Khalfan Al Muhairi - High Performance Top Coat Borcoat HE3450

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Borouge reference line 2006

© 2006 Borouge

High Performance Top Coat

Borcoat HE3450-H

2nd Kuwait Pipe Tech Conference & Exhibition 2011

Kuwait – 5th of October 2011

Khalfan Al Muhairi – Application Marketing Manager, Borouge

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© 2006 Borouge

Source:BP, IEA 2006, 2008 Gtoe = Gigatons of oil equivalent

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© 2006 Borouge

Outline

Borouge Overview

Corrosion in Oil&Gas Sector

Overview 3 layers Polyolefin Steel Pipe Coating Systems

High Performance Top Coat Borcoat HE3450-H

Conclusion Remarks

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© 2006 Borouge

Borouge…. A successful joint venture combining

resources, feedstock and technology leadership

http://www.borouge.com/

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Annual Sales Conference 2006

Strength in Europe &

High growth in the Middle East and Asia

European Customer Service Centre

Sales and agents –Middle East/Asia Pacific

Sales - Americas

Innovation Centre

Production

Borealis Head office

Joint venture centre

Our high quality pipe grades supplied to many countries,

from South Africa to Australia & New Zealand

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© 2006 Borouge Pte Ltd

Major expansions to triple capacity

• Borouge 2 expansion increased

Borouge’s capacity to 2 Million

MTA in 2010

New PP capacity will be 800 KTA

PE capacity will double from current

600 KTA to 1.2 Million MTA.Innovation Center

• Borouge 3 Toward another

success

Borouge Polyolefins production capacity will be 4.5 million tonnes per year in total by the end of 2013

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Continuing to successfully pursue our

‘Value Creation through Innovation’ path

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Innovative Polyolefin Solutions for

Oil & Gas Industry

Potable Water Gas Pipes Steel Coating Inner Lining Gravity Pipes

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Co-operation with Borealis

• Borouge and Borealis are driven by

innovation, striving to create value added

solutions for industry

• Joint manufacture and supply of

Borcoat™ PE and PP coating system

globally

• Shared technical co-operations and

Assistance

• Use of Borealis competencies and

laboratory equipments, including pilot-

line

• Global marketing presence

• Joint participation in Industry events

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© 2006 Borouge

Corrosion of steel pipelines is a major and

growing problem for the oil and gas industry

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© 2006 Borouge

Cost of Corrosion

The annual cost of corrosion worldwide in 2010 is estimated at

USD $ 2.2 Trillion (NACE-International, Houston, Texas, USA)

Source: CORROSION IN THE GULF COOPERATION COUNCIL

(GCC) STATES: STATISTICS AND FIGURES – A. Al Hashem,

Corrosion UAE 2011

Estimated

Total Cost

of

Corrosion

in GCC

States

US $ 57.96 Billion

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Onshore and Offshore PE and PP External Coatings

3LPE Systems Dominating systems for Gas and Oil pipelines

Onshore O&G - main market, growing in Water transport

Healthy growth, due to many new Onshore projects

HDPE 3LPE fulfils vast majority of projects’ technical requirements

3LPP Systems

Niche market, still project based (10% of 3LPE volumes)

Offshore - main market, Oil exploration

High Growth is in specific regions / projects

Opportunity of developing Multi-Layers PP system for elevated

Temperature and specific requirements

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Design Criteria for three layer PO Systems

Minimize risk of outer layer damage through :

Mechanical impact strength

Indentation Resistance

Resistance against UV degradation

Resistance against Thermal degradation

Resistance against Chemical attack

Low built in “extrusion stresses”

Avoid delamination between outer layer & epoxy

Maximize coating production speed

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© 2006 Borouge

BorcoatTM Coating systems for Steel Pipes

Global presence for over 30

years.

Documented track record

of over 55,000 kms of

pipeline.

Almost Approved by all

international and major

country standards

Continuous innovation and

launching of higher

performing products.

Sharing of knowledge and

experience across value

chain.

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HDPEGraftedadhesive

Epoxy

BimodalMDPE

Advanced 3LPE System

3 Layers System:

1. Fusion Bonded

Epoxy (FBE)

2. Grafted Polymer

Adhesive

3. Top coat

Borcoat HE3450

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3LPP System – Technical overview

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Dolphin Gas Project

Investment of USD 3.5 Billion including the

development cost of Gas reserves in Qatar

Transporting 3.2 Billion cubic feet per day of

Natural Gas from Qatar to UAE

Total length of offshore coated pipeline was

340 km

36” and 48” pipes had been used for offshore

part.

20 km of offshore pipeline had been coated

with PP system including a layer of PU and

HDPE jacketing on the top

320 km of offshore pipeline had been coated

with 3LPE

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© 2006 Borouge

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Demands met by

existing Borcoat

PE products:

- 50°C to +85°C

Demand for new

Borcoat PE

products

- 30°C to +90°C

Global split in demand for 3LPE coating properties

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© 2006 Borouge

Innovations in 3LPE coating systems

Operating Temp

Mechanical

Requirements

for PE Topcoat

80

70

60

Average High Very high

HD - System

MD - System

LD - System

90

Higher temperature Borcoat HE3450-H

Borcoat

HE3450

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© 2006 Borouge

Unmet needs in Pipe coating

Pipelines installed, stored and stacked in

hot climates. Surface temperature may

reach 85-90 deg during the day.

More construction activities in remote and

difficult terrain. More damage possibility to

coating due to rock impingement.

More onshore projects with higher

operating temperatures.

Sieving of soil achieves only coarse backfill

Limited access to open trench from one

side means pulling the pipe via rollers into

final position

HDD with unpredictable conditions

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© 2006 Borouge

Needs translated to material properties

Higher storage and operating

temperature

High Vicat and melting

temperature of PE and higher

stabilization

Intensive sunlight radiation

Higher risk for damages

High Water Table

Scratches and pulling of pipe on

rollers

Chemicals in the ground and

water, Aggressive Soil

Pre compounded Top coat

with good CB dispersion

Higher density of PE = higher

indentation hardness, Higher

moisture barrier

higher scratch resistance=

higher notch resistance and

resistance to crack growth

Good ESCR (environmental

stress crack resistance)

Our innovation was aimed at increasing mechanical

strength while not losing other properties

© 2

00

8 B

ore

alis A

G

02 October 2011

Presentation title

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The Borstar® bimodal process can tailor

properties for the application

BenefitsHigher mechanical

Performance,

improved processing

whilst maintaining

ESCR and

toughness.

Borstar®

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© 2006 Borouge

New Borcoat steel pipe coating solution

Borcoat HE3450-H top coat compatible with grafted adhesive

Borcoat ME0420 or ME0433 for best in class performance.

Higher mechanical & Thermal properties combined with

higher output

HE3450-H

Epoxy

ME0420/ME0433

Steel

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© 2006 Borouge

Borcoat HE3450-H resists Slow Crack Growth by

reinforcing the amorphous regions in polymer matrix

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Borcoat

HE3450-H

Vicat

Density

ESCR

Shore D

*Tensile

modulus

0.962

0.930

123.5˚C

110˚C

>5000 h

>1000 h

60

55

1050MPa

770MPa

Borcoat HE3450-H

Draft ISO 21809-3

(class B)

*not part of ISO 21809-3 requirements

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© 2006 Borouge

Pilot Line Trials with HE3450-H

Krauss-Maffei 45/30D; screen pack 40/60/40

Screw speed 25, 50, 100, 150 rpm

Monitoring processing:Output

Pressure at screw end, pressure in the die

Melt temperature in the extruder end outside the die

Torque

Monitoring coating:Neck-in winding: variation and pulsation

Melt strength: max winding

Peel strength testing

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© 2006 Borouge

Benchmarking of HE3450-H with HE3450

Moderate screw speed

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© 2006 Borouge

Benchmarking of HE3450-H with HE3450

Higher screw speed

Screw speed 150 rpm

Screw speed 100 rpm

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© 2006 Borouge

Externally verified properties

Tests acc to ISO21809-1, DIN 30670,S, NFA 49-710

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© 2006 Borouge

Commercial Project with

Borcoat HE3450-H

First trial of Borcoat HE3450-H at Jindal Saw Ltd, India.

3LPE coating was carried out on

6 inchX 6.4 mm ERW steel pipes

for Indraprastha Gas Ltd,

Citygas distribution Project in Delhi.

Combination used : Top coat - HE3450-H

Adhesive - ME0420 (220 mic)

Epoxy - 226N-11G (150 mic).

Overall thickness 2.7 mm.

Phosphoric acid wash and Chromating was done.

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© 2006 Borouge


Borcoat HE3450-H – Jindal Saw

Darod – Jafrabad pipeline project of GSPC

Extruder – Cincinnati

120 mm screw dia,

1800 kgs/hr max Output

Line speed - 5 meters / minute.

Top coat extruder speed = 42 rpm.

Melt pressure with HE3450 = 98 bar.

Melt pressure with HE3450-H = 82 bars (reduction by 16%)

Melt temperature reduced from 217 to 213 deg C

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© 2006 Borouge


Borcoat HE3450-H – Jindal Saw, India

Test results on Coating

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© 2006 Borouge

Benefits for Oil & Gas Pipeline Owners

Higher indentation hardness of the materialwill greatly reduce the damage to the coatingduring handling, transportation and installation,which will extend the protection lifetime of thesystem.

Higher Softening temperature of new materialenables the coating to handle higher surfacetemperatures of up to 90OC without softening.This property is particularly important forpipelines operating in the higher ambienttemperatures in the in the Middle East and Asia.

Higher moisture barrier/ Chemical Resistance– Test results show that water vapor permeabilityfor new grade is 50% less over current grades.Hence it is more suitable for high water tableareas in GCC.

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© 2006 Borouge

Some experience figures for pipe damages

1-2% of pipes damaged

at coating yard

Up to 4% of pipes damaged

between coating yard

and harbour or destination

(120 out of 3000 pipes)

Cost for one

repair of 10cm² coating

“300-500€”

2 persons + material

3300€ for completely

stripped and recoated

18”pipe

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Conclusion Remarks

Borouge – Value Creation through Innovation

Cost of Corrosion is increasing – Preventive vs. Corrective Strategy

All coatings will suffer and fail early if incorrectly applied or poorly specified.

3LPE coatings are the dominant coating system worldwide and increased

market share in recent years.

Over 30 years experience has shown the durability and effectiveness of

3LPE Coating System.

HDPE and particularly Bimodal HDPE offers significant benefits

Borcoat HE3450-H completes our product mix for hot climates

Borcoat HE3450-H ensures improved mechanical protection at elevated

temperatures for transport, storage, installation and operation

Tha

nk y

ou f

or y

our

atte

ntio

n

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For more information please contact:

Khalfan Al Muhairi

Application Marketing Manager, Pipe BU, Borouge

[email protected]

mailto:[email protected]

Date post:	26-Dec-2014
Category:	Business
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Khalfan Al Muhairi - High Performance Top Coat Borcoat HE3450

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