Guidelines for the use of anti-corrosion tape systems for process pipework

Transcription

1 Guidelines for the use of anti-corrosion tape systems for process pipework

2 GUIDELINES FOR THE USE OF ANTI-CORROSION TAPE SYSTEMS FOR PROCESS PIPEWORK First edition March 2017 Published by Energy Institute, London The Energy Institute is a professional membership body incorporated by Royal Charter 2003 Registered charity number

3 The Energy Institute (EI) is the chartered professional membership body for the energy industry, supporting over individuals working in or studying energy and 250 energy companies worldwide. The EI provides learning and networking opportunities to support professional development, as well as professional recognition and technical and scientific knowledge resources on energy in all its forms and applications. The EI s purpose is to develop and disseminate knowledge, skills and good practice towards a safe, secure and sustainable energy system. In fulfilling this mission, the EI addresses the depth and breadth of the energy sector, from fuels and fuels distribution to health and safety, sustainability and the environment. It also informs policy by providing a platform for debate and scientifically-sound information on energy issues. The EI is licensed by: the Engineering Council to award Chartered, Incorporated and Engineering Technician status; the Science Council to award Chartered Scientist status, and the Society for the Environment to award Chartered Environmentalist status. It also offers its own Chartered Energy Engineer, Chartered Petroleum Engineer and Chartered Energy Manager titles. A registered charity, the EI serves society with independence, professionalism and a wealth of expertise in all energy matters. This publication has been produced as a result of work carried out within the Technical Team of the EI, funded by the EI s Technical Partners. The EI s Technical Work Programme provides industry with cost-effective, value-adding knowledge on key current and future issues affecting those operating in the energy sector, both in the UK and internationally. For further information, please visit The EI gratefully acknowledges the financial contributions towards the scientific and technical programme from the following companies Apache North Sea Repsol Sinopec BP Exploration Operating Co Ltd RWE npower BP Oil UK Ltd Saudi Aramco Centrica Scottish Power Chevron North Sea Ltd SGS Chevron Products Company Shell UK Oil Products Limited CLH Shell U.K. Exploration and Production Ltd ConocoPhillips Ltd SSE DCC Energy Statkraft DONG Energy Statoil EDF Energy Tesoro ENGIE Taqa Bratani ENI Total E and P UK Limited E. ON UK Total UK Limited ExxonMobil International Ltd Tullow Oil Innogy Uniper Kuwait Petroleum International Ltd Valero Maersk Oil North Sea UK Limited Vattenfall Nexen CNOOC Vitol Energy Phillips 66 Woodside Qatar Petroleum World Fuel Services However, it should be noted that the above organisations have not all been directly involved in the development of this publication, nor do they necessarily endorse its content. Copyright 2017 by the Energy Institute, London. The Energy Institute is a professional membership body incorporated by Royal Charter Registered charity number , England All rights reserved No part of this book may be reproduced by any means, or transmitted or translated into a machine language without the written permission of the publisher. ISBN Published by the Energy Institute The information contained in this publication is provided for general information purposes only. Whilst the Energy Institute and the contributors have applied reasonable care in developing this publication, no representations or warranties, express or implied, are made by the Energy Institute or any of the contributors concerning the applicability, suitability, accuracy or completeness of the information contained herein and the Energy Institute and the contributors accept no responsibility whatsoever for the use of this information. Neither the Energy Institute nor any of the contributors shall be liable in any way for any liability, loss, cost or damage incurred as a result of the receipt or use of the information contained herein. Hard copy and electronic access to EI and IP publications is available via our website, Documents can be purchased online as downloadable pdfs or on an annual subscription for single users and companies. For more information, contact the EI Publications Team. e: pubs@energyinst.org

4 CONTENTS Page Foreword Acknowledgements Introduction Purpose Scope Anti-corrosion tape systems (ACTS) Generic ACT types Petrolatum/grease based tapes Light/medium duty or medium-thickness laminate tapes Heavy duty or high-thickness laminate tapes Monolithic viscous polymer tapes Glass fibre reinforced plastic (GRP) wraps Outer tape wraps and protection shields Surface primers Mastics/pastes Profiling compounds (profiling mastics) Liquid topcoats Properties of ACTSs Adhesion strength and peel test Advantages and disadvantages vs liquid coatings Advantages Disadvantages Use under insulation Application under pipe supports Use on corrosion resistant alloys (CRA) Selection methodology Selecting the generic system type Cost estimating Life cycle Cost elements Surface preparation Preparation standards Cost comparisons Application of ACTSs Surface preparation Surface preparation risk assurance for live equipment Surface adhesion assurance Inspection during the application process Material checks Application of the ACTS Principal application criteria Use of fillers Protection wrapping

5 Contents continued Page Primer application Checks and inspections prior to ACT application Inspections during application Inspection following application of an ACTS Documentation and close out Inspection and maintenance of ACTSs during service In-service repair technique...30 Annexes Annex A Abbreviations and definitions Annex B References and bibliography Annex C Generic ACTS components and their key properties C1 Supplier Winn and Coales (Denso ) ltd C2 Supplier Stopaq...34 C3 Supplier Chase corporation

6 Figures LIST OF FIGURES AND TABLES Page Figure 1 Typical ACT system with optional outer protection (cross section) Figure 2 Example use of a GRP wrap under a pipe support...15 Figure 3 Selection of the surface preparation procedure...20 Figure 4 Example elements for cost estimating and selection of the coating system Figure 5 Photographic example viscous polymer ACTS Figure 6 Photographic example petrolatum ACTS Table Table 1 Typical property testing methods for ACTs

7 FOREWORD These guidelines provide information to assist operators to understand the principles associated with the selection, application and maintenance of Anti Corrosion Tape Systems (ACTS) as an alternative to the conventional liquid paint systems that are commonly used to protect equipment and structures from damage due to atmospheric corrosion. It is expected that these guidelines will be of use to operations and integrity engineers and managers, corrosion engineers, technicians, contractors and inspectors, and all other parties concerned with the application, inspection and maintenance of ACTS for process plant piping systems located both offshore and onshore. In addition, it should be of value in conveying details of such activities to trainees and personnel dealing with such systems for the first time. The project to compile industry guidance for ACTS was instigated by representatives of the UK offshore oil and gas industry and was directed by a cross-industry steering group (SG). Although produced for the UK offshore oil and gas production industry, guidance provided herein is regarded as being applicable also to onshore oil and gas production and/or treatment facilities and similar industries such as petrochemical plant and refineries throughout the UK and the rest of the world. Although it is anticipated that following this publication will assist those involved in the preparation of Energy Institute (EI) technical publications, the information contained in this publication is provided as guidance only. While every reasonable care has been taken to ensure the accuracy of its contents, the EI, and the technical representatives listed in the acknowledgements, cannot accept any responsibility for any action taken, or not taken, based on this information. The EI shall not be liable to any person for any loss or damage that may arise from the use of any of the information contained in any of its publications. It is intended that these guidelines will be reviewed and revised when there are changes in related standards, industry practices or in the light of practical experience. Comments on the publication are welcome with a view to incorporating improvement at the next issue. Comments should be addressed to: The Technical Department, Energy Institute, 61 New Cavendish Street, London W1G 7AR, United Kingdom 6

8 ACKNOWLEDGEMENTS This publication has been developed under the direction of a steering group (SG) that comprised representatives of UK offshore field operators and companies engaged in specialist activities relating to the design, manufacture, installation, inspection and repair of ACTS. The EI wishes to record its appreciation of the commitment to the project and the work carried out by the following personnel who provided valuable expertise through attendance at SG meetings and who submitted information essential to the development of this publication: Paul Thornton Laurie MacKay Stefan Lewandowski James Stobie Raman Patel Ricardo Montenegro Richard Waud Maersk (SG Chairman) ConocoPhillips/Consultant (Early SG Chairman) Shell Maersk HSE BP Consultant The EI also wishes to record its appreciation of the support afforded by the following who, at various stages of the project, provided input and guidance on the draft documents, advice at SG meetings or submitted support material over the development period: Representatives/consultants from/to operators: Edgar Rodrigues TAQA Mike Gray Total Keith Umpleby Consultant Sohail Saeed Chevron Mike Hobin Chevron Christopher Scales HSE Representatives from manufacturers and suppliers of ACTS: Keith Corfield Denso David Robertson Denso Phil Low Stopaq Paul Barkley Chase Daniel Libby Chase The project was instigated by Laurie MacKay who provided valuable liaison with industry members, consultants and suppliers of ACTS necessary to get the project underway. The SG and supplier liaison activities were managed by Keith Hart (consultant to the EI) who was also the principal editor. 7

9 1 INTRODUCTION Deterioration of structures and process equipment associated with the oil and gas, power generation and petrochemical industries due to external corrosion is normally controlled by the application of conventional liquid-applied coatings that provide sacrificial, inhibitive or barrier protection. Such coatings are vulnerable to exposure to ultraviolet (UV) light and various environmental deterioration mechanisms due to ageing and their principal disadvantage is cost of maintenance. The availability of a wider range of ACTSs broadens the options and solutions available to the operator when considering methods for mitigating external corrosion especially when rehabilitation of an existing coating system is required. The principal component of an ACTS is the anti-corrosion tape (ACT). The ACT can be considered as being a layer of viscous coating compound that is a water-resistant adhesive material carried by a backing matrix which permits easy application onto the surface requiring protection. There may be a requirement to apply a liquid primer, and it may or may not be covered by an additional protective wrap, usually in the form of a tape as well. The ACTS comprises all the components (primer, wrapping tape and protective wrap) that are applied. For a given item of plant, structure or equipment use of ACTSs provides a viable alternative to conventional liquid coating systems. However, deciding whether to coat or apply an ACTS will require careful consideration and it is important that the asset life cycle should play a part in the decision process. ACTSs have improved significantly over recent years and have moved from the use of high shear strength 'hard' adhesives to viscoelastic adhesives carried by high modulus backings that have better long-term adhesion. Unlike conventional coating systems, application of an ACTS does not have the equivalent environmental restrictions on ambient conditions or the requirement for rigorous surface preparation procedures. In general, it is only necessary to have a dry, clean surface to a standard that satisfies the operator and this ease of substrate preparation is where the primary advantage of this option lies. This in turn means that the process of applying a given ACTS is more 'weather-tolerant'. Although the guidance provided herein is primarily directed at protecting process pipework, the reader is advised of positive industry experience with using ACTSs on structural nonload-bearing steel sections, particularly those exposed to aggressive corrosive environments located both offshore and in coastal areas such as oil terminals and mid-stream refineries. This publication aims to provide relevant personnel, especially integrity engineers and those involved on fabric maintenance, with guidance on where ACTSs can best be deployed on process pipework. It introduces the use of decision trees and uses industry standards to support and underpin the selection process. It includes where, when, why and how the method should be considered and provides good practice guidance for the safe and efficient use of ACTSs to achieve a cost-effective and fit-for-purpose solution. However, the Operator should consider for itself, what is the correct action to take for each particular circumstance including pipework condition, age of the asset, mechanical integrity of the component and very importantly, the economics. Other publications relating to these guidelines are listed in Annex A. The related EI publications referred to in these guidelines are: Guidance for corrosion management in oil and gas production and processing Guidelines for the management of coatings for external corrosion protection 8

10 As the application of an ACTS is essentially a surface coating process, the latter publication is of particular relevance. It also provides extensive guidance on the management of coatings including the range of work processes and procedures that are common. 1.1 PURPOSE The purpose of this publication is to provide industry with good practice guidance for the deployment of ACTs systems for both new and existing (ageing) process pipework. In particular, guidance is provided to assist operators to: Develop/amend corrosion management strategies to include the selection and use of ACTSs. Select the appropriate ACTS for a given application. Determine the correct application procedure. Determine applicable inspection techniques during and after application of tape wrap systems. Identify where there are industry technology needs especially in the area of inspection. Note: ACTSs are also suitable for protecting other items of process plant and certain structural components, which these guidelines may prove useful for. 1.2 SCOPE Although ACTSs are applicable for both new and existing equipment, the scope of this publication is aimed mainly at the rehabilitation of coatings on process pipework that have deteriorated with age and are no longer considered adequate for ongoing corrosion protection. This also applies to brownfield developments where used process pipework is redeployed for a redefined service. The scope covers the following: ACT applied at ambient conditions; tape material groups as listed in 2.1; applicable to surface pipework equipment (may also be applied to structures); both offshore and onshore locations, and splash zone application. Applications that are not covered are: underground equipment, and subsea equipment. Note: ACTSs should not be confused with those used for repair or imparting additional strength to a particular section or area of pipework or structure. Examples of these typically include wraps based on glass fibre reinforced plastic (GRP). 9