CERTIFICATION PROGRAMME

ON CORROSION MANAGEMENT
& CATHODIC PROTECTION OF
CGD NETWORKS
SMART LEARNING DIGITAL PLATFORM

KB Singh and Associates

Coatings & Cathodic Protection Consultants
MODULE 2

• FIELD JOINT COATINGS

WHAT IS FIELD JOINT COATING……….

▪ The field joint is the

bare steel area where
two pipe sections meet and
are welded together.

▪ Each pipe is 11 to 12
meters long and as such for
every 1 Km of pipe there are
83 to 85 Joints / km.
WHY ARE FIELD JOINT COATINGS IMPORTANT

What does the picture show…….

A 3LPE coated pipe welded joint above ground.

Subjected to atmospheric corrosion

Most of the rusting is seen on the circumferential and

longitudinal weld seam (Pipe in photograph is LSAW)
WHY IS CORROSION MORE ON AREA AROUND THE
WELDED SEAM ………………..
▪Welding a joint may affect the corrosion
resistance of that joint. Even with careful
filler metal matching, a welded joint may
be subject to differential corrosion.

▪That is, the weld metal and/or heat

affected zone (HAZ) may corrode faster
than the base metal or the base metal
may corrode faster than the weld metal
and/or HAZ.

▪This is true because the weld zone varies

in chemical composition, metallurgical
structure, and residual stress levels.
 WHY IS CORROSION MORE ON AREA AROUND THE
WELDED SEAM ………………..
▪Welding a joint may affect the corrosion
resistance of that joint. Even with careful
filler metal matching, a welded joint may
be subject to differential corrosion.

▪That is, the weld metal and/or heat

affected zone (HAZ) may corrode faster
than the base metal or the base metal
may corrode faster than the weld metal
and/or HAZ.

▪This is true because the weld zone varies

in chemical composition, metallurgical
structure, and residual stress levels.
 FIELD JOINTS
From a Corrosion Stand point Field joints are often considered the weakest point within a
pipeline due to many issues

▪Wrong selection of the field joint coating (Material, Operating Temperature Mechanical
Strength, Resistance to soil stresses, Compatibility with the main line coating)

▪Application in environment not conductive to coating (dew point, high humidity / dust / rain
fall etc )

▪Abrasive blasting not done properly

▪No proper PQT / Training conducted

▪Frequent changes of applicator crew.

▪Improper application.
 4. Selection Creteria
FIELD JOINTS – KNOW THE DETAILS

Cutback
120+/-10mm
150+/20mm

Weld bead
Manual
Semi Auotomatic
Automatic

3LPE Coating Bevel

FBE Toe

[Terminology of Girth weld]

 FIELD JOINTS – BEVEL OF 3LPE

If there is no bevel, then at the transition area of 3LPE to Steel (step down of 2-3mm
there will be air entrapment leading to possible corrosion at the 3LPE to steel interface
FIELD JOINTS – WELD BEAD HEIGHT/PROFILE

THICKNESS OF HEAT SHRINK SLEVES VARIES

TOP OF WELD SEAM
ON BODY
FIELD JOINTS – WELD BEAD HEIGHT/PROFILE

Pipe Size Thickness (mm)

(Specified Outside Diameter) On Pipe body On Weld Bead
(Minimum) (Minimum)
10.75” (273.1 mm) 2.5 2.0
!2.75” ( 323.9 mm) to 18" (457 mm) 2.8 2.2
20” (508 mm) to 30" (762 mm) 3.0 2.4
≥32" (813.0 mm) 3.3 2.6
FIELD JOINTS – CUTBACK

Coating cutback

Coating and/or adhesive shall terminate 120 mm

(+) 20 / (-) 0 mm from pipe ends.

Wherever specified the cut back shall be 150mm

(+) 20 / (-) 0 to facilitate automatic welding.

FBE toe of 25mm shall be maintained.

FIELD JOINTS – CUTBACK
 FIELD JOINT COATING – PERFORMANCE
▪Long-term corrosion protection performance

• Excellent adhesion to the substrate that is to be protected

• Exceptional compatibility with the factory or mainline coating

system

• The ability to be applied under extreme environmental conditions

• Ease of application
FIELD JOINT COATING – TYPE

Type of Line Coating

Type of Field Joint Coating DIRECT BURIED
Three Layer Polyethylene
Three Layer Heat Shrink PE Two Layer Heat Shrink PE Cold Applied Tape

Three Layer Polypropylene

Three Layer Heat Shrink PP Two layer Heat Shrink PE or PP

Dual Layer Fusion Bond

Spray applied FBE High build liquid epoxy Three layer Heat Shrink PE
Epoxy (DFBE)
FIELD JOINT COATING – TYPE

Type of Line Coating

Type of Field Joint Coating HDD
Three Layer Polyethylene Three Layer Heat Shrink
Fiber Glass Reinforced PE

Three Layer Polypropylene Three Layer Heat Shrink PP

or Fiber Glass Reinforced
PE
Dual Layer Fusion Bond
Spray applied FBE
Epoxy (DFBE)
 FIELD JOINT COATING HEAT SHRINK SLEEVES
THREE LAYER HEAT SHRINKABLE THREE LAYER HEAT SHRINKABLE TWO LAYER HEAT SHRINKABLE SLEEVE
SLEEVE SLEEVE FIBER GLASS REINFORCED
-Ist Layer Butyl Rubber Mastic
-First layer Epoxy -First layer Epoxy -2nd Layer Radiation X-linked HDPE or PP
-2nd Layer Hot Melt Adhesive -2nd Layer Hot Melt Adhesive
-3rd Layer Radiation X-linked HDPE or -3rd Layer Radiation X-linked HDPE or PP -PERFORMANCE LOWER THAN 3LPE
PP Fiber glass reinforced -(soil stress / peel / cathodic disbondment)

-PERFORMANCE SAME AS 3LPE / -PERFORMANCE SAME AS 3LPE / 3LPP Surface preparation required St3
3LPP COATING COATING

Surface preparation required Sa21/2

Anchor profile: 50~70 Microns Surface preparation required Sa21/2
Anchor profile: 50~70 Microns
SURFACE PREPARATION

POWER WIRE BRUSH ABRASIVE BLASTING

ST3 – POWER WIRE BRUSH Sa21/2 – ABRASIVE BLASTING

BASIC STEPS TO SURFACE PREPARATION
WHAT NEEDS TO BE DONE?

1. Remove Loose and Soluble 2. Pipe Temperature Above 3. Remove Mill Scale and
Surface Contaminants Dew Point other Insoluble Solids

Dust rating <2

Sa 21/2
Peak
4. Create Acceptable Surface
Valley
Profile

40μ 60 μ 100μ
Chloride contamination<5 ug/cm2
SURFACE PREPARATION STANDARDS
NACE SSPC Swedish British ISO 8501
#1 White Metal SP5 White Metal Sa3 First Quality Sa3

#2 Near White SP10 Near white Sa2½ Second Quality Sa2½

#3 Commercial SP6 Commercial Sa2 Third Quality Sa2

#4 Brush Blast SP7 Brush Blast Sa 1 Sa 1

SP3 Power Tool St 3 St 3
SP2 Hand Tool St 2 St 2
SP1 Solvent Wipe
SURFACE PROFILE MEASUREMENT

Visual comparator Digital profile gauge Testex tape

SURFACE PROFILE MEASUREMENT
DUST CONTAMINATION RATING CHART

40μ 60 μ 100μ
SALT CONTAMINATION METER
 PIPELINE COATINGS & FIELD JOINT COATING
3 LAYER POLYETHYLENE COATING STORAGE OF LINE PIPE
&
FIELD JOINT COATING
MATERIAL

SURFACE PREPERATION

3rd Layer Polyethylene

2nd Layer Copolymer Adhesive

TRAINED APPLICATORS &
Ist Layer FBE APPLICATION
&
QA / QC / INSPECTION
 APPLICATION PROCESS-FIELD JOINT COATING
Abrasive Blasting ABRASIVE BLASTING MEDIUM
SHOULD BE COPPER SLAG OR GARNET
Degree of Cleanliness – Sa2½ NOT SAND
Surface Profile – ( 50-75µ) COPPER SLAG STANDARD IS
ISO 11126-3

•Relative humidity shall not be greater than 85% prior to blasting.

•Steel surface temperature shall be minimum 5PPP0PPPC and 3PPP0PPPC more than the dew point.
• Relative humidity / dew point to be measured prior to start of joint coating activity.
APPLICATION PROCESS-FIELD JOINT COATING
 APPLICATION PROCESS-FIELD JOINT COATING

•Using copper slag blast only the bare steel part of the girth weld area to SA 2½ and a roughness profile
(anchor pattern) between 50 to 100 microns.
• The air compressor shall be checked for delivering air without any oil contamination
•Sweep blast adjacent PE line coating to create a rough surface for a distance minimum
100 mm from the edge of the 3LPE coating.
APPLICATION PROCESS-FIELD JOINT COATING

FBE TOE
APPLICATION PROCESS-FIELD JOINT COATING
APPLICATION PROCESS-FIELD JOINT COATING
Surface profile measurement using Testex tape & Micrometer

•Using copper slag blast only the bare steel part of the girth weld area to SA 2½ and a roughness profile
(anchor pattern) between 50 to 100 microns.
• The air compressor shall be checked for delivering air without any oil contamination
•Sweep blast adjacent PE line coating to create a rough surface for a distance minimum
100 mm from the edge of the 3LPE coating.
APPLICATION PROCESS
Pre heating of the surface Temperature measurement

•Preheat the steel surface 70-80ºC and the adjacent PE line coating to 70 - 80ºC.
• This is very important to create a bond properly to the PE line coating.
APPLICATION PROCESS
Dispensing of epoxy with the help of pumps

Mixing of epoxy in 3:1 ratio (part A:part B)

 AAPPLICATION PROCESS PLICATION PROCESS

Epoxy Primer application Wet Film Thickness check

•Apply S1301M/S1201M two pack epoxy primer over the girth weld seam first and then on the body
to a wet film thickness of > 200 microns.
APAPPLICATION PROCESS PLICATION PROCESS
APPLICATION PROCESS
SLEEVE INSTALLATION & POST HEATING
APAPPLICATION PROCESS PLICATION PROCESS
APPLICATION PROCESS
SLEEVE INSTALLATION & POST HEATING
 INSPECTION OF INSTALLED HEAT SHRINK SLEEVE
Property Test Method Frequency Acceptance Criteria
No.

Wet Film
1 Epoxy primer wet Every Joint (1 reading / quadrant) Min. 200 microns
Gauge
film thickness
Free of defects, air voids and pinholes.
2 Visual Inspection Visual Every Joint Hot melt adhesive flow evident from
both sides.
Every Joint (Three location each quadrant on
Installed Minimum Thickness Min. 3 mm on steel body body Min 2.5
3 steel body) Total 12 readings. Four readings
Thickness of HSS Gauge mm on weld bead
on the weld seam.
Holiday Detection
Brush 5 kV+5 kV/mm
4 (on complete Every Joint
detector (25 kV max)
system)
Peel Force @230C EN-12068 One per 50 joints or one days production 3.5N/mm
5 /
Or Ambient temp. ISO21809 on steel and adjacent line 3LPE coating
EN-12068 One per 50 joints or one days production 0.5 N/mm
6 Peel Force @ 600C /
ISO 21809 on steel and adjacent line 3LPE coating
 VISUAL INSPECTION
The inspection of the joint shall be done after the cooling down of the
sleeve and the substrate to ambient temperature.
The sleeve shall be visually inspected for the following points.

✓The weld bead profile contour shall be visible through the sleeve.
✓The ends of the sleeve shall be firmly bonded to the mill coating.
✓There shall be no upstanding edges.
✓Adhesive flow shall be evident at both edges of sleeve around entire
circumference of pipe / sleeve.

✓The sleeve shall be smooth, there will be no dimples, cold spots,

bubbles, punctures, burn holes or any signs of holidays.
✓There shall be no signs of entrapment of foreign materials in the
underlying adhesive.
✓Sleeve shall overlap minimum 50mm onto the adjacent PE line coating
on each side of joint.
VISUAL INSPECTION
VISUAL INSPECTION
PEEL TEST
PEEL TEST
PEEL TEST
PEEL TEST FAILURE NO BOND TO 3LPE OR STEEL
 HDD – FIELD JOINT COATINGS
Field Joint Coating:
▪ Anti Abrasion Properties.

▪ Capability to withstand high mechanical stresses.

▪ High shear strength to steel to withstand pull forces.

▪ No damage to the field joint when the pipe is pulled over the rollers.

▪ As the field joint coating has a step down, the leading edge of the field joint coating
should be designed with a special wear cone so that in case of direct shear forces acting
at the “step down”, only the wear cone should be damaged and not the main field joint
coating.
 HDD – FIELD JOINT COATINGS

• Split resistant
• Fiber glass reinforced backing
HOLIDAY DETECTION
A PAPPLICATION PROCESS
PLICATION PROCESS
AP APPLICATION PROCESS PLICATION
PROCESS
AP APPLICATION PROCESS
PLICATION PROCESS
AP
APPLICATION PROCESS
PLICATION PROCESS
DIRAX SLEEVE INSTALLED

WEAR CONE for protection

Direction of pipe pull

 DIRAX SLEEVE INSTALLED

WEAR CONE for protection

DIRAX SLEEVE PEEL
PIPE LIFTING BEFORE DRILLING
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
ACTUAL FIELD PHOTOGRAPHS
 FOR INTEGRITY OF PIPELINES –
ENSURE PROPER FIELD APPLICATION OF
FIELD JOINTS

THANK YOU