Pipeline Coating
Overview of Pipeline Coating
Pipeline coating is essential for protecting pipelines from corrosion, mechanical damage, and environmental factors like moisture and chemicals. UNIACERO’s coating service offers an alternative to welding, the chemical composition of coatings makes pipelines highly resistant to corrosion, providing a reliable solution for the protection of pipelines.
UNIACERO’s pipeline coating systems encompass a complete range of solutions that are excellent for protecting pipelines in various environments, from the mill to offshore applications.
Pipeline Coating Specifications
Material Selection
- Type of Coating: Specifications specify the type of coating material suitable for the pipeline’s operating conditions, such as Fusion-Bonded Epoxy (FBE), Polyethylene (PE), Polypropylene (PP), Polyurethane (PU), or others.
- Coating Thickness: Requirements for minimum and maximum thicknesses of the coating to ensure adequate protection against corrosion and mechanical damage.
- Adhesion Properties: Standards for adhesion strength between the coating and the pipeline substrate to prevent delamination.
Surface Preparation:
- Cleaning Standards: Procedures for cleaning the pipe surface to remove rust, grease, and contaminants before applying the primer and main coating.
- Surface Profile: Specifications for achieving the appropriate surface profile or roughness to enhance coating adhesion.
Application Techniques:
- Application Method: Guidelines on the application technique such as spraying, extrusion, wrapping, or taping depending on the coating material.
- Temperature and Environmental Conditions: Requirements for application temperatures, humidity levels, and curing conditions to ensure proper adhesion and curing of the coating.
| Production Process | Coated Pipe | |||||
| Outside Diameter | 60.3mm and up (1/8″ – ） | |||||
| Wall Thickness | 1.65mm – up mm (SCH 5S – SCH XXS) | |||||
| Pipe Length | 6 meters, 12 meters or customized. | |||||
| Production Standards | API 5L | ASTM A53 | JIS G 3422 | DIN 30671 | CAN/CSA – Z245.21 | ISO DIS21809 – 1 |
| API 5CT | ASTM A795 | DIN 30670 | DIN 30678 | NFA 49 – 710 | – | |
| Corrosion Prevention | Lacquer, Varnish, Oiling, HDG, Pre-Galvanizing | |||||
| FBE, 2LPP, 3LPP, 2LPE, 3LPE | ||||||
| End Processes | Square Cut, Bevelling, Threading, Grooving | |||||
| Joint Method | Fitting, Flange, Coupling, Clamp, Pipe Shoulder, Welding | |||||
| Further Processing | Welding, Bending, Hole Drilling, Punching, Swaging, Tapering, Flaring, Expanding | |||||
| Product Usage | Petroleum, Liquid & Gas Transmission, Structure, Piling Job, Mining, Agriculture, Fabrication, Fire Fighting, Heat Exchanging | |||||
Diverse Coating Types Tailored to Your Needs
UNIACERO offers a range of coating types tailored to meet your specific needs, and one such option is the Fusion Bonded Epoxy Powder Coating (FBE).
Fusion Bonded Epoxy Powder Coating (FBE): Fusion Bonded Epoxy, commonly known as FBE, stands as a testament to modern pipeline coating technology. This thermosetting powder, when applied, forms a solid protective layer that adheres impeccably to steel surfaces. At UNIACERO, our FBE coating is meticulously formulated to offer unparalleled protection against corrosion, ensuring that your pipelines remain operational even in the most challenging environments. What sets our FBE coating apart is its resilience. It’s not just a barrier; it’s a shield that actively resists damage, making it an environmentally friendly choice that contains no volatile organic compounds (VOCs). Furthermore, its application is a testament to precision. The powder is applied in multiple passes, ensuring uniformity and thickness. UNIACERO’s FBE coating is a reliable product, once set, it offers a robust defense, ensuring that your pipelines remain free from corrosion, damage, and wear for years to come.
Three-layer Polyethylene/Propylene (3LPE/3LPP): The 3LPE/3LPP pipeline coating system is a marvel of engineering, designed for those who seek nothing but the best for their pipelines. This multi-layered system combines the best of materials to offer a coating solution that stands unrivaled in terms of protection and durability. The system begins with a primer layer, ensuring that the subsequent layers adhere perfectly. The adhesive copolymer layer follows, acting as a bridge between the primer and the final polyolefin topcoat. This topcoat, made of either polyethylene or polypropylene, is what gives the 3LPE/3LPP its renowned resistance to high service temperatures and environmental challenges. At UNIACERO, we’ve perfected this system, ensuring that each layer complements the other, resulting in a pipeline that’s not just protected but enhanced.
Coal Tar Enamel (CTE): A nod to the classics, Coal Tar Enamel or CTE, is a pipeline coating solution that has stood the test of time. It’s a blend of modern science and time-proven methods, resulting in a coating that offers robust protection. At its core, CTE is a liquid epoxy that’s enriched with the protective properties of coal tar pitch. This combination ensures a thick, resilient coating that’s tailor-made for pipelines that face the harshest of conditions. But it’s not just about protection; it’s about longevity. CTE coatings, with their unique composition, ensure that pipelines remain corrosion-free for extended periods, reducing maintenance needs and ensuring smooth operations. At UNIACERO, our CTE coatings are a testament to our commitment to quality, offering our clients a solution that’s both efficient and effective.
Galvanization: Galvanization stands as a testament to the power of synergy. By applying a protective zinc coating to steel or iron, galvanization prevents rusting and corrosion, ensuring that your pipelines remain robust and efficient for years. At UNIACERO, our galvanization process is refined to perfection. We employ the hot-dip method, where steel pipes are submerged in molten zinc. This immersion results in a metallurgical bond between the zinc and the steel, offering a level of protection that’s unparalleled. But it’s not just about protection; galvanized pipes also boast enhanced durability, making them ideal for challenging environments, especially those prone to moisture. Furthermore, galvanization is cost-effective, ensuring that you get maximum protection without straining your budget. With UNIACERO’s galvanization, you’re not just investing in a coating; you’re investing in a legacy of excellence and durability.
Applications: Where Our Coatings Make a Difference
Pipeline for Waste Water: Our coatings are pivotal in wastewater transportation, ensuring that pipelines made of various materials, from PVC to carbon steel, remain corrosion-free and efficient. The excellent protection provided by our coatings ensures the smooth flow of wastewater, contributing to the overall reliability of the system.
Pipeline for Petroleum Oil: In the oil industry, our coatings safeguard steel pipelines, ensuring smooth transportation of crude oil to refineries and finished products to the market. The resistant nature of our coatings to external factors is particularly valuable in the demanding environment of oil transportation.
Liquid Epoxy: Ideal for weld joints, fittings, and valves, our liquid epoxy coatings offer a seamless protective layer, especially at the soil-to-air interface of underground pipelines.
Comparision of Various Coating Systems
| Property | CTE Coating | FBE Coating | 3LPE Coating |
|---|---|---|---|
| Service temperature: | 45°C | 110°C | 80°C |
| Impact resistance: | Poor | High | Excellent |
| Penetration resistance: | Initially good but changes to poor with passage of time | High | Excellent (No changes observed during service life) |
| Damages during handling & transportation: | High | High | Low |
| Cathodic disbondment: | Good | Very good | Good |
| Resistance to soil stress: | Poor | Good | Excellent |
| Resistance to water and oxygen permeation: | Good (initially) | Good | Excellent |
| Chemical resistance: | Good | Very good | Very good |
| Volume resistivity: | Good | Excellent | Excellent |
