Bahadori Essentials of Coating, Painting, and Lining for the Oil, Gas and Petrochemical Industries

1. Auflage 2015
ISBN: 978-0-12-801665-7
Verlag: Elsevier Science & Techn.
Format: EPUB
Kopierschutz: 6 - ePub Watermark

E-Book, Englisch, 830 Seiten

With the oil and gas industry facing new challenges-deeper offshore installations, more unconventional oil and gas transporting through pipelines, and refinery equipment processing these opportunity feedstocks--new corrosion challenges are appearing, and the oil and gas industry's infrastructure is only as good as the quality of protection provided and maintained. Essentials of Coating, Painting, and Linings for the Oil, Gas, and Petrochemical Industries is the first guide of its kind to directly deliver the necessary information to prevent and control corrosion for the components on the offshore rig, pipelines underground and petrochemical equipment. Written as a companion to Cathodic Corrosion Protection Systems, this must-have training tool supplies the oil and gas engineer, inspector and manager with the full picture of corrosion prevention methods specifically catered for oil and gas services. Packed with real world case studies, critical qualifications, inspection criteria, suggested procedure tests, and application methods, Essentials of Coating, Painting, and Linings for the Oil, Gas and Petrochemical Industries is a required straightforward reference for any oil and gas engineer and manager. - Understand how to select, prime and apply the right coating system for various oil and gas equipment and pipelines - both upstream and downstream - Train personnel with listed requirements, evaluation material and preparation guides, including important environmental compliance considerations - Improve the quality of your equipment, refinery and pipeline with information on repair and rejection principles

Alireza Bahadori, PhD, CEng, MIChemE, CPEng, MIEAust, RPEQ, NER is a research staff member in the School of Environment, Science and Engineering at Southern Cross University, Lismore, NSW, Australia, and managing director and CEO of Australian Oil and Gas Services, Pty. Ltd. He received his PhD from Curtin University, Perth, Western Australia. During the past twenty years, Dr. Bahadori has held various process and petroleum engineering positions and was involved in many large-scale oil and gas projects. His multiple books have been published by multiple major publishers, including Elsevier. He is Chartered Engineer (CEng) and Chartered Member of Institution of Chemical Engineers, London, UK (MIChemE). Chartered Professional Engineer (CPEng) and Chartered Member of Institution of Engineers Australia, Registered Professional Engineer of Queensland (RPEQ), Registered Chartered Engineer of Engineering Council of United Kingdom and Engineers Australia's National Engineering Register (NER).

Autoren/Hrsg.

Bahadori, Alireza

Leseproben

Chapter 1 Surface Preparation for Coating, Painting, and Lining
Abstract
The term surface preparation refers to methods used to treat the surface of substrate prior to the application of coating (painting, coating and lining, etc.). Surface preparation is the essential first-stage treatment of a steel substrate before the application of any coating, lining, and painting. It is generally accepted as being the most important factor affecting the success of a corrosion protection system. The performance of a coating is significantly influenced by its ability to adhere properly to the substrate material. This chapter covers the requirements for surface preparation of substrates prior to protecting against corrosion, both for initial construction and maintenance. The discussion includes the minimum requirements for surface preparation of ferrous metals, nonferrous metals, and nonmetallic surfaces (e.g., masonry materials and wood). Keywords
Blast acid-pickling flame-cleaning rust removal steam cleaning degreasing galvanizing abrasive blasting alkaline pickling anodic etching nickel strike immersion process 1.1. Introduction
The term surface preparation means the methods of treating the surface of substrate prior to application of coating (painting, coating and lining, etc.). Surface preparation is the essential first-stage treatment of a steel substrate before the application of any coating. It is generally accepted as being the most important factor in the complete success of a corrosion protection system. The performance of a coating is significantly influenced by its ability to adhere properly to the substrate material. For steel surfaces, residual mill scale is an unsatisfactory base to apply modern, high-performance protective coatings; therefore, it needs to be removed by abrasive blast cleaning. Other surface contaminants on the rolled steel surface, such as oil and grease, are also undesirable and must be removed before the blast cleaning process. Typical contaminants that should be removed during surface preparation include moisture, oil, grease, corrosion products, dirt, and mill scale. The surface being prepared must achieve a level of cleanliness and roughness suitable for the proposed coating and permit good adhesion of the coating. The money and effort spent on the preparation should be in a reasonable proportion to the purpose and nature of the coating. The contractor performing surface preparation must have the personnel and technical know-how to operate in a technically satisfactory and operationally reliable manner. The surfaces must be accessible and adequately illuminated. The relevant accident prevention regulations and safety provisions must be observed. All surface preparation work must be properly quality-controlled and inspected. Each subsequent coating may be applied only when the surface to be coated has been prepared in accordance with widely accepted standards. This chapter gives the minimum requirements for surface preparation of substrates prior to protecting against corrosion, both for initial construction and for maintenance. It includes the minimum requirements for surface preparation of ferrous metals, nonferrous metals and nonmetallic surfaces (e.g., masonry materials and wood). Applicable methods of surface preparation, including degreasing, pickling, manual cleaning, flame cleaning, and blasting, are discussed in this chapter. Recommendations are made regarding the selection of appropriate methods of surface preparation and the coating (including metallic coating and electroplating) to be applied. The handling of parts or assemblies after cleaning should be kept to a minimum. When handling is necessary, clean gloves or similar protection should be used. Canvas, polyvinyl chloride (PVC), and leather are suitable materials for gloves. Cleaned surfaces should be coated as soon after cleaning as is practical, and before detrimental corrosion or recontamination occurs. There is no single, universal method of cleaning by which all surfaces can be prepared for the application of protective coatings. The cleaning method for any given type of article must be carefully selected and properly carried out. All materials furnished should be of the specified quality. The entire operation of surface preparation should be performed by experienced workers skilled in the cleaning of surfaces and overseen by qualified supervisors. 1.2. Selection of Cleaning Method
The cleaning method should be selected with the following considerations in mind. The choice between blast-cleaning, acid-pickling, flame-cleaning, and manual cleaning is partly determined by the nature of the coating to be applied. It should be understood, however, that coating applied to a properly prepared (e.g., blast-cleaned) surface will always last longer than similar coating applied to flame-cleaned or manually cleaned surfaces. 1.2.1. Initial Condition of Surface (Rust Grade)
The initial condition of surfaces for preparation, which, among other factors, determines the choice and mode of execution of the preparation measures and the relevant reference sample to be used, must be determined. 1.2.2. New Construction (Uncoated Surfaces)
Grade of steel, special treatments or methods have an effect on the preparation (e.g., use of cold rolling or deep drawing methods). Figure 1.1 shows samples of the rust grades of uncoated surfaces. Figure 1.1 Examples of rust grades of uncoated surfaces. Rust levels: (A) Steel surface covered with firmly adhesive scale and largely free of rust; (B) steel surface with the beginning of rust attack; (C) steel surface from which scale has been rusted away or can be scraped off, but which exhibits only a few rust pits visible to the eye; (D) steel surface from which the scale has been rusted away and exhibits numerous visible rust pits. 1.2.3. Maintenance (Coated Surface)
Rust level of coated surfaces according to standards such as DIN 53210 and ASTM D 610 (see Figure 1.2); Figure 1.2 Rust grade of coated surfaces (example of area percentage). 1. Type of coating (e.g., type of binder and pigment, metal coating), approximate coat thickness, and date when carried out 2. Extent of blistering according to DIN 53209 and ASTM D 714 3. Additional information—e.g., on adhesion, cracking, chemical and other contaminants, and other significant phenomena 1.3. Cleanliness of the Surfaces
1.3.1. Removal of Contaminants/Coats of Materials Other Than Metal
This stage of the cleaning process includes removal of dirt, dust, soot, ash, concrete, coal slag, sand, moisture, water, acids, alkalis, soap, salts, encrustations, growths, fluxes, oily and greasy contaminants, and coatings and cementations that are loose, rusted, or unusable as an adhesion surface and corrosion products of metallic coatings. You should use either the cleaning method specified by the standards or one of the methods described in this book. 1.3.2. Removal of Coated Material Related to the Metal (Scale and Rust)
Removal of firming adherent scale is only possible with the following methods: 1. Blasting 2. Flame-cleaning 3. Pickling 4. Manual cleaning With each of these methods, only specific surface conditions can be produced and particular levels of cleanliness achieved. Correspondingly, the appearance of the prepared surface depends not only on the level of cleanliness, but also on the rust removal method used. 1.3.3. Standard Level of Cleanliness
The standard level of cleanliness for prepared steel surfaces (as listed in Tables 1.1 and 1.2) should apply. Unless otherwise specified, the level of cleanliness of uncoated surfaces should be in accordance with blasting and manual cleaning and with the provisions specified in Table 1.1 for flame-cleaning and pickling. Table 1.1 Standard Levels of Cleanliness for Prepared Steel Surfaces Standard Level of Clean-Liness Rust Removal Method Initial Condition of Steel Surface Reference Sample Photographs Essential Characteristics of The Prepared Steel Surface Remarks Uncoated Coated Sa l Blasting B C D See section 13 B Sa 1 C Sa 2 D Sa 1 Only loose scale, rust and loose coatings are removed These standard levels of cleanliness apply to blasting a. Of uncoated steel surface b. Of coated steel surfaces if the coatings are also removed sufficiently to obtain the required level of cleanliness Sa 2 B C D B Sa 2 C Sa 2 D Sa 2 Virtually all scale, rust and coatings are removed;...