrosion protection challenges to the owners and operators of refineries, terminals, pipelines, railcars etc. Internal lining schemes which have traditionally been used for the storage and transport of crude oil and refined fuels may no longer be appropriate. The aggressive nature of crude oil (higher temperatures and more sour nature), high purity refined products and the increased use of biofuels globally necessitate the demand for better linings and more certain test results.