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Case Study Based On Failure And Application Of Surface Coating (Powder Coating)

Case Study Based on Failure Analysis and Re-application of Surface Coating
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Plant assets for hydrocarbon and power generation systems are prone to numerous damage mechanisms that arise from operating and/or upset conditions, environmental factors, material defects as well as other neighborhood factors 1-2. Corrosion is one of the key degradations that pose a substantial economic burden, and may result in severe safety and environmental hazards 3. While considering the percentage for global economy in terms of corrosion, the total cost of corrosion globally amounts to ∼2.5 trillion US dollars per year. Among the corrosion mitigation measures, organic protective coatings are the most widely used, and their costs add up to two-thirds of all anti-corrosion overheads 4. 

Product Number: 51322-18109-SG
Author: Syed Umair Niaz Bukhari, Ahmad Raza Khan Rana,
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings
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$20.00
$20.00

Surface coatings are a cost-effective method for protecting metals surface and is well known for versatility, ease of maintenance, and various compositions specific to service involved. In this case study, a detailed investigation was conducted to discover the reason behind the failure of the external coating system (aliphatic polyurethane) on a riveted fire water tank for a turnkey project located in the Arabian Gulf region. Visual inspections of longitudinal seams alongside the failed coatings revealed rust stains which came from the seepage of the service. The under fill / primer layer’s dry film thickness showed significant and consistent variation from the topcoat’s thickness. Pull off adhesion tests advocated an adhesion failure between epoxy primer and aliphatic polyurethane. Cathodic disbondment test confirmed the paint manufacturer`s report and created confidence on the product chemistry. The corrosion mechanism leading to the in service failure of the applied coating is explained. 

Surface coatings are a cost-effective method for protecting metals surface and is well known for versatility, ease of maintenance, and various compositions specific to service involved. In this case study, a detailed investigation was conducted to discover the reason behind the failure of the external coating system (aliphatic polyurethane) on a riveted fire water tank for a turnkey project located in the Arabian Gulf region. Visual inspections of longitudinal seams alongside the failed coatings revealed rust stains which came from the seepage of the service. The under fill / primer layer’s dry film thickness showed significant and consistent variation from the topcoat’s thickness. Pull off adhesion tests advocated an adhesion failure between epoxy primer and aliphatic polyurethane. Cathodic disbondment test confirmed the paint manufacturer`s report and created confidence on the product chemistry. The corrosion mechanism leading to the in service failure of the applied coating is explained. 

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Product Number: 51322-18110-SG
Author: Syed Umair Niaz Bukhari
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Coatings are a composite blend of raw ingredients that are mixed, applied to a prepared substrate, and dried and cured correctly to perform to their maximum capability. Failures and defects can appear themselves at numerous times in the life of a coating. Prior to application, they can take the shape of settlement and skinning, during application as runs and sags, shortly after application as solvent popping and orange peel, and during service as blistering and rust spotting. Therefore, it is not unexpected that those coatings can suffer from premature failure and/or exhibit defects that may or may not result in failure. Coatings nowadays are the most efficient method to shield metals and thus has been widely engaged among various protective techniques 1, 2. 
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Case Study - Sharing An AC Mitigation System

Product Number: 51322-17786-SG
Author: Hycem Bahgat, Daniel Hebb, Sorin Segall, Ernesto Gudino, Karl Shen, Shan Jiang
Publication Date: 2022
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AC interference analysis between high voltage AC (HVAC) powerlines and buried pipelines is a matter of current interest due to the growing number of right-of-ways shared between powerline and pipeline infrastructure. This is only expected to increase as the worldwide energy demand grows considerably over the next 30 years,1 and stricter environmental regulations and policies are applied. Therefore, AC interference will continue to be an issue of concern for powerline and pipeline operators to protect the public, environment, and maintain asset integrity.
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Case Study: Foreign Operator DC Interference On An Existing Pipeline Systems

Product Number: 51322-17587-SG
Author: Jessica Jaskolka
Publication Date: 2022
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EN Engineering (ENE) completed an AC interference study over 68 miles of an operator’s transmission line. In addition, an ACVG survey of approximately one (1) mile of the pipeline was conducted at the take-off point of the 8” line. As a result of this AC interference study, evidence of elevated AC corrosion risk has not been found on the operator’s pipeline. However, a review of the provided data shows evidence of DC interference due to a nearby foreign rectifier groundbed at the take-off point of the operator’s line.
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