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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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Borouge reference line 2006
© 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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Borouge reference line 2006
© 2006 Borouge
Borouge…. A successful joint venture combining
resources, feedstock and technology leadership
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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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Borouge reference line 2006
© 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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Borouge reference line 2006
© 2006 Borouge Pte Ltd
Continuing to successfully pursue our
‘Value Creation through Innovation’ path
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© 2006 Borouge Pte Ltd
Innovative Polyolefin Solutions for
Oil & Gas Industry
Potable Water Gas Pipes Steel Coating Inner Lining Gravity Pipes
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© 2006 Borouge Pte Ltd
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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Borouge reference line 2006
© 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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Annual Sales Conference 2006
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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Annual Sales Conference 2006
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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Annual Sales Conference 2006
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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Annual Sales Conference 2006
3LPP System – Technical overview
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© 2009 Borouge Pte Ltd
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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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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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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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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Borcoat HE3450-H resists Slow Crack Growth by
reinforcing the amorphous regions in polymer matrix
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Annual Sales Conference 2006
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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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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Benchmarking of HE3450-H with HE3450
Moderate screw speed
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Benchmarking of HE3450-H with HE3450
Higher screw speed
Screw speed 150 rpm
Screw speed 100 rpm
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Externally verified properties
Tests acc to ISO21809-1, DIN 30670,S, NFA 49-710
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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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Commercial Project with
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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Commercial Project with
Borcoat HE3450-H – Jindal Saw, India
Test results on Coating
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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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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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© 2009 Borouge Pte Ltd
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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© 2009 Borouge Pte Ltd
For more information please contact:
Khalfan Al Muhairi
Application Marketing Manager, Pipe BU, Borouge