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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.
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During the construction of a 56km long 16 in. carbon steel sour gas pipeline, repetitive surfacepreparation failures were detected during visual inspection of pipeline girth weld internal surface prior tocoating application. Such failures represented 67% of the total pipeline girth welds and were manifestedby excessive sharp-edges at the root pass. To identify the failure causes, an investigation wasperformed through reviewing the pipeline, fabrication and coating application specifications andprocedures, quality control records and performing an extensive visual inspection through an advancedvideo robotic crawler on all pipeline girth welds made. Upon investigation analysis, the failures werecaused by sharp-edges in the root pass which were attributed to improper practices duringmanufacturing, field fabrication and pre-coating quality control. The failure analysis indicated that themechanized Gas Metal Arc Welding process, with the parameters used, was not suitable for internalgirth weld coating application. In addition, a more stringent requirement should be applied to theacceptable pipe-end diameter tolerance and pre-coating quality control to ensure absence of similarpremature surface preparation failures. The pre-coating quality control can be improved throughutilization of robotic laser contour mapping crawler for precise detection and sizing of unsatisfactorysurface weldment defects, including sharp edges.
HISTORICAL DOCUMENT. Qualifying and controlling the quality of plant-applied, single-layer fusion-bonded epoxy (FBE) coatings to the external surfaces of carbon steel pipe. Proper application, inspection and repair.
NOTE: NACE SP0394-2013—Editorial corrections were made to Table 3 and Table 4 in 2018-04-04.